New Holland EC15 - EC25 - EC35 - EC45 Mini Crawler Excavator Service Manual - PDF DOWNLOAD

SERVICE MANUAL Excavator Crawler Mini EC15 - EC25 - EC35 - EC45

EC15, EC25, EC35, EC45 CRA WLER EXCA VATOR CRAWLER EXCAV SER VICE MANU AL SERVICE MANUAL CONTENTS SECTION 00 - GENERAL INFORMA TION INFORMATION SECTION 6 - ELECTRICAL SYSTEM SECTION 7 - HYDRAULIC SYSTEM SECTION 10 - OPERA TOR’S PLA TFORM OPERAT PLATFORM SECTION 11 - TRACTION/UNDERCARRIAGE

©1999 NEW HOLLAND CONSTRUCTION

SECTION 00 - GENERAL INFORMATION

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SECTION 00 - GENERAL INFORMATION

SECTION 00 GENERAL INFORMA TION INFORMATION CONTENTS Introduction ...................................................................................................................................... 00-6 Model Codes ................................................................................................................................ 00-6 Proprietary Notice ........................................................................................................................ 00-6 To the Owner ............................................................................................................................... 00-7 About Improvements .................................................................................................................... 00-7 Company Policy ........................................................................................................................... 00-7 Parts and Accessories ................................................................................................................ 00-7 Owner Assistance ....................................................................................................................... 00-8 Precautionary Statements ................................................................................................................ 00-9 Personal Safety ........................................................................................................................... 00-9 Machine Safety ............................................................................................................................ 00-9 Safety Precaution Information ........................................................................................................ 00-10 General Safety Information ............................................................................................................ 00-14 Handle Fluids Safely .................................................................................................................. 00-14 Use Care Around High-Pressure Fluid Lines ............................................................................ 00-14 Avoid Heating Near Pressurized Fluid Lines ............................................................................. 00-14 Use Care In Handling and Servicing Batteries .......................................................................... 00-14 Prevent Battery Explosions ................................................................................................... 00-14 Use Safe Service Procedures ................................................................................................... 00-15 Service Machine Safely ............................................................................................................. 00-15 Use Proper Tools ....................................................................................................................... 00-15 Review Safety Equipment, Signs and Shields ........................................................................... 00-15 Controls ..................................................................................................................................... 00-15 Safety Decals ................................................................................................................................. 00-16 Machine Model and Serial Number Location .................................................................................. 00-18 Minimum Hardware Tightening Torques, Inch ................................................................................. 00-19 Minimum Hardware Tightening Torques, Metric .............................................................................. 00-20 Recovery and Transport of the Machine ........................................................................................ 00-21 Recovery of the Machine ........................................................................................................... 00-21 EC15 ..................................................................................................................................... 00-21 EC25/EC35/EC45 ................................................................................................................. 00-21

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Loading the Machine Using a Crane ..........................................................................................

EC15 .....................................................................................................................................

EC25/EC35/EC45 .................................................................................................................

Transporting the Machine ..........................................................................................................

EC15/EC25/EC35 .................................................................................................................

EC45 .....................................................................................................................................

Loading the Machine onto a Flatbed ..........................................................................................

Proper Support of a Raised Machine .............................................................................................

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00-22 00-22 00-23 00-24 00-24 00-24 00-25 00-25

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SECTION 00 - GENERAL INFORMATION

INTRODUCTION This service manual provides the technical information needed to properly service and maintain the Models listed below. Use this manual in conjunction with the operator’s manual which is supplied with the machine. Keep both manuals available for ready reference.

Your New Holland Construction dealer is interested in your obtaining the most from your investment and will be glad to answer any questions you may have about your machine.

When major service is required, your dealer’s staff of trained service technicians is ready to serve you.

The easiest and least time-consuming removal, disassembly, and reassembly procedures are detailed in the service manual. Modifying these procedures is not recommended.

Whenever working on New Holland Construction equipment, left and right sides of the machine are determined by standing behind the unit, looking in the direction of travel.

When in need of parts, always order genuine New Holland Construction original spare parts from your New Holland Construction dealer to maintain operating efficiency. Be prepared to give your dealer the model and engine serial numbers. The location of the numbers is described later in this section. Record the serial numbers here.

New Holland Construction machines are designed with emphasis on safety for operator protection. However, careless and negligent operation can still result in serious injury to personnel or damage to property. Be sure to read and follow all safety instructions in this manual.

Machine Model _______________________ Machine Serial Number ________________ Engine Model ________________________ Engine Serial Number __________________

MODEL CODES The range of machines included in this manual are listed below and may not be available in all countries or markets therefore, for the latest information consult your local New Holland Construction dealer.

MODEL

ENGINE TYPE - HORSEPOWER

EC15

Mitsubishi L3E four-stroke diesel engine - 17.8 hp

EC25

Mitsubishi S4L- 61KL four-stroke diesel engine - 27.5 hp

EC35

Mitsubishi S4L-2-61KL four-stroke diesel engine - 35.5 hp

EC45

Mitsubishi S4Q2-61KL four-stroke diesel engine - 46.4 hp

PR OPRIET AR Y NO TICE PROPRIET OPRIETAR ARY NOTICE The contents of this manual are proprietary data of New Holland Construction. Reproduction or use of any part for other than the operation and maintenance of New Holland Construction equipment is permissible only if expressly authorized in writing by New Holland Construction.

Additional copies may be obtained from your New Holland Construction dealer. Address requests for copies to your dealer and refer to the publication number appearing on the bottom of the manual cover.

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SECTION 00 - GENERAL INFORMATION

TO THE OWNER The warranty coverage that is extended to your machine is explained in the Warranty and Limitation of Liability form. Your dealer will provide you with a copy of the warranty and retain a copy which you have signed. After you read the warranty, ask your dealer to explain any points that you may not understand.

The machine was designed to power and propel itself. It is intended to move material in the normal and customary applications.

Do not modify or alter or permit anyone else to modify or alter this machine or any of its component’s mechanical function without first consulting an authorized New Holland Construction dealer. If you have any questions regarding machine modifications contact New Holland Contruction, 245 East North Ave., Carol Stream, IL 60188.

Your safety and the safety of those around you depend upon the care and good judgement you use while operating and maintaining this equipment. Read the safety precautions carefully.

After you have operated the machine for 50 hours, take your machine and this manual to your selling dealer. He or she will perform the factory recommended 50-hour service. You will be responsible for the cost of lubricants, fluids, filters and other items replaced as part of normal maintenance. Prior to taking the machine to your selling dealer for service, it is recommended that you contact them to determine any other charges for which you may be responsible.

ABOUT IMPROVEMENTS New Holland Construction is continually striving to improve its products. We reserve the right to make improvements or changes when it becomes practical and possible to do so, without incurring any obligation to make changes or additions to the equipment sold previously.

ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

COMP ANY POICY COMPANY Company policy is one of continuous improvement, and reserves the right to change prices and to make changes in design and specification at any time without notice and without obligation to modify units previously built.

All data given in this manual is subject to production variations. Dimensions and weights are approximate only and the illustrations do not necessarily show machines in standard condition. For exact information about any particular machine, please consult your New Holland Construction dealer.

PAR TS AND A CCESSORIES ARTS ACCESSORIES Genuine parts and accessories have been specifically designed for these machines. We would like to point out that ‘non-genuine” parts and accessories have NOT been examined and released by New Holland Construction. The installation and/or use of such products could have negative effects upon the design characteristics of your machine and thereby affect its safety. New Holland Construction is not liable for any damage caused by the use of “non-genuine” parts and assessories.

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SECTION 00 - GENERAL INFORMATION

OWNER ASSIST ANCE ASSISTANCE We at New Holland Construction and your New Holland Construction dealer want you to be completely satisfied with your investment. Normally any problems with your equipment will be handled by your dealer’s Service Department. Sometimes, however, misunderstandings can occur. If your problem has not been handled to your satisfaction, we suggest the following.

1. Contact the Owner or General Manager of the dealership, explain the problem, and request assistance. When additional assistance is needed, your dealer has direct access to our office.

2. If you cannot obtain satisfaction by doing this, contact the New Holland Construction office and provide them with: -Your name, address, and telephone number - Machine model and serial number - Dealership name and address - Machine puchase date and amount of use - Nature of problem NEW HOLLAND CONSTRUCTION 245 E. Nor th A ve North Av Carol Stream, IL 60188 Ph # (630) 260-4000 When contacting New Holland Construction, be aware that your problem will likely be resolved in the dealership using the dealer’s facilities, equipment, and personnel. So it is important that your initial contact be with the dealer.

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SECTION 00 - GENERAL INFORMATION

PRECA UTIONAR Y ST ATEMENTS PRECAUTIONAR UTIONARY STA Personal Safety Throughout this manual and on machine decals, you will find precautionary statements (“CAUTION”, “WARNING”, and “DANGER”) followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them.

CAUTION “CAUTION” BEHAVIORAL PRACTICE ACCORDING THE W ORD “CA UTION” IS USED WHERE A SAFE BEHA VIORAL PRA CTICE A CCORDING OPERATING INSTRUCTIONS TO OPERA TING AND MAINTENANCE INSTR UCTIONS AND COMMON SAFETY PRO OPERAT OTHERS FROM ACCIDENT PRACTICES TOR AND O THERS FR OM A CCIDENT PRA CTICES WILL PR OTECT THE OPERA INVOL OLVEMENT VEMENT..

INV OL VEMENT WARNING THE WORD “WARNING” DENOTES A POTENTIAL OR HIDDEN HAZARD WHICH HAS A POTENTIAL INJURY OPERAT OTHERS PO TENTIAL FOR SERIOUS INJUR Y. IT IS USED TO WARN OPERA TORS AND O THERS AV INVOL OLVEMENT EVERY APPROPRIA OPRIATE OL VEMENT OPRIA TE MEANS TO A VOID A SURPRISE INV TO EXERCISE EVER Y APPR MACHINER CHINERY WITH MA CHINER Y. DANGER THE WORD “DANGER” DENOTES A FORBIDDEN PRACTICE IN CONNECTION WITH A HAZARD..

SERIOUS HAZARD

FAILURE TO FOLLO W THE “CA UTION”, “W ARNING”, AND “D ANGER” FOLLOW “CAUTION”, “WARNING”, “DANGER” T IN SERIOUS BODIL Y INJUR Y OR DEA TH. INSTR UCTIONS MA Y RESUL MAY RESULT BODILY INJURY DEATH. INSTRUCTIONS

This “

”

symbol is used throughout this manual whenever personal safety is inv olved. ake ollow instructions uctions.. Be Careful! in volv ed. Tak e time to read and ffollo ollo w the instr uctions CALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Machine Safety Additional precautionary statements (“ATTENTION” and “IMPORTANT”) are followed by specific instructions. These statements are intended for machine safety.

ATTENTION: The word “ATTENTION” is used to warn the operator of potential machine damage if a certain procedure is not followed.

IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent minor machine damage if a certain procedure is not followed.

NOTE: The word “NOTE” is used for information containing important notes about the correct use and/ or how to proceed. Non-compliance may lead to malfunction.

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SECTION 00 - GENERAL INFORMATION

SAFETY PRECA UTION INFORMA TION PRECAUTION INFORMATION UNSAFE OPERA TING AND MAINTENANCE PRA CTICES AND IMPR OPER USE OF THE OPERATING PRACTICES IMPROPER AR T OF THE OPERA TOR OR SER VICE CHINE AND ITS A TT ACHMENTS ON THE P MACHINE ATT TTA PAR ART OPERAT SERVICE MA TECHNICIAN CAN RESUL T IN INJURIES VE THE FOLLO WING SAFETY RESULT INJURIES.. OBSER OBSERVE FOLLOWING PRECA UTIONS A T ALL TIMES: PRECAUTIONS AT 1.

FOR SERVICING, THE MACHINE SHOULD BE ON LEVEL TERRAIN, ENGINE STOPPED WITH THE WHEELS/TRACKS BLOCKED OR THE ENTIRE MACHINE CKS OFF THE GR OUND BEFORE SOLIDL Y SUPPOR TED WITH THE WHEELS/TRA SOLIDLY SUPPORTED WHEELS/TRACKS GROUND SERVICING ANY COMPONENT OF THE DRIVETRAIN.

2.

FOR SER VICING UNDER THE MO VABLE EQ UIPMENT TOR’S SEA T, SERVICING MOV EQUIPMENT UIPMENT,, SUCH AS OPER OPERT SEAT VE THE EQ UIPMENT ASSEMBL Y TO THE LA TCHED HOODS,, ETC ETC.. MO MOVE EQUIPMENT ASSEMBLY LATCHED ENGINE HOODS POSITION AND SECUREL Y LA TCH. SECURELY LATCH.

3.

DO NO T OPERA CHINE UNLESS ALL MO VABLE EQ UIPMENT IS LA TCHED NOT OPERATE MACHINE MOV EQUIPMENT LATCHED TE THE MA TE POSITION. OPERATE IN THE OPERA

4.

DO NOT SERVICE THE MACHINE WITH RAISED HYDRAULIC EQUIPMENT UNLESS CHINE IS PR OPERL Y AND SECUREL Y SUPPOR TED WITH ALL FOUR MACHINE PROPERL OPERLY SECURELY SUPPORTED THE MA WHEELS OR TRA CKS OFF THE GR OUND TRACKS GROUND OUND..

5.

DO NOT SERVICE THE MACHINE WITH THE ENGINE RUNNING UNLESS THE MA CHINE IS PR OPERL Y AND SECUREL Y SUPPOR TED WITH ALL FOUR WHEELS OR MACHINE PROPERL OPERLY SECURELY SUPPORTED TRA CKS OFF THE GR OUND TRACKS GROUND OUND..

6.

USE CA UTION AR OUND MO VING P AR TS WHEN SER VICING THE UNIT CAUTION AROUND MOVING PAR ARTS SERVICING UNIT..

7.

DO NO T OPERA TE ANY MO VEABLE EQ UIPMENT WITHOUT PR OPER INSTR UCTION. NOT OPERATE MOVEABLE EQUIPMENT PROPER INSTRUCTION.

8.

DO NO T OPERA TE MO VABLE EQ UIPMENT WITHOUT USING THE PR OPER TOOLS NOT OPERATE MOV EQUIPMENT PROPER OOLS..

9.

REINST ALL ALL SHIELDS VED FOR REINSTALL SHIELDS,, SAFETY DEVICES OR INTERLOCKS REMO REMOVED SERVICE.

10. NEVER LOOSEN ANY HYDRAULIC CONNECTIONS BEFORE RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM. 11. WEAR EYE PROTECTION SUCH AS GOGGLES, ETC. 12. WEAR EAR PR OTECTION SUCH AS EARPLUGS PRO EARPLUGS,, ETC ETC.. WHEN YOU FEEL THE NOISE LEVEL IS UNCOMFOR TABLE. UNCOMFORT 13. IF ANY SER VICING OR ADJUSTMENTS REQ UIRE THE BA TTER Y TO BE SERVICING REQUIRE BATTER TTERY DISCONNECTED TIVE GR OUND CABLE. DISCONNECTED,, DISCONNECT THE (-) NEGA NEGATIVE GROUND 14. WHEN SER VICING ELECTRICAL COMPONENTS TIVE SERVICING COMPONENTS,, DISCONNECT THE (-) NEGA NEGATIVE GROUND CABLE.

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SECTION 00 - GENERAL INFORMATION

15. IF ELECTR ONIC EQ UIPMENT REQ UIRES REMO VAL FR OM THE D ASH AREA OR THE ELECTRONIC EQUIPMENT REQUIRES REMOV FROM DASH MA CHINE, DISCONNECT THE (-) NEGA TIVE GR OUND BA TTER Y CABLE. THIS WILL MACHINE, NEGATIVE GROUND BATTER TTERY SHUT OFF POWER TO THE ELECTRICAL SYSTEM AND PREVENT DAMAGE TO THE ELECTRICAL SYSTEM. 16. IF WELDING IS REQ UIRED ON THE MA CHINE, DISCONNECT THE (-) NEGA TIVE REQUIRED MACHINE, NEGATIVE GR OUND CABLE. F AILURE TO DISCONNECT THE BA TTER Y MA Y RESUL T IN GROUND FAILURE BATTER TTERY MAY RESULT DAMAGE TO ELECTRICAL SYSTEM, MONITORING SYSTEM AND/OR OTHER ELECTRICAL COMPONENTS. 17. IF WELDING IS REQ UIRED ON AN A TT A CHMENT VE THE A TT A CHMENT REQUIRED ATT TTA CHMENT,, REMO REMOVE ATT TTA FROM THE MACHINE. 18. GIVE COMPLETE AND UNDIVIDED A TTENTION TO THE JOB A T HAND SO THA T ATTENTION AT THAT COMPLETE CONTR OL OF THE MA AINED A T ALL TIMES CONTROL MACHINE MAINTAINED AT TIMES..

CHINE IS MAINT 19. DRIVE SLO WL Y O VER R OUGH GR OUND AND ON SLOPES; KEEP ALER T FOR SLOWL WLY OVER ROUGH GROUND ALERT HOLES THER IRREGULARITIES THA T MA Y CA USE THE MA CHINE HOLES,, DITCHES AND O OTHER THAT MAY CAUSE MACHINE TO OVERTURN. 20. AVOID STEEP HILLSIDE OPERA TION WHICH COULD CA USE THE MA CHINE TO OPERATION CAUSE MACHINE OVERTURN. 21. NEVER TRANSPOR T A LO ADED B UCKET A T FULL HEIGHT TE THE MA CHINE TRANSPORT LOADED BUCKET AT HEIGHT.. OPERA OPERATE MACHINE WITH THE LOAD AS LOW AS POSSIBLE UNTIL IT BECOMES NECESSARY TO RAISE THE BOOM TO DISCHARGE THE LO AD INT O A TR UCK, CONT AINER, ETC LOAD INTO TRUCK, CONTAINER, ETC..

22. REDUCE SPEED WHEN TURNING SO THERE IS NO DANGER OF OVERTURNING. 23. NEVER DRIVE UP OR BACK UP A HILL OR INCLINE WITH A RAISED BOOM OR THE MACHINE COULD OVERTURN. 24. AL WAYS LOOK BEHIND YOU BEFORE BA CKING UP THE MA CHINE. ALW BACKING MACHINE. 25. MAINT AIN PR OPER FLUID LEVELS TO PREVENT LOSS OF PO WER, BRAKING OR MAINTAIN PROPER POWER, OTHER FUNCTIONS. 26. DO NO T ALLO W P ASSENGERS TO RIDE ON THE MA CHINE A T ANY TIME. NOT ALLOW PASSENGERS MACHINE AT 27. DO NO T ALLO W CHILDREN TO OPERA TE THE MA CHINE OR RIDE ON THE MA CHINE NOT ALLOW OPERATE MACHINE MACHINE AT ANY TIME. 28. DO NO T ALLO W ANY ONE TO OPERA TE OR SER VICE THE MA CHINE WITHOUT NOT ALLOW ANYONE OPERATE SERVICE MACHINE PROPER INSTRUCTION. 29. OSHA REQ UIRES THA T ALL OPERA TORS BE INSTR UCTED ON THE PR OPER REQUIRES THAT OPERAT INSTRUCTED PROPER OPERA TION OF THE MA CHINE BEFORE THEY OPERA TE THE UNIT OPERATION MACHINE OPERATE UNIT..

T OPERA TE THE MA CHINE IN ANY POSITION O THER THAN WHILE IN THE 30. DO NO MACHINE OTHER NOT OPERATE OPERA TOR’S SEA T WITH THE SEA T BEL T SECUREL Y F ASTENED SEAT SEAT BELT SECURELY FASTENED ASTENED..

OPERAT 31. BEFORE ST AR TING THE ENGINE, BE SURE THA T ALL OPERA TING CONTR OLS ARE STAR ARTING THAT OPERATING CONTROLS IN NEUTRAL AND THE P ARKING BRAKE IS ENGA GED PARKING ENGAGED GED..

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SECTION 00 - GENERAL INFORMATION

32. NEVER OPERA TE THE ENGINE IN A CLOSED AREA WITHOUT ADEQ UATE OPERATE ADEQU VENTILA TION. VENTILATION. 33. REFUEL THE MA CHINE OUTDOORS WITH THE ENGINE SHUT OFF CE THE MACHINE OFF.. REPLA REPLACE FUEL CAP SECUREL Y. USE AN APPR OVED FUEL CONT AINER. DO NO T SMOKE SECURELY APPRO CONTAINER. NOT WHEN HANDLING FUEL. A V OID SPILLING FUEL. AV 34. AFTER OPERA TING THE ENGINE, NEVER TOUCH THE MUFFLER, EXHA UST PIPE, OPERATING EXHAUST ENGINE OR RADIA TOR UNTIL THEY HA VE HAD TIME TO COOL. RADIAT HAVE 35. DRESS APPR OPRIA TEL Y - WEAR RELA TIVEL Y TIGHT -FITTING CLO THING WHEN APPROPRIA OPRIATEL TELY RELATIVEL TIVELY TIGHT-FITTING CLOTHING OPERA TING OR SER VICING THE MA CHINE. LOOSE OR TORN CLO THING CAN OPERATING SERVICING MACHINE. CLOTHING CA TCH IN MO VING P AR TS OR CONTR OLS CATCH MOVING PAR ARTS CONTROLS OLS..

36. BEFORE SER VICING THE MA CHINE OR ANY OF ITS A TT A CHED EQ UIPMENT SERVICING MACHINE ATT TTA EQUIPMENT UIPMENT,, BE SURE THA T THE A TT A CHMENTS ARE LO WERED TO THE GR OUND OR ARE THAT ATT TTA LOWERED GROUND SUPPOR TED SUPPORTED TED..

37. DO NOT WORK UNDER OVERHANGS, ELECTRIC WIRES, OR WHERE THERE IS DANGER OF A SLIDE. 38. WEAR AN APPR OVED SAFETY HA T WHEN OPERA TING THE MA CHINE AND WHILE APPRO HAT OPERATING MACHINE IN ANY WORK AREA. 39. WHEN DRIVING THE MA CHINE ON A PUBLIC R OAD OR HIGHW AY, USE WARNING MACHINE RO HIGHWA LIGHTS OR WARNING DEVICES AS MA Y BE REQ UIRED BY LOCAL OR ST ATE MAY REQUIRED STA GO VERNMENT REGULA TIONS GOVERNMENT REGULATIONS TIONS.. HEADLIGHTS HEADLIGHTS,, WARNING LIGHTS AND SMV SIGNS ARE A VAILABLE THR OUGH YOUR NEW HOLLAND DEALER. AV THROUGH 40. KEEP THE MACHINE CLEAN. DO NOT ALLOW TRASH, DEBRIS OR OTHER ARICLES TO A CCUMULA TE IN THE CAB T CONTR OL PED AL AREA THA T MA Y ACCUMULA CCUMULATE CAB,, FLOOR OR FOO FOOT CONTROL PEDAL THAT MAY HINDER SAFE MA CHINE OPERA TION. MACHINE OPERATION. 41. NEVER OPERA TE THE MA CHINE WITH ANY OF THE SHIELDING, SAFETY DIVICE OR OPERATE MACHINE INTERLOCKS REMO VED OR INOPERA TIVE. REMOVED INOPERATIVE. 42. NEVER OPERA TE THE MA CHINE WITHOUT WINDO WS AND/OR SCREENS IN PLA CE. OPERATE MACHINE WINDOWS PLACE. 43. NEVER EXTEND ANY P AR T OF THE BOD Y OUTSIDE OF THE OPERA TOR’S AREA. PAR ART BODY OPERAT 44. AL WAYS PR OPERL Y TIE DO WN THE EXCA VATOR TO A TR UCK OR TRAILER BEFORE ALW PROPERL OPERLY DOWN EXCAV TRUCK TRANSPOR T. TRANSPORT 45. MAKE SURE ALL PERSONNEL ARE A T A SAFE DIST ANCE A WAY FR OM THE AT DISTANCE AW FROM MA CHINE BEFORE ST AR TING THE ENGINE. MACHINE STAR ARTING 46. DO NO T ALLO W ANY ONE NEAR THE MA CHINE WHILE THE ENGINE IS R UNNING NOT ALLOW ANYONE MACHINE RUNNING AND THE MA CHINE IS OPERA TIONAL. MACHINE OPERATIONAL. 47. WHEN USING THE MA CHINE TO LIFT OBJECTS T ALLO W ANY ONE TO RIDE MACHINE OBJECTS,, DO NO NOT ALLOW ANYONE ON OBJECTS BEING LIFTED LIFTED..

CHINE AS A W ORK PLA TFORM FOR SUPPOR TING 48. DO NO T USE THE MA PLATFORM SUPPORTING NOT MACHINE MA TERIALS MATERIALS TERIALS..

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SECTION 00 - GENERAL INFORMATION

49. DO NO T LIFT PERSONNEL OR ALLO W PERSONNEL TO W ORK WHILE ST ANDING IN NOT ALLOW STANDING THE B UCKET OR ON O THER A TT A CHMENTS T A MAN-LIFT BUCKET OTHER ATT TTA CHMENTS.. THIS IS NO NOT MAN-LIFT..

OSHA REQ UIREMENTS NO YER’S RESPONSIBILITY TO FULL Y REQUIREMENTS NOW EMPLOYER’S FULLY W MAKE IT THE EMPLO UCT EA CH OPERA TOR IN THE PR OPER AND SAFE OPERA TION OF ALL INSTRUCT EACH OPERAT PROPER OPERATION INSTR OPERA TIVE EQ UIPMENT TH EMPLO YER AND EMPLO YEE SHOULD THOR OUGHL Y OPERATIVE EQUIPMENT UIPMENT.. BO BOTH EMPLOYER EMPLOYEE THOROUGHL OUGHLY FAMILIARIZE THEMSEL VES WITH THE MA CHINE OPERA TION. THEMSELVES MACHINE OPERATION.

CAUTION! CAUTION: SOME PICTURES IN THIS MANUAL SHOW SAFETY SHIELDS REMOVED OR OPEN TO SHO W P AR TS BEING SER VICED OR FOR CLARITY SHOW PAR ARTS SERVICED CLARITY.. ALL SHIELDS SHOULD BE CLOSED OR REPLA CED PRIOR TO OPERA TING THE MA CHINE. REPLACED OPERATING MACHINE.

DANGER! FASTEN SEA T BEL T SEAT BELT BEFORE ST AR TING ENGINE! STAR ARTING Read and heed all saf ety instr uction carr ying the signal w ords CA UTION, WARNING AND safety instruction carrying words CAUTION, DANGER. STUD Y THE OPERA TION AND MAINTENANCE INSTR UCTION MANU AL STUDY OPERATION INSTRUCTION MANUAL THR OUGHL Y BEFORE ST AR TING, OPERA TING, MAINT AINING, FUELING OR SER VICING THROUGHL OUGHLY STAR ARTING, OPERATING, MAINTAINING, SERVICING THIS MACHINE. Most accidents are caused by failure of some individual to follow simple and fundamental saf ety rrules ules or precaution. F or this reason most accidents can be pre vented b y safety For prev by recognizing the real cause and doing something about it before an acccident occurs.

Regardless of the care used in the design and constr uction of an y type of equipment there construction any are man y conditions that can’t be completely saf eguarded against without interf er ing with many safeguarded interfer ering reasonable accessibility and efficient operation.

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Gener al Saf ety Inf or mation General Safety Infor ormation Handle Fluids Safely

Check for leaks with a piece of cardboard.

Protect hands and body from high pressure fluids.

When working around fuel or other flammable material, do not smoke, work near heaters or other fire hazards.

If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source.

Do not store flammable material in open containers.

Store flammable fluids away from fire hazards.

Av oid Heating Near Pressur iz ed Fluid Lines Pressuriz ized

Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, oil, and debris.

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and nearby personnel.

Do not store oily rags; they can ignite and burn spontaneously.

Do not heat by welding, soldering, or using a torch near pressurized fluid lines.

Keep a first aid kit and fire extinguisher handy.

Pressurized lines can be accidentally cut or damaged when heat goes beyond the immediate flame area.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Use Care in Handling and Ser vicing Servicing Batter ies Pre v ent Batter y Explosions Prev Battery Keep sparks, lighted matches, and open flame away from the top of the battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Do not charge a frozen battery; it may explode.

Warm the battery to 60°F (16°C).

Use Care Around High Pressure Fluid Lines

WARNING

Escaping fluid under pressure can penetrate the skin causing serious injury.

IF ANY SERVICING OR ADJUSTMENTS REQUIRE BATTER TTERY REQ UIRE THE BA TTER Y TO BE DISCONNECTED,, OR WELDING IS DISCONNECTED REQUIRED ON THE MACHINE, NEGATIVE GROUND TIVE GR OUND DISCONNECT THE (-) NEGA FAILURE CABLE. F AILURE TO DISCONNECT THE BATTER TTERY MAY RESULT DAMA AMAGE BA TTER Y MA Y RESUL T IN D AMA GE TO ELECTRICAL COMPONENTS.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.

Tighten all line connections before applying pressure.

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Wear safety glasses or face shield as required.

WARNING

Wear other safety equipment appropriate to the job.

ATT TTA IF WELDING ON AN A TT A CHMENT IS REQUIRED UIRED,, FIRST REMO REMOVE REQ UIRED VE THE TTA FROM MACHINE. A CHMENT FR OM THE MA CHINE. ATT

Wear earplugs or earmuffs as required.

Ser vice Machine Saf ely Service Safely

WARNING

Use caution when working around moving parts.

STAR ARTING ENGINE ST AR TING WITH A BOOSTER BATTER TTERY REQUIRES BA TTER Y REQ UIRES EXTREME CARE AS BATTERIES PRODUCE BA TTERIES PR ODUCE EXPLOSIVE GASSES.. THE SLIGHTEST SP SPARK GASSES ARK CAN CAUSE AN EXPLOSION.

If servicing requires the boom to be in the raised position, remove any attachments and support securely. If servicing requires the complete machine to be in the supported position, support the machine with adequate jack stands or blocking with both tracks off the ground.

If servicing requires the engine to be operated, raise the machine and properly support the machine with adequate jack stands or blocking with both tracks off the ground.

FOLLOW THESE SAFETY TIPS: 1.

AL WAYS SHIELD YOUR EYES WHEN ALW CHARGING OR WORKING NEAR A BA TTER Y. AL WAYS PR OVIDE GOOD BATTER TTERY ALW PRO VENTILA TION. VENTILATION.

CAUTION BEFORE SERVICING THE MACHINE OR ATT TTA EQUIPMENT UIPMENT,, BE ANY OF ITS A TT A CHED EQ UIPMENT SURE THA T THE A TT ACHMENTS ARE ATT TTA THAT OUND LO WERED TO THE GR LOWERED GROUND OUND..

2.

CO VER THE BA TTER Y WITH A PIECE COVER BATTER TTERY OF CARPET OR O THER HEA VY OTHER HEAVY MA TERIAL. DO NO T REMO VE THE MATERIAL. NOT REMOVE BA TTER Y VENTCAPS BATTER TTERY VENTCAPS..

3.

CONNECT ONE CABLE TO THE (+) POSITIVE TERMINAL OF THE WEAK BA TTER Y. CONNECT THE O THER END BATTER TTERY OTHER OF THE CABLE TO THE (+) POSITIVE TERMINAL OF THE STRONGER BA TTER Y. BATTER TTERY

4.

CONNECT THE SECOND CABLE TO THE (-) NEGA TIVE TERMINAL OF THE NEGATIVE STR ONGER BA TTER Y. STRONGER BATTER TTERY

5.

CONNECT THE REMAINING (-) NEGA TIVE CABLE END TO THE NEGATIVE ENGINE BLOCK OR ST AR TER STAR ARTER GROUND TERMINAL.

6.

REVERSE THIS PROCEDURE WHEN DISCONNECTING THE BOOSTER.

Use Saf e Ser vice Procedures Safe Service Wear Protective Clothing

Use Proper Tools Use tools appropriate for the job.

Review Safety Equipment, Signs and Shields Replace missing or damaged safety decals.

Reinstall all shielding, safety device or interlocks removed for servicing.

Replace any damaged or missing shielding, safety device or interlocks.

Controls Operate machine and check functions for proper operation.

Check seat belt for proper opertion, wear, and damage - Replace as needed.

Wear close-fitting clothing.

00-15

SECTION 00 - GENERAL INFORMATION

SAFETY DECALS The following safety decals have been placed on the machine in the areas indicated. These decals are intended for the personal safety of you, and those working with you.

Keep the decals legible. If they are not, obtain replacements from your New Holland dealer.

00-16

SECTION 00 - GENERAL INFORMATION

1.

CA UTION: LOCA TED A T FOUR CAUTION: LOCATED AT PLACES ON THE TOP LEFT AND RIGHT SIDE OF THE CAB ENCLOSURE ON THE EC25, EC35, AND EC45 MACHINES. THESE MACHINES MUST NOT BE LIFTED WITH A HOOK.

2.

CA UTION: LOCA TED IN THE CAB ON CAUTION: LOCATED THE RIGHT CONSOLE. LOWER BOOM TO GR OUND OP ENGINE AND GROUND OUND,, ST STOP REMO VE ST AR TER KEY BEFORE REMOVE STAR ARTER LEA VING THE CAB LEAVING CAB..

3.

CAUTION: REMAIN CLEAR OF BOOM TIMES..

AT ALL TIMES

3.

WARNING: KEEP CLEAR! R OTATING RO F AN - ST OP ENGINE. FAN STOP

00-17

SECTION 00 - GENERAL INFORMATION

Machine Model and Ser ial Number Serial Location The excavator model and serial number tag, is located on the right front exterior of the operator’s cab (1).

For the tightening torques for reassembly, use the following hardware torque chart unless the torque is specified in the instructions.

00-18

SECTION 00 - GENERAL INFORMATION

MINIMUM HARDWARE TIGHTENING TORQUES IN FOO T POUNDS (NEWT ON-METERS) FOR NORMAL ASSEMBL Y APPLICA TIONS FOOT (NEWTON-METERS) ASSEMBLY APPLICATIONS INCH HARDWARE AND LOCKNUTS SAE GRADE 2 NOMINAL SIZE

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

SAE GRADE 5

UNPLATED or PLATED SILVER

PLATED w/ZnCr

PLATED w/ZnCr

GOLD

UNPLATED or PLATED SILVER

55* (6.2) 115* (13) 17 (23) 27 (37) 42 (57) 60 (81) 83 (112) 146 (198) 142 (193) 213 (289)

72* (9.7) 149* (17) 22 (30) 35 (47) 54 (73) 77 (104) 107 (149) 189 (256) 183 (248) 275 (373)

86* (9.7) 178* (20) 26 (35) 42 (57) 64 (87) 92 (125) 128 (174) 226 (306) 365 (495) 547 (742)

SAE GRADE 8 PLATED w/ZnCr

GOLD

UNPLATED or PLATED SILVER

112* (13) 229* (26) 34 (46) 54 (73) 83 (113) 120 (163) 165 (224) 293 (397) 473 (671) 708 (960)

121* (14) 250* (28) 37 (50) 59 (80) 91 (123) 130 (176) 180 (244) 319 (432) 515 (698) 773 (1048)

157* (18) 324* (37) 48 (65) 77 (104) 117 (159) 169 (229) 233 (316) 413 (560) 667 (904) 1000 (1356)

IDENTIFICA TION IDENTIFICATION CAP SCREWS AND CARRIA GE BOL TS CARRIAGE BOLTS

00-19

GRB w/GR5 BOLT

GRC w/GR8 BOLT

61* (6.9) 125* (14) 19 (26) 30 (41) 45 (61) 65B(88) 90 (122) 160 (217) 258 (350) 386 (523)

86* (9.8) 176* (20) 26 (35) 42 (57) 64 (88) 92 (125) 127 (172) 220 (306) 364 (494) 545 (739)

GOLD

NO TE: Torque vvalues alues sho wn with * are inch pounds NOTE: shown pounds..

LOCKNUTS

LOCKNUTS

SECTION 00 - GENERAL INFORMATION

MINIMUM HARDWARE TIGHTENING TORQUES IN FOO T POUNDS (NEWT ON-METERS) FOR NORMAL ASSEMBL Y APPLICA TIONS FOOT (NEWTON-METERS) ASSEMBLY APPLICATIONS METRIC HARDWARE AND LOCKNUTS CLASS 5.8

CLASS 8.8

CLASS 10.9

NOMINAL SIZE

UNPLATED

PLATED w/ZnCr

UNPLATED

PLATED w/ZnCr

UNPLATED

PLATED w/ZnCr

LOCKNUT CL8 w/CL8.8 BOLT

M4 M6 M8 M10 M12 M16 M20 M24

15*(5.8) 51* (5.8) 124* (14) 21 (28) 36 (49) 89 (121) 175 (237) 303 (411)

19* (2.2) 67* (7.6) 159* (18) 27 (36) 46 (63) 117 (158) 226 (307) 392 (531)

23* (2.6) 79* (8.9) 195* (22) 32 (63) 55 (75) 137 (186) 277 (375) 478 (648)

30* (3.4) 102* (12) 248* (28) 41 (56) 72 (97) 177 (240) 358 (4585) 619 (839)

33* (37) 115* (13) 274* (31) 45 (61) 79 (107) 198 (266) 383 (519) 662 (897)

42* (4.8) 150* (17) 354* (40) 58 (79) 102 (138) 254 (344) 495 (671) 855 (1160)

16* (1.8) 56* (6.3) 133* (15) 22 (30) 39 (53) 97 (131) 195 (255) 338 (458)

NO TE: Torque vvalues alues sho wn with * are inch pounds NOTE: shown pounds..

IDENTIFICA TION IDENTIFICATION HEX CAP SCREW AND CARRIA GE BOL TS CARRIAGE BOLTS CLASSES 5.6 AND UP

HEX NUTS AND LOCKNUTS CLASSES 05 AND UP

00-20

SECTION 00 - GENERAL INFORMATION

Reco v er y and Tr anspor Recov ery ansportt of the Machine Reco v er y of the Machine Recov ery EC15 NOTE: The recovery of the machine should be accomplished using a crane if possible.

If the machine needs to be towed, connect to either the eye (1) on the undercarriage, or the two drilled holes (2) on the dozer blade.

EC25/EC35/EC45 NOTE: The recovery of the machine should be accomplished using a crane if possible.

If the machine needs to be towed, connect to either the eye (1) on the undercarriage, or the two drilled holes (2) on the dozer blade.

00-21

SECTION 00 - GENERAL INFORMATION

Loading the Machine Using a Crane EC15

CAUTION ONLY ONL Y USE THE ORIGINAL NEW HOLLAND CONSTRUCTION CRANE LIFTING BEAM FOR THE CAB AND THE OVERHEAD GUARD (CANOPY).

USE A CRANE WITH SUFFICIENT LIFTING CAPA CITY..

CAP A CITY

To load the machine onto a flat bed trailer, etc, proceed as follows: 1.

Empty and fold in the bucket.

2.

Position the machine straight ahead.

3.

Block the uppercarriage using the swinglock (1).

4.

Raise the boom.

5.

Retract the dipperstick.

6.

Stop the engine.

7.

Dismount from the excavator and close the doors.

8.

Attach the crane lifting beam (1) on the cab or overhead guard (canopy) with four screws.

9.

Suspend the excavator on the crane lifting beam.

00-22

SECTION 00 - GENERAL INFORMATION

EC25/EC35/EC45

CAUTION ONLY ONL Y USE THE ORIGINAL NEW HOLLAND CONSTRUCTION CRANE LIFTING HARNESS. USE A CRANE WITH SUFFICIENT LIFTING CPA CITY..

CP A CITY To load the machine onto a flat bed trailer, etc, proceed as follows: 1.

Empty and fold in the bucket.

2.

Position the work equipment straight ahead.

3.

Retract the dipperstick.

4.

Move the boom upwards until it reaches distance (a) and cylinder reaches distance (b).

EC25/EC35/EC45 Distance (a) = 1300 mm (51 inches) EC25/EC35 Distance (b) = 310 mm (12 inches) EC45 Distance (b) = 215 mm (8 inches) 5.

Stop the engine.

6.

Dismount from the excavator and close the doors.

7.

Attach the excavator to the three-point crane lifting harness at the points shown (two points on the dozer blade and one on the dipperstick).

CAUTION THAT BE SURE THA T THE SPREADER BAR (1) IS CORRECTLY SEATED TED..

CORRECTL Y SEA TED

00-23

SECTION 00 - GENERAL INFORMATION

Tr anspor ting the Machine ansporting EC15/EC25/EC35 When transporting the machine on a flat bed trailer, etc., the machine must be properly lashed at the marked points, undercarriage (1) and dozer blade (2), and secured with chocks.

1.

Prior to lashing, lower the dozer blade and position the work equipment on the ground.

DANGER AW TRANSPORT BE A WARE OF THE TOTAL TRANSPOR T HEIGHT.. BE CAREFUL WHEN DRIVING IN HEIGHT TUNNELS, UNDER BRIDGES, ETC.

EC45 When transporting the machine on a flat bed trailer, etc., the machine must be properly lashed at the marked points, undercarriage (1) and dozer blade (2), and secured with chocks.

1.

Prior to lashing, lower the dozer blade and position the work equipment on the ground.

DANGER AW TRANSPORT BE A WARE OF THE TOTAL TRANSPOR T HEIGHT.. BE CAREFUL WHEN DRIVING IN HEIGHT TUNNELS, UNDER BRIDGES, ETC.

00-24

SECTION 00 - GENERAL INFORMATION

Loading the Machine onto a Flatbed 1.

Use a loading platform with an angle less than 15 degrees.

2.

Secure the vehicle with chocks so that it cannot roll.

3.

Pull the machine onto the vehicle from the rear with the front of the machine pointed away.

4.

Lash the machine for transport.

Proper Suppor Supportt of a Raised Machine When it is necessary to have the machine completely raised with the tracks off the ground to perform a repair task, securely support the machine with adequate jack stands or blocks.

00-25

SECTION 00 - GENERAL INFORMATION

THIS P AGE INTENTIONALL Y LEFT BLANK PA INTENTIONALLY

00-26

EC15, EC25, EC35, EC45 CRAWLER EXCAVATOR SERVICE MANUAL CONTENTS SECTION 00 - GENERAL INFORMATION

SECTION 6 - ELECTRICAL SYSTEM SECTION 7 - HYDRAULIC SYSTEM SECTION 10 - OPERATOR’S PLATFORM SECTION 11 - TRACTION/UNDERCARRIAGE

©1999 NEW HOLLAND CONSTRUCTION

SECTION 6 - ELECTRICAL SYSTEM

THIS PAGE INTENTIONALLY LEFT BLANK

6-2

SECTION 6 - ELECTRICAL SYSTEM

SECTION 6 ELECTRICAL SYSTEM Contents General Electrical Information ............................................................................................................. 6-8 Definition of Terms ............................................................................................................................... 6-9 Wire Abbreviations to Indicate Wire Color ......................................................................................... 6-10 Specifications .................................................................................................................................... 6-11 Instrument Panel Component Locations and Functions .................................................................... 6-12 Fuse Panel Component Locations and Functions ............................................................................. 6-13 Electrical Circuits .............................................................................................................................. 6-14 Power Supply Circuit ..................................................................................................................... 6-14 Startup and Pre-Heat Circuit ......................................................................................................... 6-15 Travel Fast/Slow Circuit ................................................................................................................. 6-17 EC15 .......................................................................................................................................... 6-17 EC25/EC35 ................................................................................................................................ 6-17 EC45 .......................................................................................................................................... 6-17 Alternator Charge Lamp & Operating Hourmeter Circuit ............................................................... 6-18 Warning Buzzer Circuit .................................................................................................................. 6-20 Oil Pressure Sensing Circuit ......................................................................................................... 6-20 Air Filter Restriction Indicator ........................................................................................................ 6-20 Hydraulic Oil Filter Clogging Indicator Circuit ................................................................................ 6-20 Coolant Temperature Indicator Circuit ............................................................................................ 6-20 Fuel Gauge Circuit ......................................................................................................................... 6-22 Heater Fan Circuit .......................................................................................................................... 6-22 Washer/Wiper Circuit ..................................................................................................................... 6-23 Working Flood Light Circuit ............................................................................................................ 6-24 Rotating Beacon Circuit ................................................................................................................. 6-24 Radio Circuit .................................................................................................................................. 6-25 Internal Lights and Socket Circuit .................................................................................................. 6-25 Horn Circuit ................................................................................................................................... 6-26 Fuel Pump Circuit .......................................................................................................................... 6-26 Removal, Installation and Wiring of Electrical Components .............................................................. 6-27 Battery ........................................................................................................................................... 6-27 EC15 .......................................................................................................................................... 6-27 Removal ................................................................................................................................. 6-27 Installation ............................................................................................................................... 6-27 EC25 and EC35 ......................................................................................................................... 6-28 Removal ................................................................................................................................. 6-28 Installation ............................................................................................................................... 6-28 6-3

SECTION 6 - ELECTRICAL SYSTEM

EC45 .......................................................................................................................................... 6-29 Removal ................................................................................................................................. 6-29 Installation ............................................................................................................................... 6-29 Fuses ............................................................................................................................................. 6-30 Fuse Panel Wiring ...................................................................................................................... 6-30 Removal (Fuses FA, FB, F1 through F13) ................................................................................. 6-31 Installation (Fuses FA, FB, F1 through F13) .............................................................................. 6-31 Relays and Diode Block ................................................................................................................ 6-32 Relay K1 .................................................................................................................................... 6-32 Diode Block K4 Wiring ............................................................................................................... 6-32 Relay K1 Wiring.......................................................................................................................... 6-32 Relay K10 Wiring ........................................................................................................................ 6-33 Relays K1, K2, K3, K4 ............................................................................................................... 6-34 Removal ................................................................................................................................. 6-34 Installation ............................................................................................................................... 6-34 Relay K10 Pre-Heat Timer Unit .................................................................................................. 6-35 Removal ................................................................................................................................. 6-37 Installation ............................................................................................................................... 6-37 Pre-Heat/Start (Ignition) Switch ................................................................................................. 6-38 Pre-Heat/Start (Ignition) Switch Wiring ................................................................................... 6-38 Removal ................................................................................................................................. 6-39 Installation ............................................................................................................................... 6-40 Fan (Heater/Ventilator) Switch ................................................................................................... 6-42 Fan Switch (S15) Wiring ......................................................................................................... 6-42 Removal ................................................................................................................................. 6-43 Installation ............................................................................................................................... 6-44 Washer/Wiper Switch ................................................................................................................. 6-46 Washer/Wiper Switch (S11) Wiring ........................................................................................ 6-46 Removal ................................................................................................................................. 6-47 Installation ............................................................................................................................... 6-48 Working Floodlight Switch .......................................................................................................... 6-50 Working Floodlight Switch Wiring ........................................................................................... 6-50 Removal ................................................................................................................................. 6-51 Installation ............................................................................................................................... 6-52 Rotating Beacon Switch ............................................................................................................. 6-54 Rotating Beacon Switch Wiring .............................................................................................. 6-54 Removal ................................................................................................................................. 6-55 Installation ............................................................................................................................... 6-56 Fast/Slow Switch ........................................................................................................................ 6-58 Removal ................................................................................................................................. 6-58 Installation ............................................................................................................................... 6-59 6-4

SECTION 6 - ELECTRICAL SYSTEM

Horn Button Switch .................................................................................................................... 6-61 Removal ................................................................................................................................. 6-61 Installation ............................................................................................................................... 6-62 Battery Charge Indicator (Red) .................................................................................................. 6-64 Removal ................................................................................................................................. 6-64 Installation ............................................................................................................................... 6-65 Pre-Heat Monitor Indicator (Orange) .......................................................................................... 6-67 Removal ................................................................................................................................. 6-67 Installation ............................................................................................................................... 6-68 Engine Oil Pressure Indicator (Red) .......................................................................................... 6-70 Removal ................................................................................................................................. 6-70 Installation ............................................................................................................................... 6-71 Air Filter Clogging Indicator (Yellow)........................................................................................... 6-73 Removal ................................................................................................................................. 6-73 Installation ............................................................................................................................... 6-74 Hydraulic Oil Filter Clogging Indicator ........................................................................................ 6-76 Removal ................................................................................................................................. 6-76 Installation ............................................................................................................................... 6-77 Hourmeter .................................................................................................................................. 6-79 Removal ................................................................................................................................. 6-79 Installation ............................................................................................................................... 6-80 Fuel Gauge ................................................................................................................................ 6-82 Removal ................................................................................................................................. 6-82 Installation ............................................................................................................................... 6-83 Coolant Temperature Gauge ...................................................................................................... 6-85 Removal ................................................................................................................................. 6-85 Installation ............................................................................................................................... 6-86 Socket ........................................................................................................................................ 6-88 Removal ................................................................................................................................. 6-88 Installation ............................................................................................................................... 6-89 Warning Buzzer.......................................................................................................................... 6-91 Removal ................................................................................................................................. 6-91 Installation ............................................................................................................................... 6-92 Interior Light and Switch ............................................................................................................. 6-94 Removal ................................................................................................................................. 6-94 Installation ............................................................................................................................... 6-94 Coolant Temperature Warning Contact ....................................................................................... 6-95 Removal ................................................................................................................................. 6-95 Installation ............................................................................................................................... 6-95 Oil Pressure Sensor .................................................................................................................. 6-96 Removal ................................................................................................................................. 6-96 Installation ............................................................................................................................... 6-96 6-5

SECTION 6 - ELECTRICAL SYSTEM

Air-Flow Maintenance Switch ..................................................................................................... 6-97 Removal ................................................................................................................................. 6-97 Installation ............................................................................................................................... 6-97 Hydraulic Oil Filter Clogging Switch ........................................................................................... 6-98 Removal ................................................................................................................................. 6-98 Installation ............................................................................................................................... 6-98 Coolant Temperature Sensor ...................................................................................................... 6-99 Removal ................................................................................................................................. 6-99 Installation ............................................................................................................................... 6-99 Radio ........................................................................................................................................ 6-100 Removal ............................................................................................................................... 6-100 Installation ............................................................................................................................. 6-100 Loudspeakers .......................................................................................................................... 6-101 Right Loudspeaker ............................................................................................................... 6-101 Removal ............................................................................................................................ 6-101 Installation ......................................................................................................................... 6-101 Left Loudspeaker .................................................................................................................. 6-102 Removal ............................................................................................................................ 6-102 Installation ......................................................................................................................... 6-102 Horn ......................................................................................................................................... 6-103 Removal ............................................................................................................................... 6-103 Installation ............................................................................................................................. 6-103 Engine Shutoff Solenoid ........................................................................................................... 6-104 EC15 .................................................................................................................................... 6-104 Removal ............................................................................................................................ 6-104 Installation ......................................................................................................................... 6-104 EC25 .................................................................................................................................... 6-105 Removal ............................................................................................................................ 6-105 Installation ......................................................................................................................... 6-105 EC35 .................................................................................................................................... 6-106 Removal ............................................................................................................................ 6-106 Installation ......................................................................................................................... 6-106 EC45 .................................................................................................................................... 6-107 Removal ............................................................................................................................ 6-107 Installation ......................................................................................................................... 6-107 Pressure Switches S30, S31, S32, and S33 (EC45 Only) ...................................................... 6-108 Removal ............................................................................................................................... 6-109 Installation ............................................................................................................................. 6-109 Hand Lever Proximity Switch, B2 (EC15 Only) ....................................................................... 6-110 Floodlights ................................................................................................................................ 6-110 Windshield Wipers .................................................................................................................... 6-110 Windshield Washer Pump ........................................................................................................ 6-110 Heater ...................................................................................................................................... 6-110 Fast/Slow Solenoid ................................................................................................................... 6-110

6-6

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC15 ............................................................................................................. 6-112 Electrical Schematic EC25 ............................................................................................................. 6-116 Electrical Schematic EC35 ............................................................................................................. 6-120 Electrical Schematic EC45 ............................................................................................................. 6-124

6-7

SECTION 6 - ELECTRICAL SYSTEM

GENERAL ELECTRICAL INFORMATION The electrical system is a 12-volt negative (-) ground system that provides battery voltage to the starting circuit, and other electrical components.

The electrical system is made up of the following components and their functions: 1. Battery - Power supply and storage.

2. Alternator/Regulator - Power supply and source to maintain fully charged system.

3. Starter motor - To crank engine for starting.

4. Ignition switch - Used to control electrical circuits and direction of battery voltage.

5. Fuse blocks/fuses/circuit breakers, cab and engine - Used to protect the electrical circuit.

6. Fuel solenoid - Controls fuel flow.

7. Switches - Used to control other electrical circuits, lights, etc.

ATTENTION: Do not connect any electrical circuits at the ignition key switch or cab fuse block(s) unless there are written instructions telling you to do so or damage to the electrical components may occur.

ATTENTION: If any servicing or adjustments require the battery to be disconnected, or welding is required on the excavator, disconnect the negative (-) ground cable. Failure to disconnect the battery may result in damage to electrical components.

6-8

SECTION 6 - ELECTRICAL SYSTEM

DEFINITION OF TERMS ALTERNATING CURRENT (A.C.) - A flow of electrons which reverses its direction of flow at regular intervals in a conductor.

AMMETER - Measures the flow of electrical current in amperes. Ammeters are connected in series with the circuit to be tested.

AMPERE - A unit of measure for the flow of current in a circuit. The ampere is used to measure electricity such as “gallons per minute” is used to measure liquid flow.

CIRCUIT - A continuous, unbroken path along a conductor through which electrical current can flow from a source, through various components, and back to the source.

CIRCUIT BREAKER - A device to protect an electrical circuit from overloads and can be reset, or will automatically reset.

COLD CRANK RATING (CCA) - The cranking load capacity of a battery at low temperatures (cold cranking amperes at 0° F).

CONTINUITY - Unbroken path along a conductor through which electrical current can flow.

CURRENT - Movement of electricity along a conductor. Current is measured in amperes.

DIODE - An electrical device that will allow current to pass through itself in one direction only.

DIODE (RESISTOR TYPE) - An electrical device that will allow current to pass through itself in one direction only and will cause resistance as the electricity passes through. The electricity coming from this type diode will be less than what is going in.

DIRECT CURRENT (D.C.) - A flow of electrons moving in the same direction along a conductor from a point of high potential to one of lower potential.

FUSE - A device to protect an electrical circuit from overloads that needs to be replaced when blown.

OHM - The standard unit for measuring resistance to flow of an electrical current.

OHMMETER - An instrument for measuring the resistance in ohms of an electrical circuit.

OPEN CIRCUIT - An open circuit occurs when a circuit is broken which interrupts the flow of current through the circuit.

RELAY - An electrical switch which opens and closes a circuit automatically when activated.

RESISTANCE - The opposing force offered by a circuit. Resistance is measured in ohms.

SHORT CIRCUIT - A part of a circuit that comes in contact with part of the same circuit or unintentionally touches a metallic object.

SOLENOID - A circular coil used for producing a magnetic field.

SWITCHES - A device used to control and direct current to circuits and will remain in this position until changed.

SWITCHES (MOMENTARY) Momentary switches are used to direct current to circuits and these switches will return to the neutral position when released.

6-9

SECTION 6 - ELECTRICAL SYSTEM

DEFINITION OF TERMS (continued) VOLT - A unit of electrical pressure which causes current to flow in a circuit.

VOLTAGE - The force which is generated to cause current to flow in an electrical circuit. Voltage is measured in volts.

VOLTMETER - An instrument for measuring the force in volts of electrical current. Voltmeters are connected in parallel to the points where voltage is to be measured.

The following are common terms used in electrical diagnostics and how they may affect the circuit and electrical components.

The term “OPEN CIRCUIT” means there is no current getting from the control point to the operating point. This means the wire carrying the current is open/broken and current cannot continue to flow. The effect is the operating component will not function.

The term “SHORT CIRCUIT” means there is current being lost to another component wire or to ground. This could result in the wrong component being operated or the blowing of the circuit protection device (fuse or breaker).

The term “GROUNDED CIRCUIT” means the current is going directly to ground and usually results in no component operation and/or blown fuse-breaker.

To test for an “OPEN CIRCUIT,” use a volt/ohm meter and check for continuity from one end of the wire to the other. If continuity is not found, trace the circuit from control point to operating point until the open is found.

To test for a “SHORT CIRCUIT,” use a volt/ohm meter and check for very low resistance in different parts of the circuit or continuity between the circuit wire and ground.

To test for a “GROUNDED CIRCUIT” use a volt/ohm meter and check for continuity between the circuit wire and ground.

The following chart shows the abbreviations for the various wire colors used to identify the electrical circuits.

WIRE ABBREVIATIONS TO INDICATE WIRE COLOR bg bl br dbl dbr

beige blue brown dark blue dark brown

dgr ge gn gr hbl

dark grey yellow green grey light blue

6-10

hbr hgr hr nt or

light brown light grey light red nature orange

rt sw vi ws

red black violet white

SECTION 6 - ELECTRICAL SYSTEM

SPECIFICA TIONS SPECIFICATIONS Alternator ...................................................................................................................................... 40 amp Battery ............................................................. BCI PC31 - 12 volt - 625 amps @ 0° F(-18° C) Top stud System Ground ..................................................................................................................... Negative (-) Protection .................................................................................................................. Fuse blocks in cab

Fuse FA FB F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14

Rating 30 A 60 A 15 A 10 A 10 A 10 A 10 A 10 A 15 A 10 A 10 A 10 A 10 A 20 A Diode 3A

Application Main fuse Fuse for pre-heater system Windshield wiper Instruments, Indicator lamps Working floodlight, front Working floodlight, rear Travel, fast/slow Horn Heater fan Fuel pump/generator Radio Option Internal light, radio Rotation beacon Socket Blocking diode for gererator D1

6-11

SECTION 6 - ELECTRICAL SYSTEM

Instrument Panel Component Locations and Functions

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Pre-heat/starter switch (ignition lock) Horn button Red - Battery charge indicator Orange - Pre-heating monitor Red - Engine oil pressure indicator Red - Air filter clogging indicator Hydraulic oil filter clogging indicator (option) Fuel gauge Operating hour meter Coolant temperature Immobilizer (option) Fast/slow (option) Windshield washer/wiper system Work floodlight(s) Heater/ventilation Blank Rotating warning beacon (option) Warning buzzer Socket

The machine warning buzzer (18) gives a signal when any of the following malfunctions occur: • Air filter clogging indicator (6) • Engine oil pressure too low (5) • Coolant temperature too high (10) • When the hydraulic oil is cold, the hydraulic oil filter clogging indicator (7) may light up briefly. It will go out once the operating temperature has been reached.

6-12

SECTION 6 - ELECTRICAL SYSTEM

Fuse Panel Component Locations and Functions

Fuse FA FB F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14

Rating 30 A 60 A 15A 10A 10A 10A 10A 10A 15A 10A 10A 10A 10A 20A Diode 3A

Function Main fuse Fuse for pre-heater system Windscreen wiper Instruments, indicator lamps Working floodlight, front Working floodlight, rear Travel, fast/slow Horn Heater fan Fuel pump/generator Radio Option Internal light, radio Rotating beacon Socket Blocking diode for generator

6-13

SECTION 6 - ELECTRICAL SYSTEM

ELECTRICAL CIRCUITS

Power Supply Circuit The power supply circuit consists of the battery which supplies initial voltage for starting the engine and the alternator (G1) that supplies voltage after the engine has started. The alternator (G1) is driven by a belt from the engine. Terminal (30) on the starter motor (M1) is the relay located on top of the starter motor.

Positive battery voltage is routed through black wire (sw), to connector (X4-1). The voltage at (X4-1) is divided into two paths. One path, through red wire (rt) and 60A fuse (FB), goes to the preheat timer control unit (K10). The second path, through wire (sw) and fuse (FA), goes to terminal (30) of the pre-heat/starter switch (ignition switch) (S2) and, via wire (30), to the interior lights, the socket in the cab, the radio presets and the rotating beacon. The preheat timer unit (K10) is not energized at this time so no current flows in the preheat circuit.

With the ignition switch (S2) is in the 0 (off) position, no current can flow through the ignition switch and the engine cannot be started.

Voltage through 30A fuse (FA) is present at all

times for the interior lights, the socket in the cab, the radio preset time and push buttons and for the rotating beacon through wire (30). These circuits can operate without the ignition switch being turned on. All components connected to wire (15), must have the key switch (S2), turned on before they can be operated. When the engine is not operating, the alternator (G1) provides no output. If the ignition switch is rotated to position 1, battery voltage routed through fuse (FA) is routed through ignition switch terminals (30) and (15) and to all other circuits via wire (15). If these circuits are left on for any length of time, the battery can be rundown.

When the engine is started, the alternator (G1) generates voltage which is fed back from terminal (B+) through wire (sw) to the battery positive terminal to charge the battery. The voltage applied to alternator terminal (G+), is used to excite the field coil in the Alternator armature, through wire (sw), through connector (XGN) terminals (6) and (7), through the fuse (F8) from voltage output wire (15).

6-14

SECTION 6 - ELECTRICAL SYSTEM

Startup and Pre-Heat Circuit The startup and pre-heat circuit includes the battery, fuses (FA and FB), the ignition switch (S2), the pre-heater time control unit (K10), the glow plugs (R1, one in each cylinder), the starter motor (M1), and the pre-heater monitor light (H2).

Positive battery current is routed through wire (sw), to connector (X4-1). The current at (X4-1) is divided into two paths. One path, through wire (rt) and fuse (FB), goes to the preheat timer control unit (K10) terminal (8). Initially, the time control is de-energized and the current cannot pass through to the glow plugs. The second path, through wire (sw) and fuse (FA), goes to terminal (30) of the ignition switch (S2). When the ignition switch is set to the run position (I), the pre-heater comes on. The battery voltage at terminal (30) of the ignition switch is connected though terminal (54), then, via wire (vi/ws) to terminal (3) on the pre-heater time control unit (K10). The time control (K10) terminal (1) is connected to chassis ground completing the time control circuit energizing the time control. When the time control unit is energized, current from terminal (8) is routed through to terminal (9) and to the glow plugs.

When the time control unit comes on, voltage is applied from terminal (3) through terminal (5), then through connector (XGN) contacts (7) and (6) to illuminate the pre-heater monitor light (H2), indicating that the glow plugs are heating. When

the light goes out, then the engine can be started by turning the ignition switch to the start position (II).

Setting the ignition switch to the start position (II), routes battery current from switch terminal (30) to terminal (50A). The current at terminal (50A) is routed through wire (rt), connector (X2) contacts (8) and (4), connector (XGN) contacts (1) and (4), and through wire (rt) to terminal (50a) on the starter motor (M1) relay coil. The starter motor cranks the engine and, at the same time, provides battery voltage through terminal (50b) of the starter moter (M1) on the (EC45), or from connector (XGN) terminal (4) (EC15/EC25/ EC35), to terminal (A), (the pull-in coil), on the engine shut-off solenoid (Y1), opening the fuel line to allow fuel to flow to the engine. When the engine starts, the ignition switch is released setting the switch to the run position and removing voltage from the ignition switch terminal (50a), thus removing voltage from the starter motor terminal (50A). This removes voltage to terminal (A) of the engine shut-off relay (Y1). Engine shut-off relay (Y1) does not release at this time because a second voltage path from terminal (54) of the ignition switch (S2) is provided via wire (sw/bl), connector (X2) contacts (7) and (3), connector (XGN) contacts (8) and (5), and wire (bl/sw) to terminal (B), (the holding coil), on engine shut-off relay (Y1). The engine will continue to run until the ignition switch is turned off, opening the voltage path to the fuel 6-15

SECTION 6 - ELECTRICAL SYSTEM

6-16

SECTION 6 - ELECTRICAL SYSTEM

shut-off relay (Y1), closing the fuel valve or the fuel supply is exhausted.

crawler control pedals, three relays (K10, K11, and K12), four diode module (D1) and the fast/ slow valve (Y3).

Travel Fast/Slow Circuit The fast/slow circuit is electrically different for each excavator.

EC15 Positive current from the wire (15) is routed through fuse (F5) and wire (ge) to terminal (5) on the fast/slow switch (S5). When switch (S5) is set to the fast position, the current is routed through wire (rt/ge), connector (XGE) contacts (3) and (2) to the (+) terminal on the proximity switch (B2), located at the left travel control lever. When the left travel lever is actuated, current at proximity switch terminal (A) is routed through wire (bl/ge/gn) and connector (XGE) contacts (3) and (2) to coil terminal (86) on the fast/slow relay (K2) energizing the relay. Voltage from fuse (F5) is routed through wire (rt/ge) to terminal (30) of the relay. When the relay is energized, the voltage at terminal 30 is routed through terminal (87), then through wire (rt) and connector (XGE) contacts (1) and (4)to the fast/ slow valve (Y2). This causes the valve to transfer to the fast position allowing the excavator to move in the fast speed condition.

EC25/EC35 This circuit includes the fuse (F5), fast/slow switch (S5) on the control panel, and the fast/ slow valve (Y3).

Positive current from the wire (15) is routed through fuse (F5) and wire (ge) to terminal (5) on the fast/slow switch (S5). When switch (S5) is set to the fast position, the current is routed through wire (rt/ge), connector (XSW) contacts (1) and (4), then through wire (rt) to the fast/slow valve (Y3). This causes the valve to transfer to the fast position allowing the excavator to move in the fast speed condition.

EC45 This circuit includes the fuse (F5), the fuse (F10), fast/slow switch (S5) on the control panel, forward and reverse pressure switches (S30, S31, S32, and S33) operated by the left and right

Positive current from the wire (15) is routed through fuse (F5) and wire (ge) to terminal (1) on the fast/slow switch (S5). When switch (S5) is set to the fast position, the current is routed through wire (rt), connector (XSW) contacts (1) and (4), then to relay (K12) terminal (86) which turns it on, since from terminal (85) wire (br) goes to connector (XDBL 1 and 4), and from there to a chassis ground connection. Positive current from the wire (15) is also routed through fuse (F10) and to terminal (3) of connector (XDBL) from terminal (2), through wire (ge) to the forward right pressure switch (S32), the reverse right pressure switch (S30), the forward left pressure switch (S33) and the reverse left pressure switch (S31).

If the forward right pressure switch (S32) is closed, the current is routed through wire (rt/bl) to the relay (K11), terminal (86), which turns it on, since wire (br) is connected to terminal (85), from there to relay (K10), terminal (85), from there to relay (K12) terminal (85), and from there to the chassis ground through connector (XDBL) terminals (1) and (4). If the forward left pressure switch (S33), is also turned on, current will pass from the pressure switch to relay (K11) terminal (30), since the relay is turned on by the closure of the pressure switch (S32), current passes to relay (K11) terminal (87), through wire (rt) to relay (K10) terminal (87), through wire (rt) to relay (K12) terminal (30), relay (K12) is turned on, whenever the fast/slow switch (S5) is set to the fast position, the current passes to relay (K12) terminal (87), from there through wire (rt) to solenoid valve (Y3), terminal (1), solenoid (Y3) terminal (2) is connected to the chassis ground through connector (XDBL) terminals (1) and (4), causing the valve to transfer to the fast position allowing the excavator to move forward in the fast speed condition.

If the reverse right pressure switch (S30) is closed, the voltage is routed through wire (rt/sw) to the relay (K10), terminal (86), which turns it on, since wire (br) is connected to terminal (85), from there to relay (K12) terminal (85), and from there to chassis ground through connector (XDBL) terminals (1) and (4). If the reverse left pressure switch (S31), is also turned on, current will pass from the pressure switch to relay (K10) terminal (30), since the relay is turned on by the closure of pressure switch (S30), current 6-17

SECTION 6 - ELECTRICAL SYSTEM

passes to relay (K10) terminal (87), through wire (rt) to relay (K12) terminal (30), relay (K12) is turned on, whenever the fast/slow switch (S5) is set to the fast position, the current passes to relay (K12) terminal (87), from there through wire (rt) to solenoid valve (Y3), terminal (1), solenoid (Y3) terminal (2) is connected to the chassis ground through connector (XDBL) terminals (1) and (4), causing the valve to transfer to the fast position allowing the excavator to move backward in the fast speed condition.

Thus, to operate in the fast position, the fast/ slow switch (S5) must be in the fast position, and either both forward pressure switches (S32 and S33) must be operated, or both reverse pressure switches (S30 and S31) must be operated. If one forward and one reverse switch

are operated, the excavator will remain in slow speed.

In addition to the Two-speed circuit, if any one of the travel pressure switches are closed, the travel motion alarm will sound. Current passes from the pressure switches to a diode in the diode module (D1) which contains four diodes, one for each pressure switch. Current passing through the diodes (D1) to terminal (87a) then by wire (gn) to the travel alarm (H1) terminal (1).

Terminal (2) of (H1) is connected to the chassis ground through wire (br) to relay (K11) terminal (85).

Alternator Charge Lamp & Operating Hourmeter Circuit When the Key Switch is turned on, the Amber Lamp (H1) with the Battery symbol turns on to indicate that the alternator is not charging. When the engine starts, the lamp should go out to indicate that the alternator is charging the battery. The lamp (H1) is turned on by current coming from wire (15) from the Key Switch, through fuse (F2) yellow wire (ge) to lamp (H1).

The gound connection is through blue wire (bl), through diode (D1), wire (bl) to the (D+) terminal of Alternator (G1), then to the chassis ground through (B-) terminal of the alternator.

The hourmeter circuit records operating hours of the excavator whenever the alternator is charging. When the engine starts, 12 Volt current comes from the alternator (G1) terminal (D+), through wire (bl), connector (XGN) terminals (1) and (4), to the cathode terminal of diode (D1), [it also goes to Relay (K1) terminal (86)], this causes the diode to be turned off, forcing the current flowing through lamp (H1) to be reduced from 2 mA, to .07 mA, which turns off the lamp. The current instead flows through wire (bl) to hourmeter (P4) terminal (D+). The negative side of hourmeter (P4), terminal (31) is connected to the chassis ground. Since the resistance of the lamp (H1) is extremely low, and the resistance of the hourmenter (P4) is very high. The lamp does not illuminate but instead, turns on the hourmeter. As long as the voltage from the alternator (G1) terminal (D+), output is present, the hourmeter will record the operating time.

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SECTION 6 - ELECTRICAL SYSTEM

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SECTION 6 - ELECTRICAL SYSTEM

Warning Buzzer Circuit The warning buzzer circuit provides a buzzer warning whenever the coolant temperature exceeds a set value, the engine oil pressure does not reach or maintain the desired level, or the air filter is clogged.

When the engine is running, the alternator provides a positive voltage output from terminal D+. This current is routed through connector (XGN) contacts (1) and (4), wire (bl) to coil terminal 86 of the warning buzzer cut-off relay (K1). The other side of the coil, terminal (85), is connected through wire (br/ge) to terminals (30) and (85) of diode block (K4). Terminals (30) and (85) are connected to the anodes of three diodes in the diode block. The cathode of one diode is connected through wire (rt/gn), at terminal (87), and connector (XGE) contacts (5) and (8) to the normally open coolant temperature switch (B3).

The cathode of a second diode is connected through wire (gn), at terminal (87a), and connector (XGN) contacts (3) and (2), to the normally closed oil pressure switch (B5). Switch (B5) opens as soon as oil pressure starts to build and remains open when normal pressure is present. The cathode of the third diode is connected through wire (bl/ws), at terminal (86), and connector (XGE) terminals (6) and (7) to the normally open air filter maintenance switch (B4).

When the engine is running normally, all three switches are open and the warning buzzer solenoid (K1) is de-energized. If any of the three switches close, warning buzzer cut off (K1) is energized. When (K1) is energized, current flows from the wire (15) then through fuse (F2) and wire (ge) to the common contact (30) of the warning buzzer cut off relay (K1). If relay (K1) is energized, current is then routed through terminal (87) and wire (ge/sw) to the warning buzzer (B11) sounding a warning.

Oil Pressure Sensing Circuit

the engine starts, the oil pressure indicator will illuminate, but the buzzer will not sound since there is no voltage present at the alternator terminal (D+).

When the engine starts, oil pressure switch (B5) opens if there is sufficient oil pressure, if not, the buzzer will sound, as soon as there is current from the (D+) terminal of the Alternator (G1).

Air Filter Restriction Indicator The air filter indicator (H4) has positive voltage from fuse (F2) applied to one side. The other side of the air filter indicator is connected through wire (bl/ws), connector (XGE) contacts (7) and (6), and wire (bl/ws) to air filter maintenance switch (B4). When normal air pressure is present, the switch (B4) is open and the air filter indicator is not illuminated. When the air filter is restricted, the air pressure is reduced below the desired value, air filter switch (B4) closes, connecting the air filter indicator to ground and illuminating the air filter restriction indicator.

Hydraulic Oil Filter Clogging Indicator Circuit The hydraulic oil filter clogging indicator (H5), has positive voltage from fuse (F2) applied to one side. The other side of the hydraulic oil filter clogging indicator is connected through wire (ge/ gn), connector (XSW) contacts (2) and (3), and wire (ge/gn) to hydraulic oil filter clogging switch (B7). When normal hydraulic pressure is present, the switch (B7) is open and the hydraulic oil filter clogging indicator is not illuminated. When the hydraulic oil filter clogging pressure increases above the desired value, hydraulic oil filter clogging switch (B7) closes, connecting the hydraulic oil filter clogging indicator to ground and illuminating the hydraulic oil filter clogging indicator.

The oil pressure indicator light (H3) has positive Coolant Temperature Indicator Circuit current routed through fuse (F2) from wire (15), applied to one side of the indicator. The other The positive voltage present at terminal (30) of side of the oil pressure indicator is connected relay (K1), is applied through wire (ge) to through wire (gn), connector (XGN) contacts (3) terminal (15) of the coolant temperature indicator and (2), and wire (gn) to oil pressure switch (B5).

(P1). The other side of the meter, terminal (G), is When normal oil pressure is present, the switch connected to ground through wire (rt/ws), (B5) is open and the oil pressure indicator is not connector (XGN) contacts (2) and (3), and wire illuminated. When the oil pressure drops below (rt/ws) to the coolant temperature sensor (B2). the desired value, oil pressure switch (B5) The sensor changes resistance as a function of closes, connecting the oil pressure indicator to temperature. As the resistance changes, the ground and illuminating the oil pressure indicator. coolant temperature indicator, which is an analog When the ignition switch is first turned on, before meter, displays the coolant temperature.

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SECTION 6 - ELECTRICAL SYSTEM

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SECTION 6 - ELECTRICAL SYSTEM

Fuel Gauge Circuit The positive voltage present at terminal (15) of the coolant temperature indicator (P1), is applied to terminal (15) of the fuel tank gauge (P2). The other side of the gauge, terminal (G), is connected to ground through wire (sw/vi), connector (XGE) contacts (8) and (5), and wire (sw/vi) to the fuel level sensor (B1). The sensor changes resistance as a function of fuel level.

As the resistance changes, the fuel gauge, which is an analog meter, displays the amount of fuel left in the fuel tank.

Heater Fan Circuit The heater fan circuit includes fuse (F7), fan switch (S15), and heater fan (M3). Positive current from line (15) is routed through fuse (F7), and wire (ge) to terminal (3) of fan switch (S15).

The fan switch is a three-position switch. In the off position, no voltage is applied to the heater fan and it is not operating. In the center position, current is routed from switch terminal (3) through switch terminal (5), wire (gn/sw), connector (XSW) contacts (5) and (8), and wire (gn/sw) to heater fan terminal (3) (EC15/EC25/EC35), or, through wire (rt) terminal (4) (EC45), causing the fan to run in slow speed. When the fan switch is fully pressed, current from switch terminal (3) is routed through switch terminal (1), wire (gn/bl), connector (XSW) contacts (6) and (7), and through wire (gn/bl) to heater fan terminal (1) (EC15/EC25/EC35), or, through wire (or) (EC45), causing the fan to run at the high speed.

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SECTION 6 - ELECTRICAL SYSTEM

Washer/Wiper Circuit The washer/wiper circuit, includes fuse (F1), washer/wiper switch (S11), wiper motor (M4) and washer pump (M5). Positive current from line (15) is applied through fuse (F1), and wire (ge) to terminal (2) of the washer/wiper switch (S11). When the washer/wiper switch (S11) is in any position, positive voltage is present from wire (15) and fuse (F1), at switch terminal (2) and also through wire (bl/sw), connector (XWS) contacts (1) and (4), and wire (bl/sw) to terminal (53a) on wiper motor (M4), for the purpose of returning the wiper blade to the park position when switch (S11) is turned off.

When the washer/wiper switch (S11) is in the off position, the wiper moter (M4) is held in the park position by the positive voltage on terminal (53a), and the negative ground on terminal (53), through wire (gn/vi) connector (XWS) contacts 3 and (2), washer/wiper switch (S11), terminal (5), through to terminal (7), and from there to the chassis ground.

When the washer/wiper switch (S11) is in the center position, current passes from switch (S11) terminal (2) to terminal (5), then through wire (gn/vi), connector (XWS) contacts (2) and (3), and wire (gn/vi) to terminal (53) of wiper motor (M4). Terminal 31 of wiper moter (M4) is connected to the chassis. This causes the wiper motor to run.

When the washer/wiper switch (S11) is in the spring loaded full on position, the washer pump is connected, current passes from switch (S11) terminal (2) to terminal (3) and terminal (5), from switch terminal (3), through wire (bl), connector (XWS) contacts (5) and (8), and wire (bl), to the (+) terminal of the wind shield washer motor (M5). The (-) terminal of the wind shield washer moter (M5), is connected to the chassis.

In addition, current passes from switch (S11) terminal (2) to terminal (5), then through wire (gn/ vi), connector (XWS) contacts (2) and (3), and wire (gn/vi) to terminal (53) of wiper moter (M4).

Terminal (31) of wiper moter (M4) is connected to the chassis. This causes the wiper moter to run while the windshield washer is running.

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SECTION 6 - ELECTRICAL SYSTEM

Working Flood Light Circuit The working flood light circuit includes fuses (F3 and F4), the working floodlight switch (S12), the rear floodlights (E5 and E6), and the front floodlights (E7 and E8). Positive current from wire (15) is applied to fuses (F3 and F4). The current passes through fuse (F3), and is routed through wire (ge) to terminal (2) of the working floodlight switch (S12). The current through fuse (F4) is routed through wire (ge) to terminal (1) of the working floodlight switch (S12). Switch (S12) is a three position switch. In the off position (0), both sets of switch contacts are open and the floodlights are turned off. When the switch is in the center position (I), current is routed from switch terminal (2) through terminal (6), then through wire (gr/rt) and connector (XWS) contacts (6) and (7) to the front flood lights (E7 and E8). Current is also applied out switch terminal (8) to switch terminal 10 to illuminate the switch. When the switch is in the (II) position, the front floodlights continue to be turned on and the current at terminal (1) of the working floodlight switch (S12) is routed through wire (gr/sw), connector (XWS) contacts (7) and (6), and wire (gr/sw) to the rear floodlights (E5 and E6). In this position both the front and rear floodlights are turned on.

Rotating Beacon Circuit The rotating beacon circuit, includes fuses (FA and F12), rotating beacon switch (S17), and the rotating beacon (E9). The rotating beacon circuit is connected to wire (30) which is directly connected to the battery and therefor can be operated without the pre-heat/start switch being turned on. Battery voltage is routed through connector (X4), fuse (FA), then through wire (30), fuse (F12), and wire (rt) to terminal (5) of the rotating beacon switch (S17). When the rotating beacon switch is turned on, current is routed from terminal (5) through terminal (1), wire (ws/vi) and connector (XEB) contacts (7) and (6) to the rotating beacon (E9), turning the beacon on. The voltage at terminal (1) of the switch is also applied to terminal (9) to illuminate the switch.

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SECTION 6 - ELECTRICAL SYSTEM

Radio Circuit The radio circuit, includes fuse (F9), and radio (B6). Positive output current from wire (15) is applied through fuse (F9), wire (ge), and connector (XEB) contacts (5) and (8) to terminal (15) on the radio. The radio chassis is connected to ground. When the radio is switched on, current flows through the radio.

Internal Lights and Socket Circuit The interior lights and socket circuit, includes fuses (FA, F11, and F13), interior light switch (S25), cab interior dome light (E21), socket (X1), and the circuit for the radio presets, (the time and station push buttons).

The interior lighting and socket circuit is directly connected to the battery hot wire (30), and can be operated without the pre-heat/start switch turned on. Positive current from the battery (G2) is routed through wire (sw), connector (X4), wire (sw), fuse (FA), wire (sw), and is connected to one side of fuse (F11) and one side of fuse (F13). From fuse (F11), current is routed first through wire (rt/ge), connector (XWS) contacts (8) and (5), wire (rt/ge) and applied to the normally open contact on the interior lighting switch (S25) and second, through wire (rt), and connector (XEB) contacts (4) and (1) to terminal (30) on the radio to store the presets of the radio.

When the interior lighting switch (S25) is turned on, voltage is applied to the interior lights (E21) for illumination.

The voltage applied to fuse (F13) is routed through the fuse and wire (rt) to the socket (X2) in the cab. The socket is 12 volt DC and can be used for accessories

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SECTION 6 - ELECTRICAL SYSTEM

Horn Circuit The horn circuit, includes fuse (F6), the horn (B10), and the horn switch (S4). Positive current from wire (15) is routed through wire (sw), fuse (F6), wire (ge), connector (XSW) contacts (8) and (5), and wire (ge) to one side of the horn.

The other side of the horn is connected through wire (br/gn), connector (XSW) contacts (6) and (7), and wire (br/gn) to horn switch (S4). When the horn switch is pressed, ground is connected to the horn and the horn sounds.

Fuel Pump Circuit The fuel pump circuit, includes the key switch (S2), wire (15), fuse (F8), wire (bl/rt), connector (X2) contacts (6) and (2), another section of wire (bl/rt), connector (XGE) contacts (6) and (7), then through another section of wire (bl/rt) to the positive terminal on fuel pump (M2). The negative side of fuel pump (M2) is connected to ground.

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SECTION 6 - ELECTRICAL SYSTEM

Removal, Installation and Wiring of Electrical Components Battery EC15 Removal The battery is located on the left side of the machine below the floor mat of the operator platform.

1. Turn off the machine.

2. Lift the floor mat on the left side of the machine, then remove the left floor cover plate.

3. Disconnect the battery negative (ground) cable first, then disconnect the positive cable.

4. Remove the clamping bracket (1).

5. Lift out the battery.

Installation 1. Place the battery in the machine with the positive terminal positioned toward the front of the machine.

2. Secure with the clamping bracket (1).

3. First connect the positive cable, then connect the battery negative (ground) cable.

NOTE: Ensure that the negative terminal is connected to the negative pole (-) and the positive terminal to the positive pole (+).

4. Install the left floor cover plate, then install the floor mat.

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SECTION 6 - ELECTRICAL SYSTEM

EC25 and EC35 Removal The battery is located below the right step plate.

1. Turn off the machine.

2. Open the right step plate by rotating the lock, accessible through the hole in the plate, onequarter turn.

3. Disconnect the battery negative (ground) cable first, then disconnect the positive cable.

4. Remove the clamping bracket (1).

5. Lift out the battery.

Installation 1. Place the battery in the machine with the positive terminal positioned toward the front of the machine (terminals toward the outside of machine).

2. Secure with the clamping bracket (1).

3. First connect the positive cable, then connect the battery negative (ground) cable.

NOTE: Ensure that the negative terminal is connected to the negative pole (-) and the positive terminal to the positive pole (+).

4. Close the right step plate and secure by rotating lock one-quarter turn.

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SECTION 6 - ELECTRICAL SYSTEM

EC45 Removal The battery is located in the engine compartment (rear left).

1. Turn off the machine.

2. Open the engine cover.

3. Disconnect the battery negative (ground) cable first, then disconnect the positive cable.

4. Remove the clamping bracket (1).

5. Lift out the battery.

Installation 1. Place the battery in the machine.

2. Secure with the clamping bracket (1).

3. First connect the positive cable, then connect the battery negative (ground) cable.

NOTE: Ensure that the negative terminal is connected to the negative pole (-) and the positive terminal to the positive pole (+).

4. Close the engine cover.

6-29

SECTION 6 - ELECTRICAL SYSTEM

FUSES

Fuse Panel Wiring

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SECTION 6 - ELECTRICAL SYSTEM

Removal Fuses (FA, FB, F1 through F13) 1. Disconnect battery negative (-) cable.

2. Remove screws (1) securing fuse and relay cover plate (2), and remove cover plate.

3. Remove fuse by pulling straight up on fuse.

Installation Fuses (FA, FB, F1 through F13) 1. Verify fuse rating.

2. Insert fuse into fuse receptacle.

3. Reattach fuse cover plate with screws.

4. Reconnect battery negative (-) cable.

6-31

SECTION 6 - ELECTRICAL SYSTEM

Relay K1

Relays and Diode Block Relay K1 Wiring Relay (K1) is the warning buzzer relay, relays (K2 and K3) are locations for optional relays, (K4) is a three-diode block. And relay (K10) is the pre-heat timer unit. Relays (K1) and (K4) are located on the fuse panel.

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SECTION 6 - ELECTRICAL SYSTEM

Relay K10 Wiring

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6-33

SECTION 6 - ELECTRICAL SYSTEM

Relays K1, K2, K3, K4 Relays (K1) through (K4) are located on the fuse and relay panel located on the console to the right of the operator. Relay (K1) is the Warning Buzzer Cut-off relay, Relay (K2) is the Fast/Slow relay used on the EC15 only, and relay (K3) is not used. Diode Block (K4) forms an OR gate circuit used in the operation of relay (K1).

Removal 1. Disconnect battery negative (-) cable.

2. Remove two screws (1) securing fuse and relay cover plate (2), and remove cover plate.

3. Remove relay from connector by pulling straight up on relay.

Installation 1. Insert relay into relay connector.

2. Reattach fuse and relay cover plate (2) with screws (1).

3. Reconnect battery negative (-) cable.

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SECTION 6 - ELECTRICAL SYSTEM

Relay K10 Pre-Heat Timer Unit The pre-heat timer unit is located in the engine compartment. The pre-heat timer units are located in different positions of the various machines but are removed in the same manner.

The pre-heat timer (1) on the EC15 is located on the right side wall of engine compartment, behind the air filter (2).

The pre-heat timer (1) on the EC25/EC35 is located on the right rear wall of the engine compartment, behind the air filter (2).

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SECTION 6 - ELECTRICAL SYSTEM

The pre-heat timer (1) on the EC45 is located on the left rear wall of engine compartment, below the air filter (2).

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SECTION 6 - ELECTRICAL SYSTEM

Removal 1. Disconnect negative (-) side of battery.

2. Remove nuts securing wires (1) to pre-heat unit (2). Disconnect wires, then reinstall nuts on terminals.

3. Disconnect wires (3) from pre-heat unit (2).

4. Remove screw (4) attaching pre-heat unit (2).

5. Remove unit from engine compartment.

Installation 1. Attach pre-heat unit (2) to engine compartment with screw (4).

2. Connect ring terminals (1) to pre-heat unit (2), and secure with nuts provided with unit.

3. Reconnect wires (3) to pre-heat unit (2).

4. Reconnect negative side of battery.

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SECTION 6 - ELECTRICAL SYSTEM

Pre-Heat/Start (Ignition) Switch Pre-Heat/Start (Ignition) Switch Wiring

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6-38

SECTION 6 - ELECTRICAL SYSTEM

Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-39

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access switch wiring. Disconnect wiring on ignition switch (1).

6. Lift switch retainers. Push ignition switch (1) out through front of pane (2).

Installation 1. Install ignition switch (1) through front of panel (2) such that switch cover hinge is toward top of panel and tabs on switch locking into switch retainers.

2. Attach wires to ignition switch.

6-40

SECTION 6 - ELECTRICAL SYSTEM

3. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

4. Attach control panel with screws and washers (1).

5. Reinstall right armrest using mounting hardware (1).

6. Reinstall seat belt bracket using mounting hardware (1).

7. Reconnect negative (-) battery cable.

6-41

SECTION 6 - ELECTRICAL SYSTEM

Fan (Heater/Ventilator) Switch Fan Switch (S15) Wiring

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6-42

SECTION 6 - ELECTRICAL SYSTEM

Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-43

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access connectors. Disconnect connector on fan switch (1).

6. Lift switch retainers. Push fan switch (1) out through front of panel (2).

Installation 1. Install fan switch (1) through front of panel (2) such that switch symbol is toward bottom of panel and tabs on switch lock into switch retainers.

2. Attach connector to fan switch on bottom of panel.

6-44

SECTION 6 - ELECTRICAL SYSTEM

3. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

4. Attach control panel with screws and washers (1).

5. Reinstall right armrest using mounting hardware (1).

6. Reinstall seat belt bracket using mounting hardware (1).

7. Reconnect negative (-) battery cable.

6-45

SECTION 6 - ELECTRICAL SYSTEM

Washer/Wiper Switch Washer/Wiper Switch (S11) Wiring

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6-46

SECTION 6 - ELECTRICAL SYSTEM

Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-47

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access connectors. Disconnect connector on washer/wiper switch (1).

6. Lift switch retainers. Push washer/wiper switch (1) out through front of panel (2).

Installation 1. Install washer/wiper switch (1) through front of panel (2) such that switch symbol is toward bottom of panel and tabs on switch lock into switch retainers.

2. Attach connector to washer/wiper switch on bottom of panel.

6-48

SECTION 6 - ELECTRICAL SYSTEM

3. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

4. Attach control panel with screws and washers (1).

5. Reinstall right armrest using mounting hardware (1).

6. Reinstall seat belt bracket using mounting hardware (1).

7. Reconnect negative (-) battery cable.

6-49

SECTION 6 - ELECTRICAL SYSTEM

Working Floodlight Switch Working Floodlight Switch Wiring

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6-50

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SECTION 6 - ELECTRICAL SYSTEM

Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-51

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access connectors. Disconnect connector on floodlight switch (1).

6. Lift switch retainers. Push floodlight switch (1) out through front of panel (2).

Installation 1. Install floodlight switch (1) through front of panel (2) such that switch symbol is toward bottom of panel and tabs on switch lock into switch retainers.

2. Attach connector to floodlight switch (1) on bottom of panel (2).

6-52

SECTION 6 - ELECTRICAL SYSTEM

3. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

4. Attach control panel with screws and washers (1).

5. Reinstall right armrest using mounting hardware (1).

6. Reinstall seat belt bracket using mounting hardware (1).

7. Reconnect negative (-) battery cable.

6-53

SECTION 6 - ELECTRICAL SYSTEM

Rotating Beacon Switch Rotating Beacon Switch Wiring

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6-54

SECTION 6 - ELECTRICAL SYSTEM

Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1)

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-55

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access connectors. Disconnect connector on rotating beacon switch (1).

6. Lift switch retainers. Push rotating beacon switch (1) out through front of panel (2).

Installation 1. Install rotating beacon switch (1) through front of panel (2) such that switch symbol is toward bottom of panel and tabs on switch lock into switch retainers.

2. Attach connector to rotating beacon switch on bottom of panel.

6-56

SECTION 6 - ELECTRICAL SYSTEM

3. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

4. Attach control panel with screws and washers (1).

5. Reinstall right armrest using mounting hardware (1).

6. Reinstall seat belt bracket using mounting hardware (1).

7. Reconnect negative (-) battery cable.

6-57

SECTION 6 - ELECTRICAL SYSTEM

Fast/Slow Switch Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-58

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access connectors. Disconnect connector on fast/ slow switch (1).

6. Lift switch retainers. Push fast/slow switch (1) out through front of panel (2).

Installation 1. Install fast/slow switch (1) through front of panel (2) such that switch symbol is toward bottom of panel and tabs on switch lock into switch retainers.

2. Attach connector to fast/slow switch (1) on bottom of panel (2).

6-59

SECTION 6 - ELECTRICAL SYSTEM

3. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

4. Attach control panel with screws and washers (1).

5. Reinstall right armrest using mounting hardware (1).

6. Reinstall seat belt bracket using mounting hardware (1).

7. Reconnect negative (-) battery cable.

6-60

SECTION 6 - ELECTRICAL SYSTEM

Horn Button Switch Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-61

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access wires.

Disconnect wires on horn button switch (1).

6. Remove mounting hardware. Push horn button switch (1) out through front of panel (2).

Installation 1. Install horn button switch (1) through front of panel (2). Be sure decal is correctly positioned.

2. Secure horn button switch with hardware supplied with the switch.

3. Attach wires to horn button switch on bottom of panel.

6-62

SECTION 6 - ELECTRICAL SYSTEM

4. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

5. Attach control panel with screws and washers (1).

6. Reinstall right armrest using mounting hardware (1).

7. Reinstall seat belt bracket using mounting hardware (1).

8. Reconnect negative (-) battery cable.

6-63

SECTION 6 - ELECTRICAL SYSTEM

Battery Charge Indicator (Red) Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-64

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access wires.

Disconnect wires on battery charge indicator (1).

6. Remove mounting hardware. Push battery charge indicator (1) out through front of panel (2).

Installation 1. Install battery charge indicator (1) through front of panel (2). Be sure decal is correctly positioned.

2. Secure battery charge indicator (1) with hardware supplied with the indicator.

3. Attach wires to battery charge indicator on bottom of panel.

6-65

SECTION 6 - ELECTRICAL SYSTEM

4. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

5. Attach control panel with screws and washers (1).

6. Reinstall right armrest using mounting hardware (1).

7. Reinstall seat belt bracket using mounting hardware (1).

8. Reconnect negative (-) battery cable.

6-66

SECTION 6 - ELECTRICAL SYSTEM

Pre-Heat Monitor Indicator (Orange) Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-67

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access wires.

Disconnect wires on pre-heat monitor indicator (1).

6. Remove mounting hardware. Push pre-heat monitor indicator (1) out through front of panel (2).

Installation 1. Install pre-heat monitor indicator (1) through front of panel (2). Be sure decal is correctly positioned.

2. Secure pre-heat monitor indicator with hardware supplied with the indicator.

3. Attach wires to pre-heat monitor indicator on bottom of panel.

6-68

SECTION 6 - ELECTRICAL SYSTEM

4. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

5. Attach control panel with screws and washers (1).

6. Reinstall right armrest using mounting hardware (1).

7. Reinstall seat belt bracket using mounting hardware (1).

8. Reconnect negative (-) battery cable.

6-69

SECTION 6 - ELECTRICAL SYSTEM

Engine Oil Pressure Indicator (Red) Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-70

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access wires.

Disconnect wires on oil pressure indicator (1).

6. Remove mounting hardware. Push engine oil pressure indicator (1) out through front of panel (2).

Installation 1. Install engine oil pressure indicator (1) through front of panel (2). Be sure decal is correctly positioned.

2. Secure engine oil pressure indicator with hardware supplied with the indicator.

3. Attach wires to engine oil pressure indicator on bottom of panel.

6-71

SECTION 6 - ELECTRICAL SYSTEM

4. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

5. Attach control panel with screws and washers (1).

6. Reinstall right armrest using mounting hardware (1).

7. Reinstall seat belt bracket using mounting hardware (1).

8. Reconnect negative (-) battery cable.

6-72

SECTION 6 - ELECTRICAL SYSTEM

Air Filter Clogging Indicator (Y ello w) (Yello ellow) Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-73

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access wires.

Disconnect wires on air filter clogging indicator (1).

6. Remove mounting hardware. Push air filter clogging indicator (1) out through front of panel (2).

Installation 1. Install air filter clogging indicator (1) through front of panel (2). Be sure decal is correctly positioned.

2. Secure air filter clogging indicator with hardware supplied with the indicator.

3. Attach wires to air filter clogging indicator on bottom of panel.

6-74

SECTION 6 - ELECTRICAL SYSTEM

4. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

5. Attach control panel with screws and washers (1).

6. Reinstall right armrest using mounting hardware (1).

7. Reinstall seat belt bracket using mounting hardware (1).

8. Reconnect negative (-) battery cable.

6-75

SECTION 6 - ELECTRICAL SYSTEM

Hydraulic Oil Filter Clogging Indicator Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-76

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access wires.

Disconnect wires on hydraulic oil filter clogging indicator (1).

Installation

6. Remove mounting hardware. Push hydraulic oil filter clogging indicator (1) out through front of panel (2).

1. Install hydraulic oil filter clogging indicator (1) through front of panel (2). Be sure decal is correctly positioned.

2. Secure hydraulic oil filter clogging indicator with hardware supplied with the indicator.

3. Attach wires to hydraulic oil filter clogging indicator on bottom of panel.

6-77

SECTION 6 - ELECTRICAL SYSTEM

4. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

5. Attach control panel with screws and washers (1).

6. Reinstall right armrest using mounting hardware (1).

7. Reinstall seat belt bracket using mounting hardware (1).

8. Reconnect negative (-) battery cable.

6-78

SECTION 6 - ELECTRICAL SYSTEM

Hour meter Hourmeter Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-79

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access wires.

Disconnect wires on hourmeter (1).

6. Remove mounting hardware. Push hourmeter (1) out through front of panel (2).

Installation 1. Install hourmeter (1) through front of panel (2). Be sure decal is correctly positioned.

2. Secure hourmeter with hardware supplied with the indicator.

3. Attach wires to hourmeter on bottom of panel.

6-80

SECTION 6 - ELECTRICAL SYSTEM

4. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

5. Attach control panel with screws and washers (1).

6. Reinstall right armrest using mounting hardware (1).

7. Reinstall seat belt bracket using mounting hardware (1).

8. Reconnect negative (-) battery cable.

6-81

SECTION 6 - ELECTRICAL SYSTEM

Fuel Gauge Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-82

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access wires.

Disconnect wires (1).

6. Remove mounting hardware (2) and bracket (3), then push fuel gauge (4) out through front of panel (5).

Installation 1. Install fuel gauge (4) through front of panel (5). Be sure fuel gauge is correctly positioned.

2. Secure fuel gauge (4) with hardware (2), and bracket (3) supplied with the gauge.

3. Attach wires (1) to fuel gauge on bottom of panel.

6-83

SECTION 6 - ELECTRICAL SYSTEM

4. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

5. Attach control panel with screws and washers (1).

6. Reinstall right armrest using mounting hardware (1).

7. Reinstall seat belt bracket using mounting hardware (1).

8. Reconnect negative (-) battery cable.

6-84

SECTION 6 - ELECTRICAL SYSTEM

Coolant Temper ature Gauge emperature Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-85

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access wires.

Disconnect wires (1).

6. Remove mounting hardware (2) and bracket (3), then push coolant temperature gauge (4) out through front of panel (5).

Installation 1. Install coolant temperature gauge (4) through front of panel (5). Be sure fuel gauge is correctly positioned.

2. Secure coolant temperature gauge (4) with hardware (2), and bracket (3), supplied with the gauge.

3. Attach wires (1) to coolant temperature gauge on bottom of panel.

6-86

SECTION 6 - ELECTRICAL SYSTEM

4. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

5. Attach control panel with screws and washers (1).

6. Reinstall right armrest using mounting hardware (1).

7. Reinstall seat belt bracket using mounting hardware (1).

8. Reconnect negative (-) battery cable.

6-87

SECTION 6 - ELECTRICAL SYSTEM

Socket Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-88

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access wires.

Disconnect wires on socket (1).

Installation 1. Install socket through front of panel.

6. Remove mounting hardware (2). Push socket out through front of panel.

2. Secure socket with hardware supplied with the socket.

3. Attach wires to socket on bottom of panel.

6-89

SECTION 6 - ELECTRICAL SYSTEM

4. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

5. Attach control panel with screws and washers (1).

6. Reinstall right armrest using mounting hardware (1).

7. Reinstall seat belt bracket using mounting hardware (1).

8. Reconnect negative (-) battery cable.

6-90

SECTION 6 - ELECTRICAL SYSTEM

W ar ning Buzz er arning Buzzer Removal 1. Disconnect negative (-) battery cable.

2. Remove seat belt bracket by removing mounting hardware (1).

3. Remove right armrest by removing mounting hardware (1).

4. Remove screws and washers (1) attaching control panel to machine.

6-91

SECTION 6 - ELECTRICAL SYSTEM

5. Turn control panel over to access wires.

Disconnect wires on warning buzzer (2).

Installation 1. Install warning buzzer through front of panel.

6. Remove mounting hardware (1). Push warning buzzer out through front of panel.

2. Secure warning buzzer with hardware supplied with the warning buzzer.

3. Attach wires to warning buzzer on bottom of panel.

6-92

SECTION 6 - ELECTRICAL SYSTEM

4. Install control panel on machine, aligning mounting holes in control panel with holes in console. Be sure not to pinch any wires.

5. Attach control panel with screws and washers (1).

6. Reinstall right armrest using mounting hardware (1).

7. Reinstall seat belt bracket using mounting hardware (1).

8. Reconnect negative (-) battery cable.

6-93

SECTION 6 - ELECTRICAL SYSTEM

Inter ior Light and Switch Interior Removal 1. Remove two screws (1) securing light fixture (2) to operator cab right side wall.

2. Disconnect wires from back of light fixture.

3. If light bulb (3) is to be replaced, remove light bulb.

Installation 1. Install light bulb (3) into light fixture.

2. Connect wires to back of light fixture.

3. Attach light fixture (2) to right side wall of cab using screws (1).

6-94

SECTION 6 - ELECTRICAL SYSTEM

Coolant Temper ature W ar ning Contact emperature arning The cooling temperature warning contact is threaded into the engine block.

Removal 1. Disconnect the wire (1) attached to the coolant temperature warning contact (2).

2. Drain the water level down below the coolant temperature warning contact level.

3. Remove the coolant temperature warning contact (2) from the engine, and also remove the o-ring seal (3).

Installation 1. Clean the thread area.

2. Apply pipe sealant to the threads of the coolant temperature warning contact.

3. Place o-ring seal (3) on threaded portion of coolant temperature warning contact (2).

4. Install the coolant temperature warning contact (2) into engine.

5. Reconnect wire (1) to coolant temperature warning contact (2).

6. Refill the cooling system with coolant previously removed, or, with a 50/50 mixture of a permanent type anti-freeze.

7. Operate the unit to remove air from the cooling system and recheck the coolant level.

6-95

SECTION 6 - ELECTRICAL SYSTEM

Oil Pressure Sensor The oil pressure sensor is threaded into the lower front portion of the engine block. On the EC15/EC25/EC35, the sensor is located on the exposed side of the engine when the engine compartment door is opened. For the EC45, the oil pressure switch is located on the side of the engine toward the back wall of the compartment.

Removal 1. Disconnect the wire (1) attached to the oil pressure sensor (2).

2. Remove the oil pressure sensor (2) from the engine block (3), and also remove the o-ring seal (4).

Installation 1. Place o-ring seal (4) on threaded portion of oil pressure sensor (2).

2. Apply pipe sealant to the threads of the oil pressure sensor.

2. Thread the oil pressure sensor (2) into the engine block (3).

3. Reconnect wire (1) to oil pressure sensor (2).

6-96

SECTION 6 - ELECTRICAL SYSTEM

Air-Flow Maintenance Switch The air-flow maintenance switch is threaded onto the air filter.

Removal 1. Disconnect wires (1) from air-flow maintenance switch (2).

2. Remove air-flow maintenance switch (2) from air filter housing (3).

Installation 1. Thread air-flow maintenance switch (2) onto air filter housing (3).

2. Reconnect wires (1) to air-flow maintenance switch (2).

6-97

SECTION 6 - ELECTRICAL SYSTEM

Hydraulic Oil Filter Clogging Switch The hydraulic oil filter clogging switch is mounted on the side of the hydraulic oil filter.

Removal 1. Disconnect wires (1) from hydraulic oil filter clogging switch (2).

2. Remove the hydraulic oil filter clogging switch (2) from the side of the hydraulic oil filter (3).

Installation 1. Clean the thread area on the hydraulic oil filter where the switch mounts.

2. Apply pipe sealant to the threads of the hydraulic oil filter clogging switch.

3. Thread the hydraulic oil filter clogging switch (2) into the side of the hydraulic filter (3).

4. Attach the wire (1) to the hydraulic oil filter clogging switch.

6-98

SECTION 6 - ELECTRICAL SYSTEM

Coolant Temper ature Sensor emperature The cooling temperature sensor is threaded into the thermostat housing.

Removal 1. Disconnect the wire (1) attached to the coolant temperature sensor (2).

2. Drain the cooling system down below the sensor level to prevent loss of coolant.

3. Remove the coolant temperature sensor (2) from the thermostat housing (3), and also remove the o-ring seal (4).

Installation 1. Clean the thread area where the coolant temperature sensor mounts.

2. Apply pipe sealant to the threads of the coolant temperature sensor.

3. Place o-ring seal (4) on threaded portion of coolant temperature warning contact (2).

4. Screw the coolant temperature sensor (2) into thermostat housing (3).

5. Reconnect wire (1) to coolant temperature sensor (2).

6. Refill the cooling system with coolant previously removed, or, with a 50/50 mixture of a permanent type anti-freeze.

7. Operate the unit to remove air from the cooling system and recheck the coolant level.

6-99

SECTION 6 - ELECTRICAL SYSTEM

Radio The radio is mounted in the right rear of the cab in the top of the right hand console.

Removal 1. Lift radio (1) out of right console (2) far enough to access wires and antenna connection.

2. Disconnect antenna.

3. Disconnect power connector.

4. Disconnect left and right speaker connections.

5. Lift radio (1) out of console (2).

Installation 1. Place radio (1) near opening in console (2).

2. Connect antenna to radio.

3. Connect speakers to radio.

4. Connect power connector to radio.

5. Slide radio (1) into console (2).

6-100

SECTION 6 - ELECTRICAL SYSTEM

Loudspeakers Speakers are mounted in both the right and left consoles on the upper rear side walls of the cab.

Both speakers are removed and installed in the same manner.

Right Loudspeaker Removal 1. Remove screws (1) securing console (2) to right rear side wall of cab.

2. Pull console away from side wall just far enough to access wires and loudspeaker mounting hardware.

3. Disconnect wires from rear of loudspeaker.

4. Remove four nuts (3) and washers (4) and (5).

5. Remove screws (6), dust cover (7), and loudspeaker grill (8) from loudspeaker (9).

Installation 1. Insert screws (6) through dust cover (7), loudspeaker grill (8), loudspeaker (9), and mounting screw holes in console (2).

2. Attach loudspeaker with washers (4) and 5, and nuts (3).

3. Connect wires to loudspeaker.

4. Attach console (2) to right side wall of cab with screws (1).

6-101

SECTION 6 - ELECTRICAL SYSTEM

Left Loudspeaker Removal 1. Remove screws (1) securing console (2) to left rear side wall of cab.

2. Pull console away from side wall just far enough to access wires and loudspeaker mounting hardware.

3. Disconnect wires from rear of loudspeaker.

4. Remove four nuts (3), and washers (4) and (5).

5. Remove screws (6), dust cover (7), and loudspeaker grill (8) from loudspeaker (9).

Installation 1. Insert screws (6) through dust cover (7), loudspeaker grill (8), loudspeaker (9), and mounting screw holes in console (2).

2. Attach loudspeaker with washers (4) and (5), and nuts (3).

3. Connect wires to loudspeaker.

4. Attach console (2) to left side wall of cab with screws (1).

6-102

SECTION 6 - ELECTRICAL SYSTEM

Hor n The horn mounts in the same manner in all machines but is located in different areas depending on the machine.

On the EC15, the horn is located in the left front corner at the same area as the battery. To access horn, remove the floor mat and the right cover plate.

On the EC25/EC35, the horn is located on the left side of the machine and is accessible by opening the left step plate.

On the EC45, the horn is located inside the opening for the dozer blade lift hydraulic cylinder.

Removal 1. Locate the horn as described above.

2. Disconnect wires to horn.

3. Remove screw (1), washer (2), and nut (3) attaching horn (4) to operator platform.

4.

Remove horn (4).

Installation 1. Attach horn (4) to appropriate location on operator platform with screw (1), washer (2), and nut (3).

2. Connect the two wires to the horn.

3. Install access panel (EC15), or left step plate (EC25/EC35).

6-103

SECTION 6 - ELECTRICAL SYSTEM

Engine Shutoff Solenoid The engine shutoff solenoid is mounted on the engine and controls fuel to the injectors. The solenoids on all four machines operate in the same manner but are mounted differently on the different engines.

EC15 Removal 1. Disconnect throttle cable (3) from throttle lever (2).

2. Remove screws (1), and bracket (4). Do not loosen nuts attaching throttle cable to bracket.

3. Disconnect connector (1).

4. Remove solenoid valve (2).

Installation 1. Apply sealant to threads of solenoid valve (2).

2. Thread solenoid valve (2) into housing.

3. Reconnect connector (1).

4. Attach throttle cable bracket (4) with screws (1).

5. Connect throttle cable (3) to throttle lever (2).

6-104

SECTION 6 - ELECTRICAL SYSTEM

EC25 Removal 1. Disconnect throttle cable (1) from throttle lever (2).

2. Disconnect connector (1).

3. Remove solenoid valve (2).

Installation 1. Apply sealant to threads of solenoid valve (2).

2. Thread solenoid valve (2) into housing.

3. Reconnect connector (1).

4. Reconnect throttle cable (1) to throttle lever (2).

6-105

SECTION 6 - ELECTRICAL SYSTEM

EC35 Removal 1. Disconnect throttle cable (1) from throttle lever (2).

2. Disconnect connector (1).

3. Remove solenoid valve (2).

Installation 1. Apply sealant to threads of solenoid valve (2).

2. Thread solenoid valve (2) into housing.

3. Reconnect connector (1).

4. Connect throttle cable (1) to throttle lever (2).

6-106

SECTION 6 - ELECTRICAL SYSTEM

EC45

Installation

Removal 1. Disconnect solenoid linkage (1).

1. Place solenoid (4) on bracket with link (1) down, and align solenoid with mounting holes in bracket.

2. Remove nuts and washers (2) attaching solenoid to bracket.

2. Attach solenoid (4) to bracket with nuts and washers (2).

3. Disconnect connector (3).

3. Attach solenoid linkage (1).

4. Remove solenoid valve (4) from bracket.

4. Reconnect connector (3).

6-107

SECTION 6 - ELECTRICAL SYSTEM

Pressure Switches S30, S31, S32, and S33 (EC45 Only) The pressure switches are located under the hydraulic valves attached to the left crawler unit pedal (1), and right crawler unit pedal, (2). The hydraulic valves are actuated by the screws (3), (4, 5, and 6), in the center of the pedal. Access for continuity checks can be made by removing the front panel. Access for removal is obtained by removing the left side panel.

6-108

SECTION 6 - ELECTRICAL SYSTEM

Removal 1. Disconnect negative side of the battery.

2. Remove left access panel (1) by removing six screws (2).

3. Disconnect the wires (1) attached to the defective switch (2).

4. Remove the switch (2).

Installation 1. Install the switch (2) to the hydraulic fitting.

2. Reconnect wires (1) to switch (2).

3. Reinstall left side panel.

4. Reconnect negative side of the battery.

5. Check operation of switch.

6-109

SECTION 6 - ELECTRICAL SYSTEM

Hand Lever Proximity Switch, B2 (EC15 Only) The removal and replacement of the hand lever proximity switch is covered in the Operator’s Platform section of this manual.

Windshield Washer Pump The removal and replacement of the windshield washer pump is covered in the Operator’s Platform section of this manual.

Heater

Floodlights The removal and replacement of the floodlights is covered in the Operator’s Platform section of this manual.

The removal and replacement of the heater is covered in the Operator’s Platform section of this manual.

Fast/Slow Solenoid

Windshield Wipers The removal and replacement of the windshield wipers is covered in the Operator’s Platform section of this manual.

The removal and installation of the fast/slow solenoid is covered in the Hydraulic section of this manual.

6-110

SECTION 6 - ELECTRICAL SYSTEM

THIS P AGE INTENTIONALL Y LEFT BLANK PA INTENTIONALLY

6-111

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC15 Sheet 1 of 4

6-112

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC15 Sheet 2 of 4

6-113

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC15 Sheet 3 of 4

6-114

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC15 Sheet 4 of 4

6-115

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC25 Sheet 1 of 4

6-116

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC25 Sheet 2 of 4

6-117

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC25 Sheet 3 of 4

6-118

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC25 Sheet 4 of 4

6-119

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC35 Sheet 1 of 4

6-120

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC35 Sheet 2 of 4

6-121

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC35 Sheet 3 of 4

6-122

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC35 Sheet 4 of 4

6-123

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC45 Sheet 1 of 4

6-124

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC45 Sheet 2 of 4

6-125

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC45 Sheet 3 of 4

6-126

SECTION 6 - ELECTRICAL SYSTEM

Electrical Schematic EC45 Sheet 4 of 4

6-127

SECTION 6 - ELECTRICAL SYSTEM

THIS PAGE INTENTIONALLY LEFT BLANK

6-128

EC15, EC25, EC35, EC45 CRA WLER EXCA VATOR EXCAV CRAWLER SER VICE MANU AL SERVICE MANUAL CONTENTS SECTION 00 - GENERAL INFORMA TION INFORMATION SECTION 6 - ELECTRICAL SYSTEM

SECTION 7 - HYDRAULIC SYSTEM SECTION 10 - OPERA TOR’S PLA TFORM OPERAT PLATFORM SECTION 11 - TRACTION/UNDERCARRIAGE

©1999 NEW HOLLAND CONSTRUCTION

SECTION 7 - HYDRAULIC SYSTEM

THIS P AGE INTENTIONALL Y LEFT BLANK PA INTENTIONALLY

7-2

SECTION 7 - HYDRAULIC SYSTEM

SECTION 7 HYDRA ULIC SYSTEM HYDRAULIC Contents General .............................................................................................................................................. 7-8 Rules for Safety at Work.................................................................................................................. 7-9 Personnel ..................................................................................................................................... 7-9 Tools ............................................................................................................................................. 7-9 Securing the Working Equipment ................................................................................................. 7-9 Hydraulic and Lubricating System ............................................................................................. 7-10 Conversions or Modifications to the Machine ............................................................................ 7-10 Returning to Operation ............................................................................................................... 7-10 Hydraulic Cylinder Gland Nut Torque Table ................................................................................... 7-11 Cylinder Drift Value ........................................................................................................................ 7-11 Specifications ................................................................................................................................ 7-12 EC15 .......................................................................................................................................... 7-12 EC25 .......................................................................................................................................... 7-13 EC35 .......................................................................................................................................... 7-14 EC45 .......................................................................................................................................... 7-15 Troubleshooting, Special Tools ....................................................................................................... 7-16 Troubleshooting Charts ................................................................................................................. 7-17 Hydraulic Control Valve .............................................................................................................. 7-17 Relief Valve ................................................................................................................................ 7-18 Work Unit ................................................................................................................................... 7-18 Hydraulic Motor .......................................................................................................................... 7-19 Hydraulic Pump.......................................................................................................................... 7-20 Swivel Joint ................................................................................................................................ 7-21 Slewing ....................................................................................................................................... 7-21 Traveling ..................................................................................................................................... 7-22 Operation Lever ......................................................................................................................... 7-23 Hydraulic Cylinder ...................................................................................................................... 7-23 Hydraulic Diagrams ....................................................................................................................... 7-24 EC15 .......................................................................................................................................... 7-24 EC15 with Overdrive .................................................................................................................. 7-26 EC25 .......................................................................................................................................... 7-28 EC25, Pilot Control, Travel Motor, and Slew Motor ..................................................................... 7-30 EC35 .......................................................................................................................................... 7-32 EC35, Pilot Control, Travel Motor, and Slew Motor ..................................................................... 7-34 EC45, Pilot Control ..................................................................................................................... 7-36 7-3

SECTION 7 - HYDRAULIC SYSTEM

EC45, Working/Traveling ............................................................................................................ 7-38 EC45, Valve Bank ...................................................................................................................... 7-40 Removal and Installation ................................................................................................................... 7-42 Hydraulic Cylinder - Boom ............................................................................................................. 7-42 EC15 .......................................................................................................................................... 7-42 Removal ................................................................................................................................. 7-42 Installation ............................................................................................................................... 7-43 EC25/EC35 ................................................................................................................................ 7-44 Removal ................................................................................................................................. 7-44 Installation ............................................................................................................................... 7-45 EC45 .......................................................................................................................................... 7-46 Removal ................................................................................................................................. 7-46 Installation ............................................................................................................................... 7-47 Hydraulic Cylinder - Stick .............................................................................................................. 7-48 EC15 .......................................................................................................................................... 7-48 Removal ................................................................................................................................. 7-48 Installation ............................................................................................................................... 7-48 EC25/EC35 ................................................................................................................................ 7-49 Removal ................................................................................................................................. 7-49 Installation ............................................................................................................................... 7-49 EC45 .......................................................................................................................................... 7-50 Removal ................................................................................................................................. 7-50 Installation ............................................................................................................................... 7-50 Hydraulic Cylinder - Bucket ........................................................................................................... 7-51 EC15/EC25 ................................................................................................................................ 7-51 Removal ................................................................................................................................. 7-51 Installation ............................................................................................................................... 7-51 EC35 .......................................................................................................................................... 7-52 Removal ................................................................................................................................. 7-52 Installation ............................................................................................................................... 7-53 EC45 .......................................................................................................................................... 7-54 Removal ................................................................................................................................. 7-54 Installation ............................................................................................................................... 7-54 Hydraulic Cylinder - Articulation .................................................................................................... 7-55 EC15 .......................................................................................................................................... 7-55 Removal ................................................................................................................................. 7-55 Installation ............................................................................................................................... 7-56 EC25/EC35 ................................................................................................................................ 7-57 Removal ................................................................................................................................. 7-57 Installation ............................................................................................................................... 7-58

7-4

SECTION 7 - HYDRAULIC SYSTEM

EC45 .......................................................................................................................................... 7-59 Removal ................................................................................................................................. 7-59 Installation ............................................................................................................................... 7-60 Hydraulic Cylinder - Dozer Blade .................................................................................................. 7-61 Travel Motor ................................................................................................................................... 7-61 Valve Banks .................................................................................................................................. 7-61 EC15 Valve Banks ..................................................................................................................... 7-61 Valve Bank 1 Removal ........................................................................................................... 7-62 Valve Bank 1 Installation ........................................................................................................ 7-63 Valve Bank 2 Removal ........................................................................................................... 7-64 Valve Bank 2 Installation ........................................................................................................ 7-65 Valve Bank 3 Removal ........................................................................................................... 7-66 Valve Bank 3 Installation ........................................................................................................ 7-67 EC25 Valve Banks ..................................................................................................................... 7-68 Valve Bank 1 Removal ........................................................................................................... 7-68 Valve Bank 1 Installation ........................................................................................................ 7-69 Valve Bank 2 Removal ........................................................................................................... 7-70 Valve Bank 2 Installation ........................................................................................................ 7-71 Valve Bank 3 Removal ........................................................................................................... 7-72 Valve Bank 3 Installation ........................................................................................................ 7-73 EC35 Valve Banks ..................................................................................................................... 7-74 Valve Bank 1 Removal ........................................................................................................... 7-74 Valve Bank 1 Installation ........................................................................................................ 7-75 Valve Bank 2 Removal ........................................................................................................... 7-76 Valve Bank 2 Installation ........................................................................................................ 7-77 Valve Bank 3 Removal ........................................................................................................... 7-78 Valve Bank 3 Installation ........................................................................................................ 7-79 EC45 Valve Bank ....................................................................................................................... 7-80 Valve Bank Removal .............................................................................................................. 7-80 Valve Bank Installation ........................................................................................................... 7-81 Reversing Valve (Backhoe - ISO) ................................................................................................. 7-82 EC15 .......................................................................................................................................... 7-82 Removal ................................................................................................................................. 7-82 Installation ............................................................................................................................... 7-83 EC25/EC35 ................................................................................................................................ 7-84 Removal ................................................................................................................................. 7-84 Installation ............................................................................................................................... 7-85 EC45 .......................................................................................................................................... 7-86 Removal ................................................................................................................................. 7-86 Installation ............................................................................................................................... 7-87

7-5

SECTION 7 - HYDRAULIC SYSTEM

Slew Drive ...................................................................................................................................... 7-88 EC15 .......................................................................................................................................... 7-88 Removal ................................................................................................................................. 7-88 Installation ............................................................................................................................... 7-88 EC25 .......................................................................................................................................... 7-89 Removal ................................................................................................................................. 7-89 Installation ............................................................................................................................... 7-90 EC35 .......................................................................................................................................... 7-91 Removal ................................................................................................................................. 7-91 Installation ............................................................................................................................... 7-92 Remote Control .............................................................................................................................. 7-93 EC15 .......................................................................................................................................... 7-93 Removal ................................................................................................................................. 7-93 Installation ............................................................................................................................... 7-94 EC25 .......................................................................................................................................... 7-96 Removal ................................................................................................................................. 7-96 Installation ............................................................................................................................... 7-97 EC35/EC45 ................................................................................................................................ 7-99 Removal ................................................................................................................................. 7-99 Installation ............................................................................................................................. 7-100 Hydraulic Pump ........................................................................................................................... 7-102 EC15 ........................................................................................................................................ 7-102 Removal ............................................................................................................................... 7-102 Installation ............................................................................................................................. 7-103 EC25/EC35 .............................................................................................................................. 7-104 Removal ............................................................................................................................... 7-104 Installation ............................................................................................................................. 7-105 EC45 ........................................................................................................................................ 7-107 Removal ............................................................................................................................... 7-107 Installation ............................................................................................................................. 7-109 Hydraulic Cooling Radiator .......................................................................................................... 7-111 EC15 ........................................................................................................................................ 7-111 Removal ............................................................................................................................... 7-111 Installation ............................................................................................................................. 7-112 EC25/EC35 .............................................................................................................................. 7-113 Removal ............................................................................................................................... 7-113 Installation ............................................................................................................................. 7-114 EC45 ........................................................................................................................................ 7-115 Removal ............................................................................................................................... 7-115 Installation ............................................................................................................................. 7-117

7-6

SECTION 7 - HYDRAULIC SYSTEM

Disassembly and Assembly ........................................................................................................... 7-119 Valve Bank .................................................................................................................................. 7-119 EC15/EC25 .............................................................................................................................. 7-119 Disassembly ......................................................................................................................... 7-119 Assembly .............................................................................................................................. 7-121 EC35 ........................................................................................................................................ 7-122 Valve Bank 1 Disassembly................................................................................................... 7-122 Valve Bank 1 Assembly ....................................................................................................... 7-124 Valve Bank 2 Disassembly................................................................................................... 7-125 Valve Bank 2 Assembly ....................................................................................................... 7-127 Valve Bank 3 Disassembly................................................................................................... 7-128 Valve Bank 3 Assembly ....................................................................................................... 7-130 Hydraulic Cylinder - Bucket ......................................................................................................... 7-131 EC15 ........................................................................................................................................ 7-131 Disassembly ......................................................................................................................... 7-131 Assembly .............................................................................................................................. 7-132 EC25/EC35/EC45 .................................................................................................................... 7-133 Disassembly ......................................................................................................................... 7-133 Assembly .............................................................................................................................. 7-134 Hydraulic Cylinder - Boom ........................................................................................................... 7-135 EC15 ........................................................................................................................................ 7-135 Disassembly ......................................................................................................................... 7-135 Assembly .............................................................................................................................. 7-136 EC25/EC35/EC45 .................................................................................................................... 7-137 Disassembly ......................................................................................................................... 7-137 Assembly .............................................................................................................................. 7-138 Hydraulic Cylinder - Stick, Articulation ........................................................................................ 7-139 EC15 ........................................................................................................................................ 7-139 Disassembly ......................................................................................................................... 7-139 Assembly .............................................................................................................................. 7-140 EC25/EC35/EC45 .................................................................................................................... 7-141 Disassembly ......................................................................................................................... 7-141 Assembly .............................................................................................................................. 7-142 Hydraulic Cylinder - Dozer Blade ................................................................................................ 7-143 EC15 ........................................................................................................................................ 7-143 Disassembly ......................................................................................................................... 7-143 Assembly .............................................................................................................................. 7-144 EC25/EC35 .............................................................................................................................. 7-145 Disassembly ......................................................................................................................... 7-145 Assembly .............................................................................................................................. 7-146

7-7

SECTION 7 - HYDRAULIC SYSTEM

GENERAL This hydraulic excavator has been built in accordance with state-of-the-art standards and recognized safety rules.

However, operating the machine if a fault is suspected or has occurred, or carrying out repair work inexpertly may endanger the lives of persons in contact with it, or damage the machine and other property.

The hydraulic excavator must be stopped immediately if any damage is suspected or occurs to ensure that the safety of the operator, of other persons at the place of use, or of other material property is not compromised.

All components are carefully coordinated. Trouble-free operation and a long service life can only be achieved with original spare parts.

7-8

SECTION 7 - HYDRAULIC SYSTEM

Rules ffor or Saf ety at W or k Safety ork

A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

WARNING

For climbing onto or off the machine, use the handrails provided for this purpose.

Personnel Always keep steps and platforms in a non-slip state.

The machine must not be started by unauthorized persons.

Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Observe the accident prevention regulations.

The hydraulic excavator may be operated, serviced or repaired only by specially trained and authorized personnel with the appropriate technical knowledge.

WARNING Secur ing the W or king Equipment Securing orking

If such knowledge is lacking, detailed instructions must be given by experienced personnel.

Before carrying out assembly work, the machine and the attachments must be secured against inadvertent and unauthorized starting, e.g., by placing chocks under tracks and by standing the working equipment on the ground.

The personnel must have read and understood the operator’s manual and in particular the chapter “Safety Instructions”.

Stand the working equipment on the ground in such a way that no movements can be made when mechanical or hydraulic connections become detached.

Only such persons may start up the machine during assembly work in order to adjust the attachments.

Incorrect operation of the machine or the attachments may result in life-threatening situations.

Secure any equipment or component which is to be mounted or dismantled or whose position is to be changed using hoists or appropriate slinging/ supporting devices to prevent them from moving, slipping or falling inadvertently.

During all work, always observe the start-up and shut-down procedures prescribed in the operator’s manual.

Systems and units (e.g. : pipes, hoses, etc.) must be properly depressurized before being opened.

Wear a safety helmet, safety footwear and gloves.

Protective devices on moving machine parts may be opened or removed only when the drive unit is stationary and protected against inadvertent starting.

Wear closely fitting working clothing when working on the machine.

Loose, wide garments may catch on machine parts and result in injury.

Before returning to service, all protective devices must be refitted.

Tools

Before carrying out assembly work, the machine and the equipment must be secured against inadvertent starting (e.g.: by placing chocks under the tracks and by standing the working equipment on the ground).

Tools, hoists, slings, trestles and other devices must be in a reliable safe state.

Metal splinters may cause injury when attachment bolts are being driven in or out.

7-9

SECTION 7 - HYDRAULIC SYSTEM

WARNING CAUTION

Hydr aulic and Lubr icating System Hydraulic Lubricating Always observe the safety regulations applicable to the product when handling oils, greases and other chemical substances.

Unused but open bores, pipelines and hose connections must be closed in a pressure-tight manner.

Refill collected hydraulic oil back into the hydraulic system only through the return-flow filters.

Dispose of waste oil in an environmentally safe manner.

Observe the correct working sequence when fitting or replacing components or equipment.

Retur ning to Oper ation Returning Operation Prior to returning the machine for operation: - Grease all lubricating points.

- Check all oil levels and make the necessary corrections.

- Carry out functional checks of all repaired components.

- Check all functions of the excavator during a test run. Release the hydraulic excavator for operation only after all functions have been found to work perfectly.

When the machine is at operating temperature, the consumables are at least at the same temperature. Precautions must therefore be taken to prevent burning or scalding.

Be careful when handling acids (e.g.: battery acid). Acid splashes may injure the eye and the skin.

Do not smoke when handling flammable liquids.

Be careful with open flames and unprotected light.

Not only fuel, but also other consumables often have a low flash point and catch fire easily.

WARNING Conversions or Modifications to the Machine Unauthorized conversions or modifications of the hydraulic excavator are forbidden for reasons of safety.

The nominal pressure of pressure relief valves must not be modified.

7-10

SECTION 7 - HYDRAULIC SYSTEM

Hydr aulic Cylinder Gland Nut Torque Tab le Hydraulic able Threads Torque in lb-ft (Nm)

M18 x 2

M40 x 1.5

M20 x 2

M42 x 2

M22 x 2

M42 x 3

M24 x 2

M48 x 3

M27 x 2

M56 x 2

M30 x 2

M60 x 2

M35 x 1.5

M70 x 2

M36 x 2

M80 x 2

M36 x 3

M90 x 2

M39 x 3

Cylinder Dr ift Value Drift Machine

Boom Cylinder

Dipstick Cylinder

EC15

6.5

8.0

EC25

5.0

7.0

EC35

4.0

8.0

EC45

3.0

3.0

Test conditions: 1. Hydraulic oil temperature must be approx. 122-140°F (50-60°C).

2. Fit test port with gauge on the cylinder.

3. Retract and extend cylinder several times and operate working equipment to its maximum reach until the gauge indicates a Ioad pressure of 1450 psi (100 bar).

4. Measure piston rod length of cylinder.

5. Measure piston rod length again after five minutes.

6. The difference converted into one minute is the drift of the cylinder.

7. The values indicated are valid for hydraulic oil weight of 10W40.

There may be differences if hydraulic with a different specification is used.

7-11

SECTION 7 - HYDRAULIC SYSTEM

SPECIFICA TIONS SPECIFICATIONS EXCA VATOR AND TRA VEL HYDRA ULICS EXCAV TRAVEL HYDRAULICS EC15 Hydraulic pump: ................................................. make ..............JSB Flow rate: ........................................................... I/min ...............19.2+19.2+13.2 Pilot pressure (high idle): .................................... psi/bar ............ 361/25 (service temperature) Shut-off pressure (high idle): .............................. psi/bar ............ 2247/155 (service temperature) Valve bank 1: ........ type ....... HV 07 VOAC Valve bank 2: ........ type ....... HV 07 VOAC Valve bank 3: ........ type ....... HV 07 VOAC Cross servo-control stick: .................................. type ................PCL 401 Pressure reducing valve: ................................... make ..............HAWE Shut-off valve: .................................................... make ..............Bergin SLEW DRIVE Slew motor with gearbox: ................................... make ..............Dinamic Oil MGLR 200 Slew pressure (valves at slew motor): ............... psi/bar ............ 1450/100 (high idle) (service temperature) PRESSURE AND SETTING VALUES (ser vice temper ature): (service temperature): Main pressure relief valve 1, 2, 3 (high idle): max. psi/bar ..........2400/165, 2400/165, 2755/190 Line Relief Pressures: Valve bank 1 (HV 07) - travel left: ......................................................... psi/bar ............ --Valve bank 2 (HV 07) - articulation: ....................................................... psi/bar ............ --- boom lift/lower: ................................................. psi/bar ............ 3045/210 - 1812/125 - bucket: ............................................................. psi/bar ............ 3045/210 - 3045/210 - travel right: ....................................................... psi/bar ............ --Valve bank 3 (HV 07) - slewing (valves at the slew motor): .................. psi/bar ............ 1450/100 (high idle) (service temperature) - dozer blade: ..................................................... psi/bar ............ --- dipperstick: ....................................................... psi/bar ............ 3045/210 - 3045/210 - breaker/slew bucket/grab rotation: ................... psi/bar ............ ---

7-12

SECTION 7 - HYDRAULIC SYSTEM

SPECIFICA TIONS SPECIFICATIONS EXCA VATOR AND TRA VEL HYDRA ULICS EXCAV TRAVEL HYDRAULICS EC25 Pressure compensated summation controlled double variable displacement pump and two gear pumps: ....................................................... make ..............Kayaba Flow rate: ........................................................... I/min. ..............38+38+27+8 Pilot pressure (high idle): .................................... psi/bar ............ 435/30 (service temperature) Valve bank 1: ........ type ....... HV 07 VOAC Valve bank 2: ........ type ....... HV 07 VOAC Valve bank 3: ........ type ....... HV 07 VOAC Cross servo-control stick: .................................. type ................ PCL 401 SLEW DRIVE Slew motor with gearbox: ................................... make ..............SOM PG 161 PR Slew pressure (valves at slew motor): ............... psi/bar ............ 2900/200 (high idle) (service temperature) PRESSURE AND SETTING VALUES (ser vice temper ature): (service temperature): Main pressure relief valve 1, 2, 3 (high idle): ...... max. psi/bar ...2755/190, 2755/190, 3045/210 Line Relief Pressures: Valve bank 1 (HV 07) - slewing (valves at the slew motor): .................. psi/bar ............ 2900/200 - 2900/200 (high idle, service temperature) - blade: ............................................................... psi/bar ............ --Valve bank 2 (HV 07) - travel left:

psi/bar

(2900/200 psi/bar shock valves at the travel motor) - bucket: ............................................................. psi/bar ............ 2537/175 - 2537/175 - boom lift/lower: ................................................. psi/bar ............ 3045/210 - 1812/125 3045/210 - 2030/140 Valve bank 3 (HV 07) - articulation: ....................................................... psi/bar ............ anti-cavitation - dipperstick: ....................................................... psi/bar ............ 3045/210 - 3045/210 - breaker/slew bucket/grab rotation: ................... psi/bar ............ --- travel right: ....................................................... psi/bar ............ 2755/190 - 2755/190 (2900/200 psi/bar shock valves at the travel motor)

7-13

SECTION 7 - HYDRAULIC SYSTEM

SPECIFICA TIONS SPECIFICATIONS EXCA VATOR AND TRA VEL HYDRA ULICS EXCAV TRAVEL HYDRAULICS EC35 Pressure compensated summation controlled double variable displacement pump and two gear pumps: ....................................................... make ..............Kayaba Flow rate: ........................................................... I/min. ..............46+46+28.5+8.5 Pilot pressure (high idle): .................................... psi/bar ............ 362/25 (service temperature) Valve bank 1: ........ type ....... Rexroth SM 12 Valve bank 2: ........ type ....... Rexroth SM 12 Valve bank 3: ........ type ....... Rexroth SM 12 Cross servo-control stick: .................................. type ................Rexroth 4TH6 SLEW DRIVE Slew motor with gearbox: ................................... make ..............SOM PG 161 PR Slew pressure (valves at slew motor): ............... psi/bar ............ 2900/200 (high idle) (service temperature) PRESSURE AND SETTING VALUES(ser vice temper ature): ALUES(service temperature): Main pressure relief valve 1 , 2, 3 (high idle): max. psi/bar ......... 3045/210, 3625/250, 3625/250 Line Relief Pressures: Valve bank 1 (SM 12) - slewing (valves at the slew motor): .................. psi/bar ............ 2900/200 - 2900/200 (high idle, service temperature) - blade: ............................................................... psi/bar ............ --Valve bank 2 (SM 12) -travel left: .......................................................... psi/bar ............ 2755/190 - 2755/190 (2900/200 psi/bar shock valves travel motor) - bucket: ............................................................. psi/bar ............ 3045/210 - 3045/210 - boom lift /lower: ................................................ psi/bar ............ 4060/280 - 2030/140 Valve bank 3 (SM 12) - articulation: ....................................................... psi/bar ............ anti-cavitation - dipperstick: ....................................................... psi/bar ............ 4060/280 - 4-60/280 - breaker/slew bucket/grab rotation: ................... psi/bar ............ 3045/210 - 3045/210 - travel right: ....................................................... psi/bar ............ 2755/190 - 2755/190 (2900/200 psi/bar shock valves travel motor)

7-14

SECTION 7 - HYDRAULIC SYSTEM

SPECIFICA TIONS SPECIFICATIONS EXCA VATOR AND TRA VEL HYDRA ULICS EXCAV TRAVEL HYDRAULICS EC45 Summation-controlled double variable displacement pump and two gear pumps: .......... make ..............Kayaba PSVD 2-26 E Flow rate: ........................................................... l/min. ..............57+57+37+10 Pilot pressure (high idle): .................................... psi/bar ............ 435/30 (service temperature) Control valve: ..................................................... type ................ Kayaba KVSE 70-10 Joystick: ............................................................. type ................ Rexroth 4TH 5 Pedal-operated valve (travel right/left, dozer blade, articulation, additional control circuit): .................................... type ................ Rexroth 2TH 6 SLEW DRIVE Slew motor with gearbox: ................................... make ..............Kayaba MSG-27 P-23 Slew pressure (valves at slew motor): ............... psi/bar ............ 205 (high idle) (service temperature) PRESSURE AND SETTING VALUES (ser vice temper ature) (service temperature) Main pressure relief valve P1 (high idle): ........... max. psi/bar ...3552/245 P2 ....................................................................... max. psi/bar ...3552/245 P3 ....................................................................... max. psi/bar ...2972/205 Line Relief Pressures: PI (main pressure relief valve: 245 psi/bar) - Travel right (valves at the travel motor): ........... psi/bar ............ 3915/270 - 3915270 - Stick: ................................................................ psi/bar ............ 4060/280 - 4060/280 - Articulation: ...................................................... psi/bar ............ anti-cavitation - Additional control circuit: .................................. psi/bar ............ 210 / 210 (slew bucket, grab rotation, rock breaker) P2 (main pressure relief valve: 245 psi/bar) - Travel left (valves at the travel motor): ............. psi/bar ............ 3915/270 - 3915270 - Boom lift/lower: ................................................. psi/bar ............ 4060/280 - 4060/280 - Bucket: ............................................................. psi/bar ............ 4060/280 - 4060/280 P3 (main pressure relief valve: 205 psi/bar) - Slewing (valves at the slew motor): ................. psi/bar ............ 2792/205 - 2792/205 - Dozer blade: ..................................................... psi/bar ............ ---

7-15

SECTION 7 - HYDRAULIC SYSTEM

TROUBLESHOOTING Special Tools

Equipment

Part No.

Test Port 8L

5 066 234 200 73185051

Screw Fitting

1 919 060 351 73183750

Test Port 10L

73188193 5 066 234 230

Screw Fitting

73184831 1 919 060 352

Test Port M12x1,5

5 066 253 605 73188194

Seal Ring 18x12x1,5

1 636 815 453 73188195

Nut 8L

73184791 1 911 060 154

Plug

73184836 1 928 000 944

Screw Fitting

73188196 1 915 000 418

Function

7-16

Quantity

Pilot pressure, working hydraulics, control pressure, travel hydraulics.

2

Brake pressure.

1

Control pressure, regulation start, housing pressure, travel hydraulics.

2

Brake inching.

1

SECTION 7 - HYDRAULIC SYSTEM

TROUBLESHOOTING CHARTS Hydraulic Control Valve Trouble The reduced The load load is drops whenwhen switching from the switching the the plunger spool from the neutral position to the UP neutral position. position.

Plunger sticking.

Spool isissticking.

Oil is leaking from the oil seal.

Reason

Corrections

leakage from from the the spool. plunger.

Oil leakage

Replace the valve housing assembly.

Oil leakage from the port relief valve.

Disassemble and clean the port relief valve or replace it.

Dirt is caught in the load check valve.

Disassemble and clean the load check valve.

The poppet, or seat of the load check valve is damaged.

Replace the poppet or lap the poppet and seat.

The oil temperature rises abnormally.

Remove the cause of a resistance to the oil flow in the pipe.

The hydraulic oil is dirty.

Replace the oil and clean the circuit.

The valve housing is distorted due to the overtightening of the pipe port joint.

Check the tightening torque.

Foreign matter is caught by the cutout of the plunger. the cutout of the spool.

Remove the foreign matter or replace the valve housing assembly.

The pressure is too high.

Check and adjust using the pressure gage.

The lever or link is bent.

Remove and check the link.

The plunger warped. spool is is warped.

Replace the valve housing assembly.

The return spring or cap is damaged or incorrectly aligned.

Replace the return spring.

The distribution of the temperature in the valve is unequal.

Warm up the circuit.

Foreign matter is adhering to the seal.

Remove and clean the seal.

The back pressure of the valve return circuit is too high.

Enlarge the return circuit.

Dirt is caught by the seal or the seal plate is loose.

Remove and clean the seal.

The spool plunger is damaged. is damaged.

Replace the valve housing assembly.

The seal is cut or damaged.

Replace the seal.

7-17

Loosen and adjust the mounting bolt.

Set the alignment by loosening the cap and retighten.

Clean the seal plate and fasten it using the bolt.

SECTION 7 - HYDRAULIC SYSTEM

Hydraulic Control Valve Trouble The plunger spool does not The does not move. move.

Reason

Corrections

The spool is clogged with dirt. plunger is clogged with dirt. Remove the dirt and clean the circuit.

Oil is collected in the plunger spool cap.

Replace the cap side seal.

Relief Valve Trouble The pressure does not rise.

Reason

Corrections

The poppet remains open due to sticking.

Disassemble to remove the dirt so that it operates smoothly.

Dirt is caught by the valve seat.

Clean all the parts.

The pilot poppet seat is damaged.

Replace the damaged part.

The pilot piston sticks to the main poppet.

Disassemble and clean the parts to remove the dirt on the surface.

The relief valve is not actuated properly.

The relief valve is worn due to dirt.

Replace the worn part.

Oil leaks.

The lock nut and adjusting screw are loose.

Adjust the pressure.

The seats damaged or the O-ring is worn.

Replace the damaged or worn part.

Each part sticks due to dirt.

Disassemble to check for flaws, and clean and reassemble.

The relief valve is unstable.

Work Unit Trouble The total working force is reduced.

Reason

Corrections

Engine output is insufficient.

Refer to the engine operation manual.

The function is reduced due to the hydraulic pump.

Replace the hydraulic pump.

The main relief valve is faulty.

Adjust the pressure or replace the main relief valve.

The amount of hydraulic oil is insufficient.

Add oil.

The viscosity of the hydraulic oil Replace with oil of appropriate is different. viscosity.

The bucket operates improperly.

The suction filter is clogged.

Replace the suction filter.

The hydraulic pump is faulty.

Replace the hydraulic pump.

The hydraulic oil amount is insufficient.

Add oil.

7-18

SECTION 7 - HYDRAULIC SYSTEM

Work Unit Trouble

Reason

The bucket force is insufficient.

The set pressure of the main or port relief valve is too low.

Adjust the pressure or replace the relief valve.

The hydraulic cylinder packing is damaged.

Replace the hydraulic cylinder packing.

The hydraulic cylinder or cylinder piston is damaged.

Replace the hydraulic cylinder, cylinder piston, or assembly.

The hydraulic cylinder packing is damaged.

Replace the hydraulic cylinder packing.

The hydraulic cylinder or cylinder piston is damaged.

Replace the hydraulic cylinder, cylinder piston, or assembly.

Oil is leaking at the control valve.

Replace the valve housing assembly.

The work unit is lubricated or greased insufficiently.

Lubricate or grease.

The connecting pin is dragging.

Replace the bushing or pin.

The bucket descends freely.

An abnormal noise occurs from the bucket joint

Corrections

Hydraulic Motor Trouble The hydraulic motor does not run.

Reason

Correction

Insufficient hydraulic oil.

Add oil.

The hydraulic motor is damaged.

Replace the hydraulic pressure pump.

Oil leaks from the hydraulic motor.

Replace the hydraulic motor.

The hydraulic motor is internally Replace the hydraulic motor or worn. worn part.

The hydraulic motor turns in one direction only.

Overload is applied on the output shaft.

Inspect the loading unit and remove the cause of overload.

The viscosity of the oil is low.

Replace the hydraulic oil with one of appropriate viscosity.

The relief valve is damaged.

Disassemble and clean the relief valve or replace it.

The spool of the counterbalance valve sticks.

Replace the counter-balance counterbalance valve.

Replace the hydraulic pump or replace the main relief valve.

7-19

SECTION 7 - HYDRAULIC SYSTEM

Hydraulic Motor Trouble The rotation speed of the hydraulic motor is insufficient.

An abnormal noise comes from the hydraulic motor.

Reason

Correction

The flow-in of the oil decreases. Lower the oil temperature.

Large oil leak.

Air is being sucked in.

Retighten the supply and suction side joints.

Oil is leaking in the hydraulic motor.

Replace the hydraulic motor.

Insufficient hydraulic oil.

Add oil.

Air is being sucked in.

Retighten the suction side joint.

The oil temperature is too high.

Lower the oil temperature.

The hydraulic motor is internally Replace the hydraulic motor. damaged or worn.

Oil is leaking at the shaft seal.

The shaft is installed improperly.

Realign the shaft.

Cavitation.

Remove the cause of the cavitation.

The oil seal is faulty.

Replace the oil seal.

The shaft is damaged or worn.

Replace the shaft.

The internal pressure of the hydraulic motor case is too high.

Replace the oil seal and clean the drain pipe.

Hydraulic Pump Trouble No oil comes out of the hydraulic pump.

The hydraulic pump pressure does not rise.

An abnormal noise occurs from the hydraulic pump.

Reason

Corrections

The hydraulic oil amount is insufficient.

Add oil.

The suction filter is clogged.

Replace the filter or replace oil if it is dirty.

Oil is leaking in the hydraulic pump.

Replace the hydraulic pump.

Air is sucked into the hydraulic pump.

Add oil or inspect the suction side hose.

The set pressure of the main relief valve is to low.

Adjust the pressure.

The suction side hose is Replace the filter or replace oil damaged or a cavitation occurs if it is dirty. due to the clogged suction filter.

The suction side joint is loose or the air is sucked in due to the insufficient hydraulic oil.

7-20

Retighten the joint or add oil.

SECTION 7 - HYDRAULIC SYSTEM

Hydraulic Pump Trouble

Reason

An abnormal noise occurs from Viscosity of hydraulic oil is high the hydraulic pump pump.(continued). (continued) and causes cavitation.

Oil leaks from the hydraulic pump.

Corrections Replace with oil of an appropriate viscosity.

The pump is not aligned with the engine.

Realign the pump with the engine.

There are bubbles in the hydraulic oil.

Remove the cause of bubbles (replace with new oil).

The hydraulic pump seal is defective.

Replace the seal or replace the hydraulic pump.

Swivel Joint Trouble The work unit force is insufficient.

There is an external oil leakage at the swivel joint.

Reason

Corrections

The swivel joint packing is not good.

Replace the swivel joint packing.

The swivel joint rotor is damaged.

Replace the swivel joint.

The swivel joint packing is defective.

Replace the swivel joint packing.

Slewing Trouble The slewing force is insufficient.

Slewing not braking properly.

Reason

Corrections

The hydraulic motor performance is reduced.

Replace the hydraulic motor.

The slew ring is seized.

Lubricate, grease, or replace the slew gear.

The set pressure of the brake valve is too low.

Adjust the pressure.

The brake valve is clogged with dirt.

Clean the brake valve.

The hydraulic motor performance is reduced.

Replace the hydraulic motor.

Oil is leaking in the control valve.

Replace the valve housing assembly.

Slewing is not stopping properly. The set pressure of the brake valve is too low.

Adjust the pressure.

The brake valve is clogged with dirt.

Clean the brake valve.

The hydraulic motor performance is reduced.

Replace the hydraulic motor.

Oil is leaking in the control valve.

Replace the valve housing assembly.

7-21

SECTION 7 - HYDRAULIC SYSTEM

Slewing Trouble An abnormal noise occurs at slewing.

Reason

Corrections

Air is being sucked into the hydraulic motor.

Add oil.

The slew bearing is insufficiently greased.

Grease.

Traveling Trouble The traveling performance is poor.

The machine does not travel smoothly.

The machine deviates from its path.

Reason

Corrections

The set pressure of the main relief valve is too low.

Adjust the pressure.

The counterbalance counter-balancevalve valveisis faulty.

Replace counter-balance the counterbalance valve.

The hydraulic motor performance is faulty.

Replace the hydraulic motor.

The swivel joint packing is damaged.

Replace the swivel joint packing.

The hydraulic pump performance is poor.

Replace the hydraulic pump.

Oil leaking at the control valve.

Replace the valve housing assembly.

The crawler tension is incorrect. Adjust the tension.

A stone or foreign matter is caught in the crawler.

Remove the stone or foreign matter.

The counter-balance valveisis counterbalance valve faulty. faulty.

Replace the counter-balance counterbalance valve.

The hydraulic motor performance is poor.

Replace the hydraulic motor.

Air is being sucked into the hydraulic motor.

Add oil.

Crawler tensions are unequal.

Adjust the tensions equally.

Hydraulic pump performance is poor.

Replace the hydraulic pump.

Hydraulic motor performance is poor.

Replace the hydraulic motor.

Oil is leaking at the control valve.

Replace the valve housing assembly.

The swivel joint packing is damaged.

Replace the swivel joint packing.

The lever link is loose.

Adjust the lever link.

7-22

SECTION 7 - HYDRAULIC SYSTEM

Operation Lever Trouble

Reason

The operation valve moves with Foreign matter is caught by the difficulty. control valve spool.

Corrections Clean the control valve.

The valve plunger sticks.

Replace the valve housing assembly.

The lever link is lubricated insufficiently.

Lubricate or grease.

The lever link sticks.

Lubricate or grease.

Hydraulic Cylinder Trouble The hydraulic cylinder pressure is insufficient.

Oil is leaking from the hydraulic cylinder.

The piston does not move smoothly.

Reason

Corrections

The set pressure of the relief valve is low.

Adjust the pressure.

Oil is leaking at the hydraulic cylinder.

Replace the cylinder packing.

The hydraulic cylinder piston or rod is damaged.

Replace the hydraulic cylinder piston or rod.

Oil is leaking at the control valve.

Replace the valve housing assembly.

The hydraulic cylinder packing is faulty.

Replace the hydraulic cylinder packing.

The hydraulic cylinder rod is damaged.

Replace the hydraulic cylinder rod.

Oil temperature rises.

Lower the oil temperature.

Air is being sucked in.

Retighten the supply and suction side joints.

7-23

SECTION 7 - HYDRAULIC SYSTEM

7-24

SECTION 7 - HYDRAULIC SYSTEM

EC15 Hydraulic Diagram - Legend Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Description Travel motor, right Travel motor, left Grab cylinder Bucket cylinder Slew drive Boom cylinder Articulated cylinder Slew bucket Grab slew motor Breaker Dipperstick cylinder Dozer blade cylinder Tread width adjustment cylinder (option) Gear pump Hydraulic oil cooler Return line filter/ventilation filter Diesel engine Pilot pressure accumulator Pressure reducing valve for pilot control Pilot control Cut-off valve Hydraulic oil tank Valve bank 1 Valve bank 2 Valve bank 3 Travel, left Travel, right Bucket Boom Articulation Additional control circuit Dipperstick Dozer blade/Tread width adjustment Slewing Gauge port Collector Changeover - dozer blade/tread width adjustment Working hydraulics cut-off/ exit barrier Changeover - rock breaker (option)

7-25

SECTION 7 - HYDRAULIC SYSTEM

7-26

SECTION 7 - HYDRAULIC SYSTEM

EC15 Hydraulic Diagram with Overdrive - Legend Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Description Travel motor, right Travel motor, left Grab cylinder Bucket cylinder Slew drive Boom cylinder Articulated cylinder Slew bucket Grab slew motor Breaker Dipperstick cylinder Dozer blade cylinder Tread width adjustment cylinder (option) Gear pump Hydraulic oil cooler Return line filter/ventilation filter Diesel engine Pilot pressure accumulator Pressure reducing valve for pilot control Pilot control Cut-off valve Hydraulic oil tank Valve bank 1 Valve bank 2 Valve bank 3 Travel, left Travel, right Bucket Boom Articulation Additional control circuit Dipperstick Dozer blade/Tread width adjustment Slewing Gauge port Collector Changeover - dozer blade/tread width adjustment Working hydraulics cut-off/exit barrier Changeover - rock breaker (option)

7-27

SECTION 7 - HYDRAULIC SYSTEM

7-28

SECTION 7 - HYDRAULIC SYSTEM

EC25 Hydraulic Diagram - Legend Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Description Travel motor, left Travel motor, right Grab cylinder Bucket cylinder Slew drive Boom cylinder Articulated cylinder Dipperstick cylinder Grab slew motor Breaker Slew bucket Dozer blade cylinder Ventilation filter Gear pump Hydraulic oil cooler Return line filter Diesel engine Pilot pressure accumulator Relay valve slew brake Pilot control Cut-off valve - working hydraulics/exit barrier Hydraulic oil tank Valve bank 1 Valve bank 2 Valve bank 3 Dozer blade Slewing Boom Bucket Travel, left Travel, right Additional control circuit Dipperstick Articulation Collector Pressureless return Thermostat valve Valve fast/slow Gauge port

7-29

SECTION 7 - HYDRAULIC SYSTEM

EC25 Hydraulic Diagram of Pilot Control, Travel Motor, and Slew Motor

7-30

SECTION 7 - HYDRAULIC SYSTEM

THIS PAGE INTENTIONALLY LEFT BLANK

7-31

SECTION 7 - HYDRAULIC SYSTEM

7-32

SECTION 7 - HYDRAULIC SYSTEM

EC35 Hydraulic Diagram - Legend Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Description Travel motor, left Travel motor, right Grab cylinder Bucket cylinder Slew drive Boom cylinder Articulated cylinder Dipperstick cylinder Grab slew motor Breaker Slew bucket Dozer blade cylinder Ventilation filter Gear pump Hydraulic oil cooler Return line filter Diesel engine Pilot pressure accumulator Relay valve slew brake Pilot control Cut-off valve - working hydraulics/exit barrier Hydraulic oil tank Valve bank 1 Valve bank 2 Valve bank 3 Dozer blade Slewing Boom Bucket Travel, left Travel, right Additional control circuit Dipperstick Articulation Collector Pressureless return line Thermostat valve Valve fast/slow Gauge port

7-33

SECTION 7 - HYDRAULIC SYSTEM

EC35 Hydraulic Diagram of Pilot Control, Travel Motor, and Slew Motor

7-34

SECTION 7 - HYDRAULIC SYSTEM

THIS PAGE INTENTIONALLY LEFT BLANK

7-35

SECTION 7 - HYDRAULIC SYSTEM

7-36

SECTION 7 - HYDRAULIC SYSTEM

EC45 Hydraulic Diagram, Pilot Control - Legend Item 1 2 5 14 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42

Description Travel motor, left Travel motor, right Slew drive Hydraulic pump Diesel engine Pilot pressure accumulator Relay valve for slew brake Pilot-operated valve - slewing, dipperstick Pilot-operated valve - boom, bucket Pilot-operated valve - articulation Pilot-operated valve - travel, left Pilot-operated valve - travel, right Pilot-operated valve - additional control circuit Pilot-operated valve - dozer blade Working hydraulics cut-off/exit barrier Hydraulic oil tank Valve bank Valve segment, slewing Valve segment, dozer blade Valve segment, additional control circuit Valve segment, articulation Valve segment, dipperstick Valve segment, travel, right Valve segment, travel, left Valve segment, boom Valve segment, bucket Valve segment, traveling straight on Selector valve, fast/slow Gauge port

7-37

SECTION 7 - HYDRAULIC SYSTEM

7-38

SECTION 7 - HYDRAULIC SYSTEM

EC45 Hydraulic Diagram, Working/Traveling - Legend Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 28 29 30 31 32 33 34 35 36 37 38 39 40 42

Description Travel motor, left Travel motor, right Grab cylinder Bucket cylinder Slew drive Boom cylinder Articulated cylinder Dipperstick cylinder Grab slew motor Breaker Slew bucket Dozer blade cylinder Ventilation filter Hydraulic pump Hydraulic oil cooler Return line filter Diesel engine Hydraulic oil tank Valve bank Valve segment, slewing Valve segment, dozer blade Valve segment, additional control circuit Valve segment, articulation Valve segment, dipperstick Valve segment, travel, right Valve segment, travel, left Valve segment, boom Valve segment, bucket Valve segment, traveling straight on Thermostat valve Gauge port

7-39

SECTION 7 - HYDRAULIC SYSTEM

7-40

SECTION 7 - HYDRAULIC SYSTEM

EC45 Hydraulic Diagram, Valve Bank - Legend Item 1 2 3 4 5 6 7 8 9 10 11

Description Valve bank Valve segment, slewing Valve segment, dozer blade Valve segment, additional control circuit Valve segment, articulation Valve segment, dipperstick Valve segment, travel, right Valve segment, travel, left Valve segment, boom Valve segment, bucket Valve segment, traveling straight on

7-41

SECTION 7 - HYDRAULIC SYSTEM

REMOVAL AND INSTALLATION Hydraulic Cylinder - Boom EC15 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the two hydraulic hoses (1), and plug hoses.

4. Remove screw, washer, and sleeve (2), securing pin (3).

WARNING HYDRAULIC CYLINDER IS HEAVY AND REQUIRES SUPPORT BEFORE REMOVING SUPPORT PINS. 5. Support cylinder (4).

6. Drive out pin (3), to separate cylinder (4), from kingpin (5).

7. Remove screw, washer, and sleeve (6), securing pin (7).

8. Drive out pin (7), to separate cylinder (4), from boom (8).

7-42

SECTION 7 - HYDRAULIC SYSTEM

Installation 1. Attach cylinder (4), to boom (8), with pin (7).

2. Secure pin (7), with screw, washer, and sleeve (6).

3. Torque screw (6), to 55 lb-ft (79 Nm).

4. Attach cylinder (4), to kingpin (5), with pin (3).

5. Secure pin (3), with screw, washer, and sleeve (2).

6. Torque screw (2), to 55 lb-ft (79 Nm).

7. Attach two hydraulic lines (1).

8. Operate machine and check for leaks.

7-43

SECTION 7 - HYDRAULIC SYSTEM

EC25/EC35 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the two hydraulic hoses (1), and plug hoses.

4. Remove screw, washer, and sleeve (2), securing pin (3).

WARNING HYDRAULIC CYLINDER IS HEAVY AND REQUIRES SUPPORT BEFORE REMOVING SUPPORT PINS. 5. Support cylinder (4).

6. Drive out pin (3), to separate cylinder (4), from kingpin (5).

7. Remove screw, washer, and sleeve (6), securing pin (7).

8. Drive out pin (7), to separate cylinder (4), from boom (8).

7-44

SECTION 7 - HYDRAULIC SYSTEM

Installation 1. Attach cylinder (4), to boom (8), with pin (7).

2. Secure pin (7), with screw, washer, and sleeve (6).

3. Torque screw (6), to 55 lb-ft (79 Nm).

4. Attach cylinder (4), to kingpin (5), with pin (3).

5. Secure pin (3), with screw, washer, and sleeve (2).

6. Torque screw (2), to 55 lb-ft (79 Nm).

7. Attach two hydraulic lines (1).

8. Operate machine and check for leaks.

7-45

SECTION 7 - HYDRAULIC SYSTEM

EC45 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the two hydraulic hoses (1), and plug hoses.

4. Remove screw, washer, and sleeve (2), securing pin (3).

WARNING HYDRAULIC CYLINDER IS HEAVY AND REQUIRES SUPPORT BEFORE REMOVING SUPPORT PINS. 5. Support cylinder (4).

6. Drive out pin (3), to separate cylinder (4), from kingpin (5).

7. Remove screw, washer, and sleeve (6), securing pin (7).

8. Drive out pin (7), to separate cylinder (4), from boom (8).

7-46

SECTION 7 - HYDRAULIC SYSTEM

Installation 1. Attach cylinder (4), to boom (8), with pin (7).

2. Secure pin (7), with screw, washer, and sleeve (6).

3. Torque screw (6), to 55 lb-ft (79 Nm).

4. Attach cylinder (4), to kingpin (5), with pin (3).

5. Secure pin (3), with screw, washer, and sleeve (2).

6. Torque screw (2), to 55 lb-ft (79 Nm).

7. Attach two hydraulic lines (1).

8. Operate machine and check for leaks.

7-47

SECTION 7 - HYDRAULIC SYSTEM

Hydraulic Cylinder - Stick EC15 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the two hydraulic hoses (1), and plug hoses.

4. Remove screw, washer, and sleeve (2), securing pin (3).

5. Support cylinder (4).

6. Drive out pin (3), to separate cylinder (4), from boom (5).

7. Remove screw, washer, and sleeve (6), securing pin (7).

8. Drive out pin (7), to separate cylinder (4), from stick (8).

Installation 1. Attach cylinder (4), to stick (8), with pin (7).

2. Secure pin (7), with screw, washer, and sleeve (6).

3. Torque screw (6), to 55 lb-ft (79 Nm).

4. Attach cylinder (4), to boom (5), with pin (3).

5. Secure pin (3), with screw, washer, and sleeve (2).

6. Torque screw (2), to 55 lb-ft (79 Nm).

7. Attach two hydraulic lines (1).

8. Operate machine and check for leaks.

7-48

SECTION 7 - HYDRAULIC SYSTEM

EC25/EC35 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the two hydraulic hoses (1), and plug hoses.

4. Remove screw, washer, and sleeve (2), securing pin (3).

5. Support cylinder (4).

6. Drive out pin (3), to separate cylinder (4), from boom (5).

7. Remove screw, washer, and sleeve (6), securing pin (7).

8. Drive out pin (7), to separate cylinder (4), from stick (8).

Installation 1. Attach cylinder (4), to stick (8), with pin (7).

2. Secure pin (7), with screw, washer, and sleeve (6).

3. Torque screw (6), to 55 lb-ft (79 Nm).

4. Attach cylinder (4), to boom (5), with pin (3).

5. Secure pin (3), with screw, washer, and sleeve (2).

6. Torque screw (2), to 55 lb-ft (79 Nm).

7. Attach two hydraulic lines (1).

8. Operate machine and check for leaks.

7-49

SECTION 7 - HYDRAULIC SYSTEM

EC45 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the two hydraulic hoses (1), and plug hoses.

4. Remove screw, washer, and sleeve (2), securing pin (3).

5. Support cylinder (4).

6. Drive out pin (3), to separate cylinder (4), from boom (5).

7. Remove screw, washer, and sleeve (6), securing pin (7).

8. Drive out pin (7), to separate cylinder (4), from stick (8).

Installation 1. Attach cylinder (4), to stick (8), with pin (7).

2. Secure pin (7), with screw, washer, and sleeve (6).

3. Torque screw (6), to 55 lb-ft (79 Nm).

4. Attach cylinder (4), to boom (5), with pin (3).

5. Secure pin (3), with screw, washer, and sleeve (2).

6. Torque screw (2), to 55 lb-ft (79 Nm).

7. Attach two hydraulic lines (1).

8. Operate machine and check for leaks.

7-50

SECTION 7 - HYDRAULIC SYSTEM

Hydraulic Cylinder - Bucket EC15/EC25 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the two hydraulic hoses (1), and plug hoses.

4. Remove screw, washer, and sleeve (2), secure pin (3).

5. Support cylinder (4).

6. Drive out pin (3), to separate cylinder (4), from stick (5).

7. Remove screw, two washers, and nut (6), securing pin (7), to tilt link (8).

8. Drive out pin (7), to separate cylinder (4), from tilt link (8).

Installation 1. Attach cylinder (4), to tilt link (8), with pin (7).

2. Secure pin (7), with screw, two washers, and nut (6).

3. Torque nut (6), to 35 lb-in (40 Nm).

4. Attach cylinder (4), to stick (5), with pin (3).

5. Secure pin (3), with screw, washer, and sleeve (2).

6. Torque screw (2), to 55 lb-ft (79 Nm).

7. Attach two hydraulic lines (1).

8. Operate machine and check for leaks.

7-51

SECTION 7 - HYDRAULIC SYSTEM

EC35 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the two hydraulic hoses (1), and plug hoses.

4. Remove screw, washer, and sleeve (2), securing pin (3).

5. Support cylinder (4).

6. Drive out pin (3), to separate cylinder (4), from stick (5).

7. Remove screw, two washers, and nut (6), securing pin (7), to tilt link (8).

8. Drive out pin (7), to separate cylinder (4), from tilt links (8).

9. Remove cylinder.

10. Disconnect hydraulic fitting (9).

11. Remove clamp (10), then remove tube (12), and bracket (11).

7-52

SECTION 7 - HYDRAULIC SYSTEM

Installation 1. Attach tube (9), to cylinder (4).

2. Place bracket (11), on cylinder (4), and attach tube (12), to bracket (11), with clamp (10).

3. Attach cylinder (4), to tilt links (8), with pin (7).

4. Secure pin (7), with screw, two washers, and nut (6).

5. Torque nut (6), to 35 lb-in (40 Nm).

6. Attach cylinder (4), to stick (5), with pin (3).

7. Secure pin (3), with screw, washer, and sleeve (2).

8. Torque screw (2), to 55 lb-ft (79 Nm).

9. Attach two hydraulic lines (1).

10. Operate machine and check for leaks.

7-53

SECTION 7 - HYDRAULIC SYSTEM

EC45 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the two hydraulic hoses (1), and plug hoses.

4. Remove screw, washer, and sleeve (2), secure pin (3).

5. Support cylinder (4).

6. Drive out pin (3), to separate cylinder (4), from stick (5).

7. Remove screw, two washers, and nut (6), securing pin (7), to tilt link (8).

8. Drive out pin (7), to separate cylinder (4), from tilt links (8).

Installation 1. Attach cylinder (4), to tilt link (8), with pin (7).

2. Secure pin (7), with screw, two washers, and nut (6).

3. Torque nut (6), to 35 lb-in (40 Nm).

4. Attach cylinder (4), to stick (5), with pin (3).

5. Secure pin (3), with screw, washer, and sleeve (2).

6. Torque screw (2), to 55 lb-ft (79 Nm).

7. Attach two hydraulic lines (1).

8. Operate machine and check for leaks.

7-54

SECTION 7 - HYDRAULIC SYSTEM

Hydraulic Cylinder - Articulation EC15 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the hydraulic hose (1), and remove the throttle (2), from front cylinder fitting (3), and plug hose.

4. Disconnect the hydraulic hose (4), from rear cylinder fitting (5), and plug hose.

5. Remove screw, washer, and sleeve (2), securing pin (3).

6. Support cylinder (1).

7. Drive out pin (3), to separate cylinder (1), from undercarriage (4).

7-55

SECTION 7 - HYDRAULIC SYSTEM

8. Remove screw, two washers, and sleeve (1), securing pin (2), to kingpin (3).

9. Drive out pin (2), to separate cylinder (4), from kingpin (3).

Installation 1. Attach cylinder (4), to kingpin (3), with pin (2).

2. Secure pin (2), with screw, washer, and sleeve (1).

3. Torque screw (1), to 58 lb-ft (79 Nm).

4. Attach cylinder (1), to undercarriage (4), with pin (3).

5. Secure pin (3), with screw, washer, and sleeve (2).

6. Torque screw (2), to 58 lb-ft (79 Nm).

7. Attach hydraulic line (4), to cylinder rear fitting (5).

8. Attach hydraulic line (1), with throttle (2), to front cylinder fitting (3).

9. Operate machine and check for leaks.

7-56

SECTION 7 - HYDRAULIC SYSTEM

EC25/EC35 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the hydraulic hoses (1), from cylinder (2), and plug hose.

4. Remove screw, two washers, and nut (3), securing pin (4), to undercarriage (5).

5. Remove screw, washer, and sleeve (2), securing pin (3).

6. Support cylinder (1).

7. Drive out pin (3), to separate cylinder (1), from kingpin (4).

8. Remove cylinder.

7-57

SECTION 7 - HYDRAULIC SYSTEM

Installation 1. Slide cylinder into machine.

2. Attach cylinder (1), to kingpin (4), with pin (3).

3. Secure pin (3), with screw, washer, and sleeve (2).

4. Torque screw (2), to 101 lb-ft (138 Nm).

5. Attach cylinder (2), to undercarriage (5), with pin (4).

6. Secure pin (4), with screw, two washers, and nut (3).

7. Torque screw (3), to 101 lb-ft (138 Nm).

8. Attach hydraulic line (1), to cylinder (2).

9. Operate machine and check for leaks

7-58

SECTION 7 - HYDRAULIC SYSTEM

EC45 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Disconnect the hydraulic hoses to cylinder (1), from cylinder (2), and plug hose.

4. Remove screw, two washers, and nut (3), securing pin (4), to undercarriage (5).

5. Remove screw, washer, and sleeve (2), securing pin (3).

6. Support cylinder (1).

7. Drive out pin (3), to separate cylinder (1), from kingpin (4).

8. Remove cylinder.

7-59

SECTION 7 - HYDRAULIC SYSTEM

Installation 1. Slide cylinder into machine.

2. Attach cylinder (1), to kingpin (4), with pin (3).

3. Secure pin (3), with screw, washer, and sleeve (2).

4. Torque screw (2), to 101 lb-ft (138 Nm).

5. Attach cylinder (2), to undercarriage (5), with pin (4).

6. Secure pin (4), with screw, two washer, and nut (3).

7. Torque screw (3), to 101 lb-ft (138 Nm).

8. Attach all hydraulic lines (1), to cylinder (2).

9. Operate machine and check for leaks.

7-60

SECTION 7 - HYDRAULIC SYSTEM

Hydraulic Cylinder - Dozer Blade The removal of the dozer blade cylinder is covered in Traction/Undercarriage, Section 11 of this manual.

Travel Motor The removal and installation of the travel motor is described in Traction/Undercarriage, Section 11 of this manual.

Valve Banks EC15 Valve Banks There are three valve banks in the EC15 machine. Access is obtained by removing the floor mat and removing the cover plate. The valve banks control the following operations Valve Bank (1)

Travel right, bucket, boom, and articulation

Valve Bank (2)

Stick, dozer blade, slewing, and additional control circuit

Valve bank (3)

Travel left

7-61

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 1 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove cap on hydraulic tank filter to remove pressure in hydraulic tank.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Label and disconnect all hydraulic hoses connected to valve (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of valve. Label all hoses that are disconnected and plug hoses.

6. Disconnect the articulation linkage (3).

7. Disconnect the travel right linkage (4).

8. Remove four screws, washers, and nuts (2), attaching valve (1), to upper carriage.

9. Remove valve (1).

7-62

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 1 Installation 1. Align the mounting holes in valve (1), with holes in upper carriage.

2. Attach valve (1), to upper carriage with four screws, washers, and nuts (2).

3. Connect travel right linkage (4).

4. Connect articulation linkage (3).

5. Apply sealant on the hydraulic fittings and connect all hydraulic hoses disconnected during removal.

6. Add hydraulic oil, if necessary, to hydraulic tank then tighten cap on hydraulic filter.

7. Operate machine and check for any hydraulic oil leaks.

8. Stop machine and remove key.

9. Install floor cover plate and floor mat.

7-63

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 2 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove cap on hydraulic tank filter to remove pressure in hydraulic tank.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Label and disconnect all hydraulic hoses connected to valve (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of valve. Label all hoses that are disconnected and plug hoses.

6. Disconnect the dozer blade linkage (3).

7. Disconnect the travel optional additional control pedal linkage (4).

8. Remove four screws, washers, and nuts (2), attaching valve (1), to upper carriage.

9. Remove valve (1).

7-64

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 2 Installation 1. Align the mounting holes in valve (1), with holes in upper carriage.

2. Attach valve (1), to upper carriage with four screws, washers, and nuts (2).

3. Connect additional control pedal linkage (4).

4. Connect dozer blade linkage (3).

5. Apply sealant on the hydraulic fittings and connect all hydraulic hoses disconnected during removal.

6. Add hydraulic oil, if necessary, to hydraulic tank then tighten cap on hydraulic filter.

7. Operate machine and check for any hydraulic oil leaks.

8. Stop machine and remove key.

9. Install floor cover plate and floor mat.

7-65

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 3 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove cap on hydraulic tank filter to remove pressure in hydraulic tank.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Label and disconnect all hydraulic hoses connected to valve (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of valve. Label all hoses that are disconnected and plug hoses.

6. Disconnect the left travel linkage (3).

7. Remove four screws, washers, and nuts (2), attaching valve (1), to upper carriage.

8. Remove valve (1).

7-66

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 3 Installation 1. Align the mounting holes in valve (1), with holes in uppercarriage.

2. Attach valve (1), to upper carriage with four screws, washers, and nuts (2).

3. Connect travel left linkage (3).

4. Apply sealant on the hydraulic fittings and connect all hydraulic hoses disconnected during removal.

5. Add hydraulic oil, if necessary, to hydraulic tank then tighten cap on hydraulic filter.

6. Operate machine and check for any hydraulic oil leaks.

7. Stop machine and remove key.

8. Install floor cover plate and floor mat.

7-67

SECTION 7 - HYDRAULIC SYSTEM

EC25 Valve Banks There are three valve banks in the EC25 machine. Access is obtained by removing the floor mat and removing the cover plate. The valve banks control the following operations Valve Bank (1)

Dozer blade, slewing

Valve bank (2)

Travel left, bucket, and boom

Valve Bank (3)

Travel right, additional control circuit, and articulation, stick

Valve Bank 1 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove cap on hydraulic tank filter to remove pressure in hydraulic tank.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Label and disconnect all hydraulic hoses connected to valve (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of valve. Label all hoses that are disconnected and plug hoses.

6. Disconnect the dozer blade linkage (3).

7. Remove four screws, washers, and nuts (2), attaching valve (1), to upper carriage.

8. Remove valve (1).

7-68

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 1 Installation 1. Align the mounting holes in valve (1), with holes in upper carriage.

2. Attach valve (1), to undercarriage with four screws, washers, and nuts (2).

3. Connect the dozer blade linkage (3).

4. Apply sealant on the hydraulic fittings and connect all hydraulic hoses disconnected during removal.

5. Add hydraulic oil, if necessary, to hydraulic tank then tighten cap on hydraulic filter.

6. Operate machine and check for any hydraulic oil leaks.

7. Stop machine and remove key.

8. Install floor cover plate and floor mat.

7-69

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 2 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove cap on hydraulic tank filter to remove pressure in hydraulic tank.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Label and disconnect all hydraulic hoses connected to valve (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of valve. Label all hoses that are disconnected and plug hoses.

6. Disconnect the travel left linkage (3).

7. Remove four screws, washers, and nuts (2), attaching valve (1), to upper carriage.

8. Remove valve (1).

7-70

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 2 Installation 1. Align the mounting holes in valve (1), with holes in uppercarriage.

2. Attach valve (1), to undercarriage with four screws, washers, and nuts (2).

3. Connect travel left linkage (3).

4. Apply sealant on the hydraulic fittings and connect all hydraulic hoses disconnected during removal.

5. Add hydraulic oil, if necessary, to hydraulic tank then tighten cap on hydraulic filter.

6. Operate machine and check for any hydraulic oil leaks.

7. Stop machine and remove key.

8. Install floor cover plate and floor mat.

7-71

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 3 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove cap on hydraulic tank filter to remove pressure in hydraulic tank.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Label and disconnect all hydraulic hoses connected to valve (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of valve. Label all hoses that are disconnected and plug hoses.

6. Disconnect the articulation linkage (3).

7. Disconnect the additional control circuit linkage (4).

8. Disconnect the right travel linkage (5).

9. Remove four screws, washers, and nuts (2), attaching valve (1), to upper carriage.

10. Remove valve (1).

7-72

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 3 Installation 1. Align the mounting holes in valve (1), with holes in upper carriage.

2. Attach valve (1), to upper carriage with four screws, washers, and nuts (2).

3. Connect the articulation linkage (3).

4. Connect the additional control circuit linkage (4).

5. Connect the right travel linkage (5).

6. Apply sealant on the hydraulic fittings and connect all hydraulic hoses disconnected during removal.

7. Add hydraulic oil, if necessary, to hydraulic tank then tighten cap on hydraulic filter.

8. Operate machine and check for any hydraulic oil leaks.

9. Stop machine and remove key.

10. Install floor cover plate and floor mat.

7-73

SECTION 7 - HYDRAULIC SYSTEM

EC35 Valve Banks There are three valve banks in the EC35 machine. Access is obtained by removing the floor mat and removing the cover plate. The valve banks control the following operations: Valve Bank (1)

Dozer blade, slewing

Valve bank (2)

Travel left, bucket, and boom

Valve Bank (3)

Travel right, additional control circuit, articulation, and stick

Valve Bank 1 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove cap on hydraulic tank filter to remove pressure in hydraulic tank.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Label and disconnect all hydraulic hoses connected to valve (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of valve. Label all hoses that are disconnected and plug hoses.

6. Disconnect the dozer blade linkage (3).

7. Remove four screws, washers, and nuts (2), attaching valve (1), to upper carriage.

8. Remove valve (1).

7-74

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 1 Installation 1. Align the mounting holes in valve (1), with holes in upper carriage.

2. Attach valve (1), to upper carriage with four screws, washers, and nuts (2).

3. Connect the dozer blade linkage (3).

4. Apply sealant on the hydraulic fittings and connect all hydraulic hoses disconnected during removal.

5. Add hydraulic oil, if necessary, to hydraulic tank then tighten cap on hydraulic filter.

6. Operate machine and check for any hydraulic oil leaks.

7. Stop machine and remove key.

8. Install floor cover plate and floor mat.

7-75

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 2 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove cap on hydraulic tank filter to remove pressure in hydraulic tank.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Label and disconnect all hydraulic hoses connected to valve (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of valve. Label all hoses that are disconnected and plug hoses.

6. Disconnect the travel left linkage (3).

7. Remove four screws, washers, and nuts (2), attaching valve (1), to upper carriage.

8. Remove valve (1).

7-76

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 2 Installation 1. Align the mounting holes in valve (1), with holes in uppercarriage.

2. Attach valve (1), to upper carriage with four screws, washers, and nuts (2).

3. Connect travel left linkage (3).

4. Apply sealant on the hydraulic fittings and connect all hydraulic hoses disconnected during removal.

5. Add hydraulic oil, if necessary, to hydraulic tank then tighten cap on hydraulic filter.

6. Operate machine and check for any hydraulic oil leaks.

7. Stop machine and remove key.

8. Install floor cover plate and floor mat.

7-77

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 3 Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove cap on hydraulic tank filter to remove pressure in hydraulic tank.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Label and disconnect all hydraulic hoses connected to valve (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of valve. Label all hoses that are disconnected and plug hoses.

6. Disconnect the articulation linkage (3).

7. Disconnect the additional control circuit linkage (4).

8. Disconnect the right travel linkage (5).

9. Remove four screws, washers, and nuts (2), attaching valve (1), to upper carriage.

10. Remove valve (1).

7-78

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank 3 Installation 1. Align the mounting holes in valve (1), with holes in uppercarriage.

2. Attach valve (1), to upper carriage with four screws, washers, and nuts (2).

3. Connect the articulation linkage (3).

4. Connect the additional control circuit linkage (4).

5. Connect the right travel linkage (5).

6. Apply sealant on the hydraulic fittings and connect all hydraulic hoses disconnected during removal.

7. Add hydraulic oil, if necessary, to hydraulic tank then tighten cap on hydraulic filter.

8. Operate machine and check for any hydraulic oil leaks.

9. Stop machine and remove key.

10. Install floor cover plate and floor mat.

7-79

SECTION 7 - HYDRAULIC SYSTEM

EC45 Valve Bank There is one valve bank in the EC45 machine.

Access is obtained by removing the right access plate (1). The valve bank controls the following operations: Dozer blade, slewing, travel left, bucket, boom, travel right, additional control circuit, articulation, and stick.

Valve Bank Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove cap on hydraulic tank filter to remove pressure in hydraulic tank.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Remove the screws and washers (2), then remove access panel (1).

6. Label and disconnect all hydraulic hoses connected to valve (1), and plug hoses.

7. Remove four screws, washers, and nuts (2), attaching valve (1), to upper carriage.

8. Remove valve (1).

7-80

SECTION 7 - HYDRAULIC SYSTEM

Valve Bank Installation 1. Align the mounting holes in valve (1), with holes in upper carriage.

2. Attach valve (1), to upper carriage with four screws, washers, and nuts (2).

3. Apply sealant on the hydraulic fittings and connect all hydraulic hoses disconnected during removal.

4. Add hydraulic oil, if necessary, to hydraulic tank then tighten cap on hydraulic filter.

5. Operate machine and check for any hydraulic oil leaks.

6. Stop machine and remove key.

7. Install access cover plate (1), and attach with screws and washers (2).

7-81

SECTION 7 - HYDRAULIC SYSTEM

Reversing Valve (Backhoe - ISO) EC15 The reversing valve is located below the remote control to the left of the operator’s seat.

Removal 1. Remove four screws and crown washers (1), attaching panel (2), to operator’s platform (3).

2. Remove panel (2).

3. Lower the bucket and dozer blade to the ground.

4. Turn off engine and remove key.

5. Label then disconnect the eight hydraulic hoses (1), from reversing valve (2), and plug hoses.

6. Remove the two bolts, two washers, and two nuts (3), attaching valve (2), to bracket (4).

7. Remove valve (2).

7-82

SECTION 7 - HYDRAULIC SYSTEM

Installation 1. Align holes in reversing valve (2), with holes in bracket (4).

2. Attach reversing valve (2), to bracket (4), with two bolts, two washers, and two nuts (3).

3. Attach the eight hydraulic lines (1), to valve (2).

4. Slide panel (2), over lever and attach panel with four screws and crown washers (1).

7-83

SECTION 7 - HYDRAULIC SYSTEM

EC25/EC35 The reversing valve is located below the remote control to the right side of the operator’s seat.

Removal 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove four screws and crown washers (1), attaching panel (2), to operator’s platform (3).

4. Rotate reversing valve (4) to the “B” position.

NOTE: Removal of floor mat may help by providing additional clearance for panel.

5. Remove panel (2), by sliding panel up and toward outside of truck so that lever (5), passes through slot in panel.

6. Label, then disconnect the eight hydraulic hoses (1), from reversing valve (2), and plug hoses.

7. Remove the bolts, washers, and nuts (3), attaching valve (2), to bracket (4).

8. Remove valve (2).

7-84

SECTION 7 - HYDRAULIC SYSTEM

Installation 1. Align holes in reversing valve (2), with holes in bracket (4).

2. Attach reversing valve (2), to bracket (4), with bolts, washers, and nuts (3).

3. Attach the eight hydraulic lines (1), to valve (2).

4. Slide panel (2), over lever and attach panel with four screws and crown washers (1).

7-85

SECTION 7 - HYDRAULIC SYSTEM

EC45 The reversing valve is located below the remote control to the right side of the operator’s seat.

Removal 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Remove four screws and crown washers (1), attaching panel (2), to operator’s platform (3).

4. Rotate reversing valve (4), to the “B” position.

NOTE: Removal of floor mat may help by providing additional clearance for panel.

5. Remove panel (2), by sliding panel up and toward outside of truck so that lever (5), passes through slot in panel.

6. Label, then disconnect the eight hydraulic hoses (1), from reversing valve (2), and plug hoses.

7. Remove the bolts, washers, and nuts (3), attaching valve (2), to bracket (4).

8. Remove valve (2).

7-86

SECTION 7 - HYDRAULIC SYSTEM

Installation 1. Align holes in reversing valve (2), with holes in bracket (4).

2. Attach reversing valve (2), to bracket (4), with bolts, washers, and nuts (3).

3. Attach the eight hydraulic lines (1), to valve (2).

4. Slide panel (2), over lever (4) and 5, then attach panel with four screws and crown washers (1).

7-87

SECTION 7 - HYDRAULIC SYSTEM

Slew Drive EC15 The slew motor (1), is located under the floor plate toward the left side of the machine. The slew motor can be accessed by removing the floor mat and the floor cover plate.

Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS. 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Label, then disconnect the hydraulic hoses from slew motor (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of slew motor. Label all hoses that are disconnected and plug hoses.

4. Remove the four bolts (2), attaching slew motor (1), to upper carriage (3).

5. Remove slew motor (1).

Installation 1. Align holes in slew motor (1), with holes in upper carriage (3).

2. Attach slew motor (1), to upper carriage (3), with four bolts (2).

3. Torque bolts (2), to 92 lb-ft (125 Nm).

4. Apply sealant, then attach all hydraulic lines disconnected during removal.

5. Operate machine and check for hydraulic oil leaks.

6. Turn ignition off and remove key.

7. Install floor cover plate and floor mat.

7-88

SECTION 7 - HYDRAULIC SYSTEM

EC25 The slew motor (1), is located under the floor plate toward the left side of the machine. The slew motor can be accessed by removing the floor mat and the floor cover plate.

Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS.

1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Label, then disconnect the hydraulic hoses from slew motor (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of slew motor. Label all hoses that are disconnected and plug hoses.

4. Remove roll pins (4).

5. Remove the four bolts (2), attaching slew motor (1), to upper carriage (3).

6. Remove slew motor (1).

Installation

7-89

SECTION 7 - HYDRAULIC SYSTEM

1. Align holes in slew motor (1), with holes in upper carriage (3).

2. Install roll pins (4).

3. Attach slew motor (1), to upper carriage (3), with four bolts (2).

4. Torque bolts (2), to 183 lb-ft (250 Nm).

5. Apply sealant, then attach all hydraulic lines disconnected during removal.

6. Operate machine and check for hydraulic oil leaks.

7. Turn ignition off and remove key.

8. Install floor cover plate and floor mat.

7-90

SECTION 7 - HYDRAULIC SYSTEM

EC35 The slew motor (1), is located under the floor plate toward the left side of the machine. The slew motor can be accessed by removing the floor mat and the floor cover plate.

Removal WARNING BUCKET AND DOZER BLADE MUST BE FULLY LOWERED AND PUMP MUST NOT BE OPERATING WHEN REMOVING HYDRAULIC COMPONENTS.

1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Label, then disconnect the hydraulic hoses from slew motor (1), and plug hoses.

NOTE: It may be necessary to disconnect additional hoses to provide clearance for removal of slew motor. Label all hoses that are disconnected and plug hoses.

4. Remove roll pins (4).

5. Remove the four bolts (2), attaching slew motor (1), to upper carriage (3).

6. Remove slew motor (1).

7-91

SECTION 7 - HYDRAULIC SYSTEM

Installation 1. Align holes in slew motor (1), with holes in upper carriage (3).

2. Install roll pins (4).

3. Attach slew motor (1), to upper carriage (3), with four bolts (2).

4. Torque bolts (2), to 212 lb-ft (290 Nm).

5. Apply sealant, then attach all hydraulic lines disconnected during removal.

6. Operate machine and check for hydraulic oil leaks.

7. Turn ignition off and remove key.

8. Install floor cover plate and floor mat.

7-92

SECTION 7 - HYDRAULIC SYSTEM

Remote Control EC15 The remote control (joy stick) assemblies (1), are located on each side of the operator’s seat.

Both controls are identical.

Removal 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Open the filter cap on the hydraulic oil tank to relieve system pressure.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Remove screws and crown washers (2) from cover (3), in order for the valves to be serviced.

6. Disconnect the six hydraulic hoses (2), from the housing (1).

7-93

SECTION 7 - HYDRAULIC SYSTEM

7. Roll the bellow (4), up, to gain access to screws attaching the joy stick mounting plate to the operator’s platform.

8. Remove four screws (2), then completely remove the valve (1), including joy stick assembly.

9. Loosen nut (5), and unscrew joy stick from valve.

10. If oil is leaking from one of the plunger sets (8), remove nut (6), and actuator plate (7), to access plungers (8).

NOTE: Plunger set (8), includes a return spring, spring with tappet, and a plunger seal kit.

11. Remove plunger set (8).

12. Inspect the seat inside of the housing (3). If seat is damaged, replace housing.

Installation 1. Install plunger set (8), into housing (1).

2. Install actuator plate (7), and secure with nut (6). Position actuator plate for minimum play.

3. Screw joy stick with bellow (4), and nut (5), onto valve.

4. Tighten nut (5), to secure joy stick to valve.

5. Position valve so that cutout (9), is toward the left rear.

6. Attach valve to operator’s platform with four screws (2).

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7. Attach the six hydraulic hoses (2), to the valve (1).

8. Close cap on hydraulic oil tank filter.

9. Start machine and check for leaks under bellows and at hydraulic hoses.

10. Stop machine.

11. Turn bellows (1), back down.

12. Install cover plate (3), with screws and crown washers (2).

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SECTION 7 - HYDRAULIC SYSTEM

EC25 The remote control (joy stick) assemblies (1), are located on each side of the operator’s seat.

Both controls are identical.

Removal 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Open the filter cap on the hydraulic oil tank to relieve system pressure.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Remove screws and crown washers (2), from cover (3), in order for the valves to be serviced.

6. Disconnect the six hydraulic hoses (2), from the housing (1).

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7. Roll the bellow (4), up, to gain access to screws attaching the joy stick mounting plate to the operators platform.

8. Remove four screws (2), then completely remove the valve (1), including joy stick assembly.

9. Loosen nut (5), and unscrew joy stick from valve.

10. If oil is leaking from one of the plunger sets (8), remove nut (6), and actuator plate (7), to access plungers (8).

NOTE: Plunger set (8), includes a return spring, spring with tappet, and a plunger seal kit.

11. Remove plunger set (8).

12. Inspect the seat inside of the housing (3). If seat is damaged, replace housing.

Installation 1. Install plunger set (8), into housing (1).

2. Install actuator plate (7), and secure with nut (6). Position actuator plate for minimum play.

3. Screw joy stick with bellows (4), and nut (5), onto valve.

4. Tighten nut (5), to secure joy stick to valve.

5. Position valve so that cutout (9), is toward the left rear.

6. Attach valve to operator’s platform with four screws (2).

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7. Attach the six hydraulic hoses (2), to the valve (1).

8. Close cap on hydraulic oil tank filter.

9. Start machine and check for leaks under bellows and at hydraulic hoses.

10. Stop machine.

11. Turn bellows (1), back down.

12. Install cover plate (3), with screws and crown washers (2).

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SECTION 7 - HYDRAULIC SYSTEM

EC35/EC45 The remote control (joy stick) assemblies are located on each side of the operator’s seat. Both controls are identical.

Removal 1. Lower the bucket and dozer blade to the ground.

2. Turn off engine and remove key.

3. Open the filter cap on the hydraulic oil tank to relieve system pressure.

4. Connect a vacuum pump in place of the ventilation filter on the hydraulic oil tank, and turn the pump on.

5. Turn up the bellows (3).

6. Loosen the nut (1).

7. Unscrew the handle (2), with bellows (3), and remove from machine.

8. Remove the screws and crown washers from cover (1), then remove cover.

9. Remove the universal joint (2), while holding onto valve housing (3).

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10. Remove valve housing (1), from retaining plate (2).

11. Pry the leaking tappet set (1), out of the housing (2).

12. Check the seat surface in the housing (2), for scratches, corrosion or other damage. If housing (2), requires replacement, disconnect hydraulic fittings and plug hoses.

Installation 1. If housing was removed, reconnect hydraulic hoses.

2. Press in a new tappet set (1).

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3. Install valve housing (1), into retaining plate (2).

4. Install universal joint (2), while holding valve housing (3).

5. Install cover (1), over valve, using screws and crown washers.

6. Install handle (2), with bellows (3), to universal joint.

7. Tighten nut (1).

8. Disconnect vacuum pump and install ventilation filter on the hydraulic oil tank.

9. Install the filter cap on the hydraulic oil tank.

10. Start machine and check for leaks at hydraulic fitting and at tappet sets. Repair and leaks.

11. Turn off machine and remove key.

12. Turn bellows (3), down over top of valve.

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SECTION 7 - HYDRAULIC SYSTEM

Hydraulic Pump EC15 Removal 1. Park the machine in a safe place.

2. Remove the key from the ignition.

3. Open the filter cap on the hydraulic oil tank to relieve system pressure.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Clean the pump compartment thoroughly.

6. Obtain a clean receptacle large enough to hold the hydraulic oil that will be removed from the hydraulic tank.

7. Remove the vent cap (1).

8. Remove the drain plug on the left side of the hydraulic oil tank and drain the oil.

9. Disconnect all hydraulic hoses attached to the hydraulic oil tank.

10. Remove the bolts (2), attaching the hydraulic oil tank (3), to the brackets, and remove hydraulic oil tank from truck.

11. Disconnect the fittings (1), pressure hose and suction hose from pump (2). Allow hydraulic oil to drain into the container.

12. Plug the hoses and pump ports.

WARNING PUMP IS HEAVY, DO NOT REMOVE BOLTS UNTIL INSTRUCTED. 13. Loosen, but do not remove, the four bolts (3), attaching the pump to the engine.

14. Attach a sling to the pump (2).

15. Remove the four mounting bolts previously loosened.

16. Remove the pump from the engine compartment. Pump will need to be taken out at an angle to clear frame.

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Installation 1. Clean the hydraulic tank, flush the hydraulic system, and replace the hydraulic filter element before installing the pump.

2. Attach a sling to the pump and lower the pump into the engine compartment.

3. Apply Loctite to four bolts (3), and attach the pump to the engine with the four bolts (3).

4. Torque bolts (3), to 18 lb-ft (25 Nm).

5. Attach fittings (1), pressure hose and suction hose to the pump (2).

6. Attach hydraulic oil tank (3), to bracket with bolts (2).

7. Connect hoses to hydraulic oil tank.

8. Install drain plug into hydraulic oil tank.

9. Install vent cap (1).

10. Refill hydraulic system. If reusing the drain oil, be sure to inspect the oil for contamination. If oil is not clean, do not reuse.

11. Start machine and check for leaks.

12. Allow hydraulic oil to reach normal operating temperature.

13. Check pump pressure.

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EC25/EC35 Removal 1. Park the machine in a safe place.

2. Remove the key from the ignition.

3. Open the filter cap on the hydraulic oil tank to relieve system pressure.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Clean the pump compartment thoroughly.

6. Obtain a clean container large enough to hold the hydraulic oil that will be removed from the hydraulic tank.

7. Remove the four nuts and washers (1), attaching muffler pipe (2), to exhaust manifold (3).

8. Remove the bolts (1), attaching the muffler (2), to the bracket.

9. Remove muffler.

10. Place a container large enough to hold the hydraulic oil under the hydraulic oil tank, then remove tank drain fitting to drain the tank.

11. Disconnect the fittings (1), pressure hoses and suction hose from pump (2). Allow hydraulic oil to drain into the container.

12. Plug the hoses and pump ports.

WARNING PUMP IS HEAVY, DO NOT REMOVE BOLTS UNTIL INSTRUCTED. 13. Loosen, but do not remove, the two bolts (3), attaching the pump to the engine.

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14. Attach a sling to the pump (2).

15. Remove the two mounting bolts (3), previously loosened.

16. Remove the pump from the engine compartment. Pump will need to be taken out at an angle to clear frame.

Installation 1. Clean the hydraulic tank, flush the hydraulic system, and replace the hydraulic filter element before installing the pump.

2. Attach a sling to the pump and lower the pump into the engine compartment.

3. Apply Loctite to two bolts (3), and attach the pump to the engine with the two bolts (3).

4. Torque bolts (3), to 62 lb-ft (85 Nm).

5. Attach fittings (1), pressure hoses and suction hose to the pump (2).

6. Install the drain fitting in the hydraulic oil tank.

7. Install vent cap on hydraulic oil tank.

8. Refill hydraulic system. If reusing the drain oil, be sure to inspect the oil for contamination. If oil is not clean, do not reuse.

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9. Mount muffler (2), on bracket and attach with bolts and washers (1).

10. Torque bolts (1), to 45 lb-ft (61 Nm).

11. Attach muffler pipe (2), to exhaust manifold (3), with four nuts and washers (1).

12. Torque nuts (1), to 35 lb-in (40 Nm).

13. Start machine and check for leaks.

14. Allow hydraulic oil to reach normal operating temperature.

15. Check pump pressure.

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EC45 Removal 1. Park the machine in a safe place.

2. Remove the key from the ignition.

3. Open the filter cap on the hydraulic oil tank to relieve system pressure.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Clean the pump compartment thoroughly.

6. Obtain a clean receptacle large enough to hold the hydraulic oil that will be removed from the hydraulic tank.

7. Remove the cap (1), on the drain located on the bottom of the hydraulic tank.

NOTE: A special drain hose, part number 73184059, is recommended for connection to the drain. This hose has a special fitting for opening the drain.

If the hose is not available, the drain fitting must be removed to drain the hydraulic tank.

8. Place a container large enough to hold the hydraulic oil under the tank, then connect special drain hose (1), to hydraulic tank fitting (2), or remove tank drain fitting (2), to drain the tank.

9. Disconnect the fittings (1), and pressure hoses (2), from pump (3). Allow hydraulic oil to drain into the container.

10. Plug the hoses and pump ports.

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11. Remove the bolt (1), from the suction flange with a hexagon wrench.

12. Remove the suction hose (2), and allow hydraulic oil to drain into the container.

WARNING PUMP IS HEAVY, DO NOT REMOVE BOLTS UNTIL INSTRUCTED. 13. Loosen, but do not remove, the two bolts (1), attaching the pump to the engine.

14. Attach a sling (1), to the pump (2).

15. Remove the two mounting bolts previously loosened.

16. Remove the pump from the engine compartment. Pump will need to be taken out at an angle to clear frame.

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Installation 1. Clean the hydraulic tank, flush the hydraulic system, and replace the hydraulic filter element before installing the pump.

2. Attach a sling (1), to the pump (2), and lower the pump into the engine compartment.

3. Apply Loctite to two bolts (1), and attach the pump to the engine with the two bolts.

4. Torque bolts (1), to 161 lb-ft (220 Nm).

5. Attach the suction hose (2), to the suction flange with a bolt (1).

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6. Attach fittings (1), and pressure hoses (2), to the pump (3).

7. Remove drain hose (1), from drain fitting (2).

If drain fitting (2), has been removed, install the drain fitting.

8. Install cap (1), on drain fitting.

9. Refill hydraulic system. If reusing the drain oil, be sure to inspect the oil for contamination. If oil is not clean, do not reuse.

10. Start machine and check for leaks.

11. Allow hydraulic oil to reach normal operating temperature.

12. Check pump pressure.

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Hydraulic Cooling Radiator EC15 Removal 1. Park the machine in a safe place.

2. Remove the key from the ignition.

3. Open the filter cap on the hydraulic oil tank to relieve system pressure.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Open the engine compartment door.

6. Obtain a clean receptacle large enough to hold the hydraulic oil that will be removed from the hydraulic tank.

7. Place the container under the tank, then remove tank drain fitting, to drain the tank.

8. Replace fitting when tank is drained.

9. Disconnect the fittings (1), from oil cooler (2).

Allow hydraulic oil to drain into the container.

10. Plug the hoses.

11. Remove the bolt (1), washer (2), and nut (3), attaching oil cooler (4), to bracket (5).

12. Remove the bolt (6), washer (7), and nut (8), attaching oil cooler (4), to bracket (9).

13. Remove the bolt (10), washer (11), and nut (12), attaching oil cooler (4), to angle plate (13).

14. Remove the oil cooler (4), and allow hydraulic oil from oil cooler to drain into the container.

15. Remove nut (14), and washer (15), from bumper (18).

16. Remove bumper (18).

17. Remove washer (16), and nut (17), from bumper (18).

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Installation 1. Clean the hydraulic tank, flush the hydraulic system, and replace the hydraulic filter element before installing the oil cooler.

2. Place nut (17), on bumper (18).

3. Install bumper (18), with nut attached to oil cooler (4), with washer (16), washer (15), and nut (14).

4. Attach oil cooler (4), to angle plate (13), with bolt (10), washer (11), and nut (12).

5. Attach oil cooler (4), to bracket (9), with bolt (6), washer (7), and nut (8).

6. Attach oil cooler (4), to bracket (5), with bolt (1), washer (2), and nut (3).

7. Attach hydraulic fittings (1), to oil cooler (2).

8. Refill hydraulic system tank with hydraulic oil.

9. Operate machine and check for leaks.

10. Close engine compartment door.

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SECTION 7 - HYDRAULIC SYSTEM

EC25/EC35 Removal 1. Park the machine in a safe place.

2. Remove the key from the ignition.

3. Open the filter cap on the hydraulic oil tank to relieve system pressure.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Open the engine compartment door.

6. Obtain a clean receptacle large enough to hold the hydraulic oil that will be removed from the hydraulic tank.

7. Place the container under the tank, then remove tank drain fitting (2), to drain the tank.

8. Replace fitting when tank is drained.

9. Disconnect the fittings (1), from oil cooler (2).

Allow hydraulic oil to drain into the container.

10. Plug the hoses.

11. Remove the four bolts (1), four washers (2), 3, and 4, and four nuts (5), attaching oil cooler (6), to bracket (7).

12. Remove the oil cooler (6), and allow hydraulic oil from oil cooler to drain into the container.

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SECTION 7 - HYDRAULIC SYSTEM

Installation 1. Clean the hydraulic tank, flush the hydraulic system, and replace the hydraulic filter element before installing the oil cooler.

2. Attach oil cooler (6), to bracket (7), with four bolts (1), four washers (2), (3), and (4), and nut (5).

3. Attach hydraulic fittings (1), to oil cooler (2).

4. Refill hydraulic system tank with hydraulic oil.

5. Operate machine and check for leaks.

6. Close engine compartment door.

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EC45 Removal 1. Park the machine in a safe place.

2. Remove the key from the ignition.

3. Open the filter cap on the hydraulic oil tank to relieve system pressure.

4. Operate remote controls several times to release any pressure in the hydraulic system.

5. Open the engine compartment door.

6. Obtain a clean receptacle large enough to hold the hydraulic oil that will be removed from the hydraulic tank.

7. Obtain a clean receptacle large enough to hold the coolant that will be removed from the cooling system.

8. Remove the cap (1), on the drain located on the bottom of the hydraulic tank.

NOTE: A special drain hose, part number 73184059, is recommended for connection to the drain. This hose has a special fitting for opening the drain. If the hose is not available, the drain fitting must be removed to drain the hydraulic tank.

9. Place a container large enough to hold the hydraulic oil under the hydraulic tank, then connect special drain hose (1), to hydraulic tank fitting (2), or remove tank drain fitting (2), to drain the tank.

10. Disconnect drain hose or replace fitting as applicable.

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11. Install cap (1), on the drain located on the bottom of the hydraulic tank.

12. Disconnect hydraulic fittings (1), from water/ oil cooler (2).

13. Plug hydraulic hoses.

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14. Disconnect overflow hose (1), and clamp (23), from water/oil cooler (2).

15. Remove cap (3).

16. Place a container large enough to hold the coolant under the water/oil cooler tank, then open drain valve and drain coolant into the container.

17. Close drain valve.

18. Loosen clamp (4), and disconnect hose (5).

19. Loosen clamp (6), and disconnect hose (7).

20. Remove bolt (8), and washer (9), attaching water/oil coolant to bracket (10).

21. Remove bolt (11), washer (12), rubber bearing (13), and stud (14), connecting bracket (25), to water/oil cooler (2).

22. Remove bolt (15), washer (16), rubber bearing (17), and stud (18), connecting bracket (24), to water/oil cooler (2).

23. Remove bolt (19), washer (20), rubber bearing (21), and stud (22), connecting bracket (24), to water/oil cooler (2).

Installation 1. Clean the hydraulic tank, flush the hydraulic system, and replace the hydraulic filter element before installing the water/oil cooler.

2. Install studs (18) and 22, in bottom of water/ oil cooler (2).

3. Install rubber bearings (17) and 21, on studs, and set assembly on bracket (24).

4. Attach assembly to bracket (24), with washers (16) and (20), and bolts (15) and (19).

5. Install stud (14), in water/oil cooler (2).

6. Install rubber bearings (13), on stud.

7. Attach rubber bearing (13), to bracket (25), with washer (12), and bolt (11).

8. Attach overflow hose (1), and clamp (23), to water/oil cooler (2).

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9. Attach hose (5), to water/oil cooler (2), with clamp (4).

10. Attach hose (7), to water/oil cooler (2), with clamp (6).

11. Attach bracket (10), to water/oil cooler (2), with washer (9), and bolt (8).

12. Install cap (3), on water/oil cooler (2).

13. Connect hydraulic hoses (1), to water/oil cooler (2).

14. Check that drain on water cooler is closed then refill water cooler.

15. Refill hydraulic system with hydraulic oil.

16. Operate machine and check for water or hydraulic oil leaks and correct any problems.

17. Close the engine compartment door.

18. Remove key.

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DISASSEMBLY AND ASSEMBLY Valve Bank EC15/EC25 Three valve banks are used in the EC15 excacator. One valve bank contains four valves and a divider block. The second consists of four valves without the divider block, and the third consists of a single valve assembly. The valves are either lever operated or pilot operated. The disassembly and assembly procedure below is for a typical valve and is applicable to all three valve assemblies.

Disassembly 1. Remove the nuts and washers (1), from the four rods (2).

2. Slide the rods (2), out of the assembly.

3. Separate the valve sections.

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SECTION 7 - HYDRAULIC SYSTEM

4. Remove only the components which are defective. The main valve components are as follows: 1.

2.

3.

4.

5.

6.

7.

8.

9.

Main Pressure Valve Anti-Cavitation Port Relief Lever Bracket Control Spool Stroke Y-Plug Load Check Valve One-Way Valve Seal Kit

Refer to illustration on previous page.

Assembly 1. Install valve components previously removed.

NOTE: When assembling the valves, the “A” sides must be facing the same direction and the “B” sides must be facing the same direction.

2. Align the valve sections with the “A” sides together and the “B” sides together. Be sure all seals are in place between sections.

3. Insert the four tie rods (2), through the valve sections and secure with nut (1).

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EC35 Three valve banks are used in the EC25 and EC35 excavators. One valve bank contains four valves, the second consists of three valves, and the third consists of two valves. The valves are either lever operated or pilot operated. The disassembly and assembly procedure below is for a typical valve and is applicable to all three valve assemblies. The valve banks control the following operations Valve Bank 1

Dozer blade, slewing

Valve bank 2

Travel left, bucket, and boom

Valve Bank 3

Travel right, additional control circuit, articulation, and stick

Valve Bank 1 Disassembly 1. Remove the nuts (1), from the four rods (2).

2. Slide the rods (2), out of the assembly.

3. Separate the valve sections.

4. Remove only the components which are defective. The main valve components are as follows: 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Tie Rod Nut Main Relief Valve One-Way Valve Plug Kit Control Valve Valve Control Load Check Valve Plug Seals

Components 3-10 refer to illustration on following page.

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SECTION 7 - HYDRAULIC SYSTEM

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SECTION 7 - HYDRAULIC SYSTEM

Valve Bank (1) Assembly 1. Install valve components previously removed.

NOTE: When assembling the valve, the ”A” sides must be facing the same direction and the “B” sides must be facing the same direction.

2. Align the valve section with the “A” sides together and the “B” sides together. Be sure all seals are in place between sections.

3. Insert the four tie rods (2), through the valve sections and secure with nut (1).

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SECTION 7 - HYDRAULIC SYSTEM

Valve Bank (2) Disassembly 1. Remove the nuts (1), from the four rods (2).

2. Slide the rods (2), out of the assembly.

3. Separate the valve sections.

4. Remove only the components which are defective. The main valve components are as follows: 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Tie Rod Nut Main Relief Valve Port Relief Valve One-Way Valve Control Valve Valve Control Lever Load Check Valve End Bracket Seals

Components 3-10 refer to illustration on following page.

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SECTION 7 - HYDRAULIC SYSTEM

Valve Bank (2) Assembly 1. Install valve components previously removed.

NOTE: When assembling the valve, the ”A” sides must be facing the same direction and the “B” sides must be facing the same direction.

2. Align the valve section with the “A” sides together and the “B” sides together. Be sure all seals are in place between sections.

3. Insert the four tie rods (2), through the valve sections and secure with nut (1).

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SECTION 7 - HYDRAULIC SYSTEM

Valve Bank (3) Disassembly 1. Remove the nuts (1), from the four rods (2).

2. Slide the rods (2), out of the assembly.

3. Separate the valve sections.

4. Remove only the components which are defective. The main valve components are as follows: 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Nut Tie Rod Main Relief Valve Port Relief Valve One-Way Valve Control Valve Valve Control Lever Load Check Valve End Bracket Seals

Components 3-10 refer to illustration on following page.

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SECTION 7 - HYDRAULIC SYSTEM

Valve Bank (3) Assembly 1. Install valve components previously removed.

NOTE: When assembling the valve, the ”A” sides must be facing the same direction and the “B” sides must be facing the same direction.

2. Align the valve section with the “A” sides together and the “B” sides together. Be sure all seals are in place between sections.

3. Insert the four tie rods (2), through the valve sections and secure with nut (1).

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SECTION 7 - HYDRAULIC SYSTEM

Hydraulic Cylinder - Bucket EC15 Disassembly 1. Remove cylinder from machine as previously described.

2. Clamp the hydraulic cylinder horizontally in a suitable vise.

3. Place a container under the cylinder to collect the oil.

4. Use a hook wrench and unscrew the gland nut (10), from the cylinder housing (1).

5. Pull the piston rod assembly (6), with piston (8), and gland nut (10), out of cylinder housing (1).

6. Clamp the piston rod eye horizontally in a suitable vise.

NOTE: Nut is held by Loctite, warm to 392°F (200°C) if necessary.

7. Remove the nut (7), then remove the piston (8), with the seal (9).

8. Remove the gland nut (10), from the piston rod (6).

9. Remove the rod seal (11), and scraper ring (12), from gland nut (10).

10. Check the piston rod (6), for damage.

11. Remove the snap rings (4), and check the bearings (3).

12. Carefully remove seals (9), and O-rings (13) and (14), taking care not to damage the piston (8), or gland nut (10).

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Assembly NOTE: Replace all seals and O-rings with new parts during assembly. Coat seals and O-rings with oil.

1. Clean all threaded surfaces.

2. Install piston seal (9), on piston (8).

3. Install O-rings (13) and (14), on gland nut (10).

4. Check bearings (3), for damage and replace if defective.

5. Install one bearing (3), in piston rod (6), and secure with snap ring (4).

6. Install one bearing (3), in cylinder housing (1), and secure with snap ring (4).

7. Insert scraper ring (12), and rod seal (11), into gland nut (10).

8. Slide gland nut (10), with O-rings installed, on piston rod (6).

NOTE: Nut (7), must be free from grease.

9. Apply Loctite to nut (7).

10. Attach piston (8), to piston rod (6), with nut (7).

11. Torque nut (7), to 300 lb-ft (410 Nm).

12. Slide assembled piston rod into housing (1).

13. Tighten gland nut (10), to value specified in Torque Table, page 7-11.

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EC25/EC35/EC45 Disassembly 1. Remove cylinder from machine as previously described.

2. Clamp the hydraulic cylinder horizontally in a suitable vise.

3. Place a container under the cylinder to collect any oil.

4. Use a hook wrench and unscrew the gland (10), from the cylinder housing (1).

5. Pull the piston rod assembly (5), with piston (8), and gland nut (10), out of cylinder housing (1).

6. Clamp the piston rod eye horizontally in a suitable vise.

NOTE: Nut is held by Loctite, warm to 392°F (200°C) if necessary.

7. Remove the nut (6), then remove the piston (8), with the seals (9).

8. Remove the gland nut (10), from the piston rod (5).

9. Remove the rod seal (11), and scraper ring (12), from gland nut (10).

10. Check the piston rod (5), for damage.

11. Remove the snap rings (4), and check the bearings (3).

12. Carefully remove seals (9), O-rings (13) and 15, and backup washer (14), taking care not to damage the piston (8), or gland nut (10).

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Assembly NOTE: Replace all seals and O-rings with new parts during assembly. Coat seals and O-rings with oil.

1. Clean all threaded surfaces 2. Check bearings (3), for damage and replace if defective.

3. Install one bearing (3), in piston rod (5), and secure with snap ring (4).

4. Install one bearing (3), in cylinder housing (1), and secure with snap ring (4).

5. Install piston seal (9), on piston (8).

6. Install O-rings (13) and 15, and backup ring (14), on gland nut (10).

7. Insert scraper ring (12), and rod seal (11), into gland nut (10).

8. Slide gland nut (10), with O-rings and backup rings installed, on piston rod (5).

NOTE: Nut (6), must be free from grease.

9. Apply Loctite to nut (6).

10. Attach piston (8), to piston rod (5), with nut (6).

11. Torque nut (6), to 330 lb-ft (450 Nm).

12. Slide assembled piston rod into housing (1).

13. Tighten gland nut (10), to value specified in Torque Table, page 7-11.

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Hydraulic Cylinder - Boom EC15 Disassembly 1. Remove cylinder from machine as previously described.

2. Clamp the hydraulic cylinder horizontally in a suitable vise.

3. Place a container under the cylinder to collect the oil.

4. Use a hook wrench and unscrew the gland nut (12), from the cylinder housing (1).

5. Pull the piston rod assembly (6), with piston (7), and gland nut (12), out of cylinder housing (1).

6. Clamp the piston rod eye horizontally in a suitable vise.

NOTE: Nut (11), is held by Loctite, warm to 392°F (200°C) if necessary.

7. Remove the nut (11), then remove the piston (7), with the piston seal (8), piston guide strap (9), and retaining ring (10), attached.

8. Remove the gland nut (12), from the piston rod (6).

9. Remove the rod seal (13), and scraper ring (14), from gland nut (12).

10. Check the piston rod (6), for damage.

11. Remove the snap rings (4), and check the bearings (3).

12. Carefully remove piston seal (8), piston guide strap (9), and retaining ring (10), from piston (7), taking care not to damage the piston.

13. Remove O-rings (15) and 17, and backup ring (16), taking care not to damage the gland nut (12).

7-135

SECTION 7 - HYDRAULIC SYSTEM

Assembly NOTE: Replace all seals, backup rings, and O-rings with new parts during assembly. Coat seals, backup ring, and O-rings with oil.

1. Clean all threaded surfaces 2. Install piston seal (8), piston guide strap (9), and retaining ring (10), on piston (7).

3. Install O-rings (15) and 17, and backup ring (16), on gland nut (12).

4. Check bearings (3), for damage and replace if defective.

5. Install one bearing (3), in piston rod (6), and secure with snap ring (4).

6. Install one bearing (3), in cylinder housing (1), and secure with snap ring (4).

7. Insert scraper ring (14), and rod seal (13), into gland nut (12).

8. Slide gland nut (12), with O-rings and backup ring installed, on piston rod (6).

NOTE: Nut (11), must be free from grease.

9. Apply Loctite to nut (11).

10. Attach piston (7), to piston rod (6), with nut (11).

11. Torque nut (11), to 329 lb-ft (450 Nm).

12. Slide assembled piston rod into housing (1).

13. Tighten gland nut (12), to value specified in Torque Table, page 7-11.

7-136

SECTION 7 - HYDRAULIC SYSTEM

EC25/EC35/EC45 Disassembly 1. Remove cylinder from machine as previously described.

2. Clamp the hydraulic cylinder horizontally in a suitable vise.

3. Place a container under the cylinder to collect the oil.

4. Use a hook wrench and unscrew the gland nut (10), from the cylinder housing (1).

5. Pull the piston rod assembly (5), with piston (7), and gland nut (10), out of cylinder housing (1).

6. Clamp the piston rod eye horizontally in a suitable vise.

NOTE: Nut (6), is held by Loctite, warm to 392°F (200°C) if necessary.

7. Remove the nut (6), then remove the piston (7), with the piston seal (8), and retaining rings (9), attached.

8. Remove the gland nut (10), from the piston rod (5).

9. Remove the rod seal (11), and scraper ring (12), from gland nut (10).

10. Check the piston rod (5), for damage.

11. Remove the snap rings (4), and check the bearings (3).

12. Carefully remove piston seal (8), and retaining rings (9), from piston (7), taking care not to damage the piston.

13. Remove O-rings (13) and (15), and backup ring (14), taking care not to damage the gland nut (10).

7-137

SECTION 7 - HYDRAULIC SYSTEM

Assembly NOTE: Replace all seals, backup rings, and O-rings with new parts during assembly. Coat seals, backup ring, and O-rings with oil.

1. Clean all threaded surfaces.

2. Install piston seal (8), and retaining rings (9), on piston (7).

3. Install O-rings (13) and (15), and backup ring (14), on gland nut (10).

4. Check bearings (3), for damage and replace if defective.

5. Install one bearing (3), in piston rod (5), and secure with snap ring (4).

6. Install one bearing (3), in cylinder housing (1), and secure with snap ring (4).

7. Insert scraper ring (12), and rod seal (11), into gland nut (10).

8. Slide gland nut (10), with O-rings and backup ring installed, on piston rod (5).

NOTE: Nut (6), must be free from grease.

9. Apply Loctite to nut (6).

10. Attach piston (7), to piston rod (5), with nut (6).

11. Torque nut (6), to the following, EC25, 600 lb-ft (810 Nm) EC35, 775 lb-ft (1050 Nm) EC45, 790 lb-ft (1075 Nm) 12. Slide assembled piston rod into housing (1).

13. Tighten gland nut (10), to value specified in Torque Table, page 7-11.

7-138

SECTION 7 - HYDRAULIC SYSTEM

Hydraulic Cylinder - Stick, Articulation EC15 Disassembly 1. Remove cylinder from machine as previously described.

2. Clamp the hydraulic cylinder horizontally in a suitable vise.

3. Place a container under the cylinder to collect the oil.

4. Use a hook wrench and unscrew the gland nut (12), from the cylinder housing (1).

5. Pull the piston rod assembly (7), with piston (8), and gland nut (10), out of cylinder housing (1).

6. Clamp the piston rod eye horizontally in a suitable vise.

NOTE: Nut (6), is held by Loctite, warm to 392°F (200°C) if necessary.

7. Remove the nut (6), then remove the piston (7), with the piston seal (8), and retaining ring (9), attached.

8. Remove the gland nut (12), from the piston rod (5).

9. Remove the rod seal (11), and scraper ring (10), from gland nut (12).

10. Check the piston rod (5), for damage.

11. Remove the snap rings (4), and check the bearings (3).

12. Carefully remove piston seal (8), and retaining ring (9), from piston (7), taking care not to damage the piston.

13. Remove O-rings (13) and (14), taking care not to damage the gland nut (12).

7-139

SECTION 7 - HYDRAULIC SYSTEM

Assembly NOTE: Replace all seals, backup rings, and O-rings with new parts during assembly. Coat seals, backup ring, and O-rings with oil.

1. Clean all threaded surfaces.

2. Install piston seal (8), and retaining ring (9), on piston (7).

3. Install O-rings (13) and (14), on gland nut (10).

4. Check bearings (3), for damage and replace if defective.

5. Install one bearing (3), in piston rod (5), and secure with snap ring (4).

6. Install one bearing (3), in cylinder housing (1), and secure with snap ring (4).

7. Insert scraper ring (10), and rod seal (11), into gland nut (12).

8. Slide gland nut (12), with O-rings installed, on piston rod (5).

NOTE: Nut (6), must be free from grease.

9. Apply Loctite to nut (6).

10. Attach piston (7), to piston rod (5), with nut (6).

11. Torque nut (6), to 300 lb-ft (410 Nm) 12. Slide assembled piston rod into housing (1).

13. Tighten gland nut (10), to value specified in Torque Table, page 7-11.

7-140

SECTION 7 - HYDRAULIC SYSTEM

EC25/EC35/EC45 Disassembly 1. Remove cylinder from machine as previously described.

2. Clamp the hydraulic cylinder horizontally in a suitable vise.

3. Place a container under the cylinder to collect the oil.

4. Use a hook wrench and unscrew the gland nut (10), from the cylinder housing (1).

5. Pull the piston rod assembly (5), with piston (7), and gland nut (10), out of cylinder housing (1).

6. Clamp the piston rod eye horizontally in a suitable vise.

NOTE: Nut (6), is held by Loctite, warm to 392°F (200°C) if necessary.

7. Remove the nut (6), then remove the piston (7), with the piston seal (8), and retaining rings (9), attached.

8. Remove the gland nut (10), from the piston rod (5).

9. Remove the rod seal (11), and scraper ring (12), from gland nut (10).

10. Check the piston rod (5), for damage.

11. Remove the snap rings (4), and check the bearings (3).

12. Carefully remove piston seal (8), and retaining rings (9), from piston (7), taking care not to damage the piston.

13. Remove O-rings (13) and (15), and backup ring (14), taking care not to damage the gland nut (10).

7-141

SECTION 7 - HYDRAULIC SYSTEM

Assembly NOTE: Replace all seals, backup rings, and O-rings with new parts during assembly. Coat seals, backup ring, and O-rings with oil.

1. Clean all threaded surfaces.

2. Install piston seal (8), and retaining rings (9), on piston (7).

3. Install O-rings (13) and (15), and backup ring (14), on gland nut (10).

4. Check bearings (3), for damage and replace if defective.

5. Install one bearing (3), in piston rod (5), and secure with snap ring (4).

6. Install one bearing (3), in cylinder housing (1), and secure with snap ring (4).

7. Insert scraper ring (12), and rod seal (11), into gland nut (10).

8. Slide gland nut (10), with O-rings and backup ring installed, on piston rod (5).

NOTE: Nut (6), must be free from grease.

9. Apply Loctite to nut (6).

10. Attach piston (7), to piston rod (5), with nut (6).

11. Torque nut (6), to the following, Stick EC25, 330 lb-ft (450 Nm) EC35, 330 lb-ft (450 Nm) EC45, 775 lb-ft (1050 Nm) Articulatiion EC25, 600 lb-ft (810Nm) EC35, 600 lb-ft (810Nm) EC45, 775 lb-ft (1050 Nm) 12. Slide assembled piston rod into housing (1).

13. Tighten gland nut (10), to value specified in Torque Table, page 7-11.

7-142

SECTION 7 - HYDRAULIC SYSTEM

Hydraulic Cylinder - Dozer Blade EC15 Disassembly 1. Remove cylinder from machine as previously described.

2. Clamp the hydraulic cylinder horizontally in a suitable vise.

3. Place a container under the cylinder to collect the oil.

4. Use a hook wrench and unscrew the gland nut (8), from the cylinder housing (1).

5. Pull the piston rod assembly (4), with piston (6), and gland nut (8), out of cylinder housing (1).

6. Clamp the piston rod eye horizontally in a suitable vise.

NOTE: Nut (5), is held by Loctite, warm to 392°F (200°C) if necessary.

7. Remove the nut (5), then remove the piston (6), with the piston seal (7), attached.

8. Remove the gland nut (8), from the piston rod (4).

9. Remove the rod seal (9), and scraper ring (10), from gland nut (8).

10. Check the piston rod (4), for damage.

11. Remove the bushings (3), and check bushings for damage.

12. Carefully remove piston seal (7), from piston (6), taking care not to damage the piston.

13. Remove O-rings (11) and (12), taking care not to damage the gland nut (8).

14. Remove safety valve (15).

7-143

SECTION 7 - HYDRAULIC SYSTEM

Assembly NOTE: Replace all seals, and O-rings with new parts during assembly. Coat seals and O-rings with oil.

1. Clean all threaded surfaces.

2. Install piston seal (7), on piston (6).

3. Install O-rings (11) and (12), on gland nut (8).

4. Check bushings (3), for damage and replace if defective.

5. Install one bushing (3), in piston rod (4).

6. Install one bushing (3), in cylinder housing (1).

7. Insert scraper ring (10), and rod seal (9), into gland nut (8).

8. Slide gland nut (8), with O-rings installed on piston rod (4).

NOTE: Nut (5), must be free from grease.

9. Apply Loctite to nut (5).

10. Attach piston (6), to piston rod (4), with nut (5).

11. Torque nut (5), to 300 lb-ft (410 Nm).

12. Slide assembled piston rod into housing (1).

13. Tighten gland nut (8), to value specified in Torque Table, page 7-11.

14. Install safety valve (15).

7-144

SECTION 7 - HYDRAULIC SYSTEM

EC25/EC35 Disassembly

1. Remove cylinder from machine as previously described.

2. Clamp the hydraulic cylinder horizontally in a suitable vise.

3. Place a container under the cylinder to collect the oil.

4. Use a hook wrench and unscrew the gland nut (8), from the cylinder housing (1).

5. Pull the piston rod assembly (4), with piston (6), and gland nut (8), out of cylinder housing (1).

6. Clamp the piston rod eye horizontally in a suitable vise.

NOTE: Nut (5), is held by Loctite, warm to 392°F (200°C) if necessary.

7. Remove the nut (5), then remove the piston (6), with the piston seal (7), attached.

8. Remove the gland nut (8), from the piston rod (4).

9. Remove the rod seal (9), and scraper ring (10), from gland nut (8).

10. Check the piston rod (4), for damage.

11. Remove grease fittings (14).

12. Remove the bushings (3), and check bushings for damage.

13. Carefully remove piston seal (7), from piston (6), taking care not to damage the piston.

14. Remove O-rings (11) and (13), and backup ring (12), taking care not to damage the gland nut (8).

15. Remove safety valve (15).

7-145

SECTION 7 - HYDRAULIC SYSTEM

Assembly NOTE: Replace all seals, backup rings, and O-rings with new parts during assembly. Coat seals, backup rings, and O-rings with oil.

1. Clean all threaded surfaces.

2. Install piston seal (7), on piston (6).

3. Install O-rings (11) and (13), and backup ring (12), on gland nut (8).

4. Check bushings (3), for damage and replace if defective.

5. Install one bushing (3), in piston rod (4), and install grease fitting (14).

6. Install one bushing (3), in cylinder housing (1), and install grease fitting (14).

7. Insert scraper ring (10), and rod seal (9), into gland nut (8).

8. Slide gland nut (8), with O-rings and backup rings installed, on piston rod (4).

NOTE: Nut (5), must be free from grease.

9. Apply Loctite to nut (5).

10. Attach piston (6), to piston rod (4), with nut (5).

11. Torque nut (5), to 600 lb-ft (810 Nm).

12. Slide assembled piston rod into housing (1).

13. Tighten gland nut (8), to value specified in Torque Table, page 7-11.

14. Install safety valve (15).

7-146

EC15, EC25, EC35, EC45 CRA WLER EXCA VATOR CRAWLER EXCAV SER VICE MANU AL SERVICE MANUAL CONTENTS SECTION 00 - GENERAL INFORMA TION INFORMATION SECTION 6 - ELECTRICAL SYSTEM SECTION 7 - HYDRAULIC SYSTEM

SECTION 10 - OPERA TOR’S PLA TFORM OPERAT PLATFORM SECTION 11 - TRACTION/UNDERCARRIAGE

©1999 NEW HOLLAND CONSTRUCTION

SECTION 10 - OPERATOR’S PLATFORM

THIS P AGE INTENTIONALL Y LEFT BLANK PA INTENTIONALLY

10-2

SECTION 10 - OPERATOR’S PLATFORM

SECTION 10 OPERA TOR’S PLA TFORM OPERAT PLATFORM Contents General ............................................................................................................................................. 10-6 ROPS/FOPS Unit .......................................................................................................................... 10-7 Removal ..................................................................................................................................... 10-7 Installation .................................................................................................................................. 10-8 Cab .............................................................................................................................................. 10-10 Removal ................................................................................................................................... 10-10 Installation ................................................................................................................................ 10-13 Arm Rest ..................................................................................................................................... 10-17 Removal ................................................................................................................................... 10-17 Installation ................................................................................................................................ 10-17 Seat Belt ...................................................................................................................................... 10-17 Removal ................................................................................................................................... 10-17 Installation ................................................................................................................................ 10-17 Seat Belt Latch ............................................................................................................................ 10-18 Removal ................................................................................................................................... 10-18 Installation ................................................................................................................................ 10-18 Seat ............................................................................................................................................. 10-18 Removal ................................................................................................................................... 10-18 Installation ................................................................................................................................ 10-18 Seat Cushions ............................................................................................................................. 10-19 Removal ................................................................................................................................... 10-19 Installation ................................................................................................................................ 10-19 Heater .......................................................................................................................................... 10-20 EC15 ........................................................................................................................................ 10-20 Removal ............................................................................................................................... 10-20 Installation ............................................................................................................................. 10-20 EC25/EC35/EC45 .................................................................................................................... 10-21 Removal ............................................................................................................................... 10-21 Installation ............................................................................................................................. 10-22 Windshield Wipers and Washers ................................................................................................. 10-24 Wiper Arm ................................................................................................................................ 10-24 Removal ............................................................................................................................... 10-24 Installation ............................................................................................................................. 10-25 10-3

SECTION 10 - OPERATOR’S PLATFORM

Windshield Washer ................................................................................................................... 10-26 Removal ............................................................................................................................... 10-26 Installation ............................................................................................................................. 10-27 Interior Light ................................................................................................................................. 10-28 Removal ................................................................................................................................... 10-28 Installation ................................................................................................................................ 10-28 Working Lights ............................................................................................................................. 10-29 Cab Mounted ............................................................................................................................ 10-29 Removal ............................................................................................................................... 10-29 Installation ............................................................................................................................. 10-29 Boom Mounted ......................................................................................................................... 10-30 Removal ............................................................................................................................... 10-30 Installation ............................................................................................................................. 10-30 Radio (Covered in Section 6, Electrical System). ....................................................................... 10-31 Loudspeakers (Covered in Section 6, Electrical System). .......................................................... 10-31 Accelerator .................................................................................................................................. 10-32 EC15 ........................................................................................................................................ 10-32 Removal ............................................................................................................................... 10-32 Installation ............................................................................................................................. 10-33 EC25/EC35 .............................................................................................................................. 10-34 Removal ............................................................................................................................... 10-34 Installation ............................................................................................................................. 10-35 EC45 ........................................................................................................................................ 10-36 Removal ............................................................................................................................... 10-36 Installation ............................................................................................................................. 10-37 Hydraulic Cutoff Lever ................................................................................................................. 10-38 EC15 ........................................................................................................................................ 10-38 Removal ............................................................................................................................... 10-38 Installation ............................................................................................................................. 10-39 EC25 ........................................................................................................................................ 10-40 Removal ............................................................................................................................... 10-40 Installation ............................................................................................................................. 10-42 EC35 ........................................................................................................................................ 10-43 Removal ............................................................................................................................... 10-43 Installation ............................................................................................................................. 10-45 EC45 ........................................................................................................................................ 10-47 Removal ............................................................................................................................... 10-47 Installation ............................................................................................................................. 10-49 Remote Control (Covered in Section 7, Hydraulic System). ....................................................... 10-50 Reversing Lever (Covered in Section 7, Hydraulic System). ...................................................... 10-50

10-4

SECTION 10 - OPERATOR’S PLATFORM

Articulation Pedal ......................................................................................................................... 10-51 EC15/EC25/EC35 .................................................................................................................... 10-51 Removal ............................................................................................................................... 10-51 Installation ............................................................................................................................. 10-52 EC45 ........................................................................................................................................ 10-53 Removal ............................................................................................................................... 10-53 Installation ............................................................................................................................. 10-54 Left Crawler Control Pedal ........................................................................................................... 10-55 EC15/EC25/EC35 .................................................................................................................... 10-55 Removal ............................................................................................................................... 10-55 Installation ............................................................................................................................. 10-56 EC45 ........................................................................................................................................ 10-57 Removal ............................................................................................................................... 10-57 Installation ............................................................................................................................. 10-58 Right Crawler Control Pedal ........................................................................................................ 10-59 EC15/EC25/EC35 .................................................................................................................... 10-59 Removal ............................................................................................................................... 10-59 Installation ............................................................................................................................. 10-60 EC45 ........................................................................................................................................ 10-61 Removal ............................................................................................................................... 10-61 Installation ............................................................................................................................. 10-62 Optional Control Pedal ................................................................................................................. 10-63 EC15/EC25/EC35 .................................................................................................................... 10-63 Removal ............................................................................................................................... 10-63 Installation ............................................................................................................................ 10-64 EC45 ........................................................................................................................................ 10-65 Removal ............................................................................................................................... 10-65 Installation ............................................................................................................................. 10-66 Dozer Blade Control Lever .......................................................................................................... 10-67 EC15/EC25/EC35 .................................................................................................................... 10-67 Removal ............................................................................................................................... 10-67 Installation ............................................................................................................................. 10-68 EC45 ........................................................................................................................................ 10-69 Removal ............................................................................................................................... 10-69 Installation ............................................................................................................................. 10-70 Upper Carriage Lock Bolt ............................................................................................................ 10-71 EC15 ........................................................................................................................................ 10-71 Removal ............................................................................................................................... 10-71 Installation ............................................................................................................................. 10-71

10-5

SECTION 10 - OPERATOR’S PLATFORM

GENERAL The operator’s platform can be accessed from either side of the machine. A ROPS/FOPS unit is standard on all machines.

As an option, the excavator can be purchased with a fully enclosed cab that is ROPS/FOPS certified.

The cab has locking doors on both sides and is equipped with a heater, front windshield washer/wiper, and cloth seat.

10-6

SECTION 10 - OPERATOR’S PLATFORM

ROPS/FOPS Unit Removal 1. Remove work lights, if installed.

2. Remove side view mirrors, if installed.

3. Disconnect any ground straps attached to the ROPS/FOPS unit.

4. Disconnect any wires or cables attached to the ROPS/FOPS unit.

5. Remove the four screws and washers (1), attaching the left and right side of the ROPS/ FOPS unit (2), to the platform (3).

6. Remove the two screws and washers (1), attaching the back of the ROPS/FOPS unit (2), to the platform.

10-7

SECTION 10 - OPERATOR’S PLATFORM

7. Attach the crane lifting beam (1), to the ROPS/FOPS unit with four screws.

CAUTION USE A HOIST OF SUFFICIENT LIFTING CAPA CAP A CITY FOR THE WEIGHT OF THE UNIT..

R OPS/FOPS UNIT CAUTION BE SURE SUFFICIENT CLEARANCE EXISTS ABOVE THE MACHINE TO ALLOW REMOV REMO VAL. 8. Lift the ROPS/FOPS unit off the machine platform and carefully set on ground.

Installation 1. Attach the crane lifting beam (1), to the ROPS/FOPS unit with four screws.

CAUTION USE A HOIST OF SUFFICIENT LIFTING CAPA CAP A CITY FOR THE WEIGHT OF THE UNIT..

R OPS/FOPS UNIT CAUTION BE SURE SUFFICIENT CLEARANCE EXISTS ABOVE THE MACHINE TO ALLOW INSTALLA ALLATION. INST ALLA TION.

2. Carefully lift the ROPS/FOPS unit and set down on the machine platform aligning the mounting holes at the side and rear.

10-8

SECTION 10 - OPERATOR’S PLATFORM

3. Attach the back edge of the ROPS/FOPS unit with the two screws and washers (1).

4. Torque screws to 58 lb.-ft (80 Nm).

5. Attach the left and right side of the ROPS/ FOPS unit with the four screws and washers (1).

6. Torque screws to 58 lb.-ft (80 Nm).

7. Reconnect any wires disconnected during removal.

8. Reconnect any ground strap disconnected during removal.

9. Install side view mirrors, if applicable.

10. Install work lights, if applicable.

10-9

SECTION 10 - OPERATOR’S PLATFORM

Cab Removal 1. Remove work lights, if installed.

2. Remove side view mirrors, if installed.

3. Remove front windshield wiper assembly, if installed.

4. Remove windshield washer, if installed.

5. Remove radio, if installed.

6. Disconnect any ground straps attached to the cab.

7. Disconnect any wires or cables attached to the cab.

8. Open both cab doors and latch the doors open.

9. Remove the three screws (1), attaching the right side cover (2), and remove cover.

10. Disconnect the electrical connection to the pump motor (1), for the windshield washer reservoir (2).

11. Disconnect washer hose and slide washer reservoir (2), up and out of “V” shaped bracket. Set reservoir with attached pump aside.

12. Remove bolt and washer (3).

10-10

SECTION 10 - OPERATOR’S PLATFORM

13. Remove screws (1), attaching right rear cover (2), and remove cover.

14. Remove bolt (1).

10-11

SECTION 10 - OPERATOR’S PLATFORM

15. Remove the two bolts and washers (1), attaching the front of the cab (2), to the platform (one on each side).

16. Remove the two nuts and washers (1), attaching the cab (2), to the platform (one on each side).

10-12

SECTION 10 - OPERATOR’S PLATFORM

17. Attach the crane lifting beam (1), to cab unit with four screws.

CAUTION USE A HOIST OF SUFFICIENT LIFTING CAPA CAP A CITY FOR THE WEIGHT OF THE R OPS/FOPS UNIT UNIT.. CAB WEIGHS ABOUT 352 LB. (160 KG).

CAUTION BE SURE SUFFICIENT CLEARANCE EXISTS ABOVE THE MACHINE TO ALLOW REMOV REMO VAL. 18. Lift the cab unit off the machine platform and carefully set on ground.

19. Remove crane lifting beam from cab.

WARNING NOT OPERATE MACHINE DO NO T OPERA TE THE MA CHINE WITHOUT EITHER THE CAB OR THE ALLED..

INSTALLED ALLED R OPS/ FOPS UNIT INST Installation 1. Attach the crane lifting beam (1), to cab unit with four screws.

CAUTION USE A HOIST OF SUFFICIENT LIFTING CAPA CAP A CITY FOR THE WEIGHT OF THE CAB UNIT UNIT.. CAB WEIGHS ABOUT 352 LB LB..

(160 KG).

CAUTION BE SURE SUFFICIENT CLEARANCE EXISTS ABOVE THE MACHINE TO ALLOW REMOV REMO VAL. 2. Lift the cab unit off the ground and carefully set on operator’s platform, aligning mounting holes at front and rear, and insuring studs on side of operator’s platform are properly aligned with holes in cab frame.

3. Remove crane lifting beam from cab.

10-13

SECTION 10 - OPERATOR’S PLATFORM

4. Install the two screws and washers (1), attaching front of cab unit to the platform.

5. Torque the screws (1), to 58 lb.-ft (80 Nm).

6. Install the two nuts and washers (1), attaching side of cab unit to the platform.

7. Torque the nuts (5), and screws (1), to 58 lb.ft (80 Nm).

8. Install the bolt and washer (3).

9. Slide washer bottle (2), into “V” shaped bracket.

10. Connect windshield washer electrical cable and water hose.

10-14

SECTION 10 - OPERATOR’S PLATFORM

11. Attach left rear cover (2), with three screws (1).

12. Install bolt (1).

10-15

SECTION 10 - OPERATOR’S PLATFORM

13. Install three screws (1), to attach right side cover.

14. Install work lights, if applicable.

15. Install side view mirrors, if applicable.

16. Install front windshield wiper, if applicable 17. Connect wires to electrical components installed.

18. Attach and ground wires that were disconnected.

19. Install radio, if applicable.

10-16

SECTION 10 - OPERATOR’S PLATFORM

Ar m Rest Arm Removal 1. Remove the four screws (1), attaching the arm rest (2), to the control housing.

2. Remove arm rest (2).

Installation 1. Align the elongated mounting holes in the arm rest (2), with the holes in the control housing.

2. Attach arm rest (2), with the four screws (1).

Do not tighten screws at this time.

3. Adjust the desired height of the arm rest (2).

4. Tighten screws (1), to secure arm rest (2), in place.

Seat Belt The seat belt is located on the left side of the operator’s seat.

Removal 1. Remove the two screws (1), attaching the seat belt (2), to the cab.

2. Remove seat belt (2).

Installation 1. Align the mounting holes in the seat belt (2), with the holes in the cab.

2. Attach seat belt (2), with the two screws (1).

10-17

SECTION 10 - OPERATOR’S PLATFORM

Seat Belt Latch The seat belt latch is located on the right side of the operator’s seat.

Removal 1. Remove the two screws (2), attaching the seat belt latch (1), to the cab.

2. Remove seat belt latch (1).

Installation 1. Align the mounting holes in the seat belt latch (1), with the holes in the cab.

2. Attach seat belt latch (1), with the two screws (2).

Seat The seat can be removed for replacement or to access the heater in cab-equipped machines.

The seat is the same on cab and non-cab machines except for the material.

WARNING OPERATE MACHINE NEVER OPERA TE MA CHINE WITHOUT SEAT BELTS PROPERL OPERLY INSTALLED ALLED..

SEA T BEL TS PR OPERL Y INST ALLED Removal 1. Remove two screws and washers (1), attaching stop plate (2).

2. Slide seat (3), off channel (4).

Installation 1. Slide seat (3), onto channels (4).

2. Attach stop plate (2), with two screws and washers (1).

10-18

SECTION 10 - OPERATOR’S PLATFORM

Seat Cushions Removal 1. Remove clamp (1), hold back cushion (2).

2. Remove back cushion from metal pan.

3. Remove clamp (3), holding seat cushion (4).

4. Remove seat cushions from metal pan (5).

Installation 1. Place seat cushion (4), in metal pan (5), pushing down to make sure the cushion is firmly seated.

2. Install clamp (3), to hold seat cushion (4), in place.

3. Place back cushion (2), in metal pan, pushing down to make sure the cushion is firmly seated.

4. Install clamp (1), to hold back cushion (2), in place.

10-19

SECTION 10 - OPERATOR’S PLATFORM

Heater The heater is standard on cab-equipped machines. It consists of a blower assembly, heater coil, and hoses. The hoses are attached to the engine block through a water shutoff valve. The heater used on the EC15 has a different configuration than the heater used on the EC25/EC35/EC45.

EC15 Removal 1. Disconnect electrical connector from heater (1).

2. Turn off heater water valve at engine.

3. Remove clamps (2), from hoses (3), and disconnect hoses (3), from heater coil (4).

4. If hoses are to be replaced, disconnect other end of hoses from engine.

5. Remove clamp (8), and disconnect drain hose (7).

6. Remove two screws and washers (5), attaching heater (1), to bracket (6).

7. Remove heater assembly from compartment.

Installation 1. Install heater (1), in compartment and attach to bracket (6), with two screws and washers (5).

2. Attach drain hose (7), to heater (1), with clamp (8).

3. Attach heater hoses (3), to heater coil (4), with clamps (2).

4. Connect heater electrical cable connector to receptacle on heater (2).

5. Open heater water shutoff valve.

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SECTION 10 - OPERATOR’S PLATFORM

EC25/EC35/EC45 Removal 1. Remove seat.

2. Remove plate (1), by removing two screws and washer (2), from front of plate, and two screws and washers (3), from back of plate.

3. Disconnect electrical cable (2), from heater (1).

4. Turn off heater water valve at engine.

5. Remove clamps (3), from hoses (4), and disconnect hoses (4), from heater coil (5).

6. If hoses are to be replaced, disconnect other end of hoses from engine.

7. Remove clamp, and disconnect drain hose.

8. Remove two screws and washers (1), attaching heater (2), to bracket (3).

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SECTION 10 - OPERATOR’S PLATFORM

9. Loosen screw (1), located through access hole.

10. Remove heater assembly (2), from compartment.

Installation 1. Install heater (2), in compartment with mounting flange on heater under screw (1).

2. Attach heater (2), to bracket (3), with two screws and washers (1).

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SECTION 10 - OPERATOR’S PLATFORM

3. Attach drain hose to heater with clamp.

4. Attach heater hoses (4), to heater coil (5), with clamps (3).

5. Connect heater electrical cable (2), to receptacle on heater (1).

6. Open heater water shutoff valve.

7. Attach plate (1), with two screws and washers (2), at front of plate, and two screws and washers (3), at back of plate.

8. Install seat.

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SECTION 10 - OPERATOR’S PLATFORM

Windshield Wipers and Washers The motor for the windshield wiper is located at the lower right of the front windshield. The motor is covered to prevent accumulation of dirt and debris.

Wiper Ar m Arm The wiper arm can be removed without removing the wiper motor.

Removal 1. Remove two screws (1), and remove housing (2).

2. Lift hinge covers (1).

3. Remove nut (2), and spring washer (3).

4. Remove wiper arm assembly (4).

5. Remove cap (5), nut (6), washer (7), and cable protection (8).

6. Disconnect motor connector (12).

7. Remove screw (10), and washer (11), attaching motor assembly (9), and remove motor assembly.

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SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Attach motor assembly (9), with screws (10), and washers (11).

2. Connect motor connector (12).

3. Install cable protection (8), washer (7), nut (6), and cap (5).

4. Install wiper arm assembly (4), and attach with spring washer (3), and nut (2).

5. Install housing (2), with two screws (1).

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SECTION 10 - OPERATOR’S PLATFORM

Windshield Washer The windshield washer container and pump motor are located under the right rear cover.

Removal 1. Remove the three screws (1), attaching the right rear cover (2), and remove cover.

2. Disconnect the electrical connection (1), for the windshield washer bottle (2).

3. Disconnect washer hose and slide washer bottle (2), up and out of “V” shaped bracket.

10-26

SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Slide washer bottle (2), into “V” shaped bracket.

2. Connect windshield washer cable and hose.

3. Attach right rear cover (2), with three screws (1).

10-27

SECTION 10 - OPERATOR’S PLATFORM

Inter ior Light Interior The interior light is mounted on the right cab vertical support.

Removal 1. Remove screws (1), and interior light assembly (2), from vertical support.

2. If only light bulb is to be changed, remove bulb and install new one.

3. If interior light assembly (2), is to be replaced, disconnect wires.

Installation 1. Install bulbs into interior light assembly (2).

2. Attach interior light assembly (2), to vertical cab support with screws (1).

3. Reconnect wires.

10-28

SECTION 10 - OPERATOR’S PLATFORM

W or king Lights orking The working lights are mounted on the front cab or ROPS support or on the boom.

Cab Mounted Removal 1. Disconnect connector (1).

2. Remove nut, washer, and screw (2), attaching light bracket (3), to cab support.

3. Remove light (4), with bracket (3), attached.

4. Separate working light (4), from bracket (3), by removing nut, washer, and screw (5).

Installation 1. Attach bracket (3), to working light (4), with screw, washer, and nut (5).

2. Attach bracket (3), to cab support with nut, washer, and screw (2).

3. Connect working light connector (1).

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SECTION 10 - OPERATOR’S PLATFORM

Boom Mounted Removal 1. Disconnect connector (1).

2. Remove screw (2), and washer (3), attaching light assembly (4), to boom.

3. Remove light assembly (4), from boom.

4. Replace bulb (5), if defective.

Installation 1. Attach light assembly (4), to boom with washer (3), and screw (2).

2. Connect working light connector (1).

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SECTION 10 - OPERATOR’S PLATFORM

Radio Removal and installation of the radio is covered in Section 6, Electrical System.

Loudspeakers Removal and installation of the loudspeakers is covered in Section 6, Electrical System.

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SECTION 10 - OPERATOR’S PLATFORM

Accelerator EC15 Removal 1. Remove four screws and crown washers (1), attaching cover panel (2).

2. Slide cover panel off.

3. Remove knob (3), from accelerator control (2).

4. Remove three screws and washers (1), attaching accelerator (2), to bracket.

5. Remove accelerator from bracket.

6. In engine compartment, disconnect accelerator cable end (3), from throttle arm (4).

7. Loosen nuts on throttle cable and remove accelerator cable from bracket (5).

8. If bracket (5), requires replacement, remove screw and washer (6).

9. Pull accelerator cable out of engine compartment and remove the accelerator (2), from the machine.

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SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Attach bracket (5), with screws and washers (6), if previously removed.

2. Place accelerator (2), in proper location on operator’s platform and thread accelerator cable through to the engine compartment.

3. Place accelerator cable in slot in bracket (5), and tighten nuts.

4. Connect cable end (3), to accelerator lever (4).

5. Install accelerator (2), so that shaft extends through opening in housing.

6. Attach accelerator (2), to bracket with three screws and washers (1).

7. Install knob (3), on accelerator shaft.

WARNING STA MOVEING PAR ARTS ST AY CLEAR OF MO VEING P AR TS IN COMPAR ARTMENT ENGINE COMP AR TMENT WHEN MAKING FOLLOWING ADUSTMENT..

THE FOLLO WING ADUSTMENT 8. Start engine.

9. Place accelerator in the fast idle position.

10. In engine compartment, adjust cable end for 2600 rpm.

11. Close engine compartment.

12. Shut off engine.

13. Install cover over accelerator control and attach with four screws and crown washers.

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SECTION 10 - OPERATOR’S PLATFORM

EC25/EC35 Removal 1. Remove four screws and crown washers (1), attaching cover panel (2).

2. Slide cover panel off.

3. Remove knob (3), from accelerator control (2).

4. Remove three screws and washers (1), attaching accelerator (2), to bracket.

5. Remove accelerator from bracket.

6. In engine compartment, disconnect accelerator cable end (3), from throttle arm.

7. Loosen nuts on accelerator cable and remove accelerator cable from bracket (5).

8. If bracket (5), requires replacement, remove screw and washer (6).

9. Pull accelerator cable out of engine compartment and remove the accelerator (2), from the machine.

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SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Attach bracket (5), with screws and washers (6), if previously removed.

2. Place accelerator (2), in proper location on operator’s platform and thread accelerator cable through to the engine compartment.

3. Place accelerator cable in slot in bracket (5), with one nut on each side of the bracket, and tighten nuts.

4. Connect cable end (3), to accelerator lever.

5. Install accelerator (2), so that shaft extends through opening in housing.

6. Attach accelerator (2), to bracket with three screws and washers (1).

7. Install knob (3), on accelerator shaft.

WARNING STA MOVIING PAR ARTS ST AY CLEAR OF MO VIING P AR TS IN COMPAR ARTMENT ENGINE COMP AR TMENT WHEN MAKING WING ADJUSTMENT THE FOLLO FOLLOWING ADJUSTMENT..

8. Start engine.

9. Place accelerator in the fast idle position.

10. In engine compartment, adjust cable end for 2600 rpm.

11. Shut engine compartment.

12. Shut off engine.

13. Install cover over accelerator control and attach with four screws and crown washers.

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SECTION 10 - OPERATOR’S PLATFORM

EC45 Removal 1. Remove four screws and crown washers (1), attaching cover panel (2).

2. Slide cover panel off.

3. Remove knob (3), from accelerator control (2).

4. Remove three screws and washers (1), attaching accelerator (2), to bracket.

5. Remove accelerator from bracket.

6. In engine compartment, disconnect accelerator cable end (3), from throttle arm.

7. Loosen nuts on throttle cable and remove accelerator cable from bracket (5).

8. If bracket (5), requires replacement, remove screw and washer (6).

9. Pull accelerator cable out of engine compartment and remove the accelerator (2), from the machine.

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SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Attach bracket (5), with screws and washers (6), if previously removed.

2. Place accelerator (2), in proper location on operator’s platform and thread accelerator cable through to the engine compartment.

3. Place accelerator cable in slot in bracket (5), with one nut on each side of the bracket, and tighten nuts.

4. Connect cable end (3), to accelerator lever.

5. Install accelerator (2), so that shaft extends through opening in housing.

6. Attach accelerator (2), to bracket with three screws and washers (1).

7. Install knob (3), on accelerator shaft.

WARNING MAY HOT AV CONTA ENGINE MA Y BE HO T A V OID CONT A CT WITH ENGINE. WARNING STA MOVING PAR ARTS ST AY CLEAR OF MO VING P AR TS IN COMPAR ARTMENT ENGINE COMP AR TMENT WHEN MAKING FOLLOWING ADUSTMENT..

THE FOLLO WING ADUSTMENT 8. Start engine.

9. Place accelerator in the fast idle position.

10. In engine compartment, adjust cable end for 2600 rpm.

11. Shut engine compartment.

12. Shut off engine.

13. Install cover over accelerator control and attach with four screws and crown washers.

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SECTION 10 - OPERATOR’S PLATFORM

Hydraulic Cutoff Lever The hydraulic cutoff lever locks the hydraulic motion controls when in the up (locked) position.

The control has levers both to the right and left of the operator. The controls are unlocked by moving the control lever fully forward. The lever operates a ball tap, which cuts off hydraulic fluid to the remote controllers.

EC15 Removal 1. Remove screws (3), and brackets (2), releasing hydraulic lever (1).

2. If ball tap (13), is to be replaced, lower the bucket and dozer blade to the ground.

3. Make sure the hydraulic system is not under pressure.

4. Remove pin (1), to disengage rod end (2), from lever (3).

5. Loosen jam nut (4), and remove rod end (2), from rod (5).

6. Loosen jam nut (6), and remove yoke (7), from rod (5).

7. Remove pin (8), and disengage yoke (7), from link (9).

8. Remove screw (10), and washers (11) and 12, disconnecting link (9), from ball tap (13).

9. If ball tap (13), requires replacement, remove screws (14), and washers (15), attaching ball tap (13), to bracket.

10. Disconnect the two hydraulic fittings from the ball tap (13), and remove ball tap.

11. Plug hydraulic lines.

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SECTION 10 - OPERATOR’S PLATFORM

Installation 1. If ball tap (13), was removed, attach ball tap (13), to bracket with screws (14), and washers (15).

2. Apply sealant to hydraulic fittings, then connect hydraulic fittings to ball tap (13).

3. Connect link (9), to ball tap (13), with screw (10), and washers (11) and (12).

4. Connect yoke (7), to link (9), and secure with pin (8).

5. Install jam nut (6), on rod (5).

6. Screw rod (5), into yoke (7), and tighten jam nut (6), against yoke (7).

7. Install jam nut (4), on rod (5).

8. Screw rod end (2), onto rod (5), and tighten jam nut (4), against rod end (2).

9. Attach rod end (2), to lever (3), with pin (1).

10. Attach lever (1), to panel under seat with brackets (2), and screws (3).

11. Check operation of lever. If lever does not fully cutoff hydraulic fluid, adjust rod length by readjusting position of yoke and rod end.

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SECTION 10 - OPERATOR’S PLATFORM

EC25 Removal 1. If ball tap is to be replaced, lower the bucket and dozer blade to the ground.

2. Make sure the hydraulic system is not under pressure.

3. Remove knob (1), from lever (2).

4. Remove three screws and crown washers (3), attaching housing (4).

5. Remove housing (4).

6. Open access door (5).

7. Place reversing switch (1), in the “B” position.

8. Remove four screws and crown washers (2), attaching housing (3).

NOTE: In some instances the floor mat may have to be taken out for clearance in removing the housing (3).

9. Remove housing (3), by sliding to the right so that lever (4), can side through the slot, and reversing switch (1), can slide through the circular opening.

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SECTION 10 - OPERATOR’S PLATFORM

10. Remove screws (1), and brackets (2), attaching lever (3), on the inside of the seat base. Brackets are accessible through access door.

11. Remove right lever (3).

12. Remove pin (1), attaching clevis (2), to lever (3).

13. Remove screws (4), nuts (5), and washers, (6), then remove lever (3).

14. Loosen jam nut (8), then remove clevis (2), from threaded rod (7).

15. Remove pin (9), attaching clevis (10), to link (11).

16. Remove jam nuts (8) and (12), from threaded rod (7).

17. Remove screw (13), washers (14) and (15), link (11), and washer (16), from ball tap (17).

18. If ball tap (17), requires replacement, remove screws (18), and washers (19), attaching ball tap (17), to bracket (20).

19. Disconnect the two hydraulic fittings from the ball tap (17), and remove ball tap.

20. Plug hydraulic lines.

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SECTION 10 - OPERATOR’S PLATFORM

Installation 1. If ball tap (17), was removed, attach ball tap (17), to bracket with screws (18), and washers (19).

2. Apply sealant to hydraulic fittings, then connect hydraulic fittings to ball tap (17).

3. Connect link (11), to ball tap (17), with screw (13), and washers (14), (15), and (16).

4. Connect clevis (10), to link (11), and secure with pin (9).

5. Install jam nut (12), on threaded rod (7).

6. Screw threaded rod (7), into clevis (10), and tighten jam nut (12), against clevis (10).

7. Install jam nut (8), on threaded rod (7).

8. Screw clevis (2), onto rod (7), and tighten jam nut (8), against clevis (2).

9. Install lever (3), into housing and attach with nuts (5), washers (6), and screws (4).

10. Attach clevis (2), to lever (3), with pin (1).

11. Attach lever (3), to panel under seat with brackets (2), and screws (1) (two places).

12. Check operation of lever. If lever does not fully cutoff hydraulic fluid, adjust rod length by readjusting position of clevises on threaded rod.

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SECTION 10 - OPERATOR’S PLATFORM

EC35 Removal 1. Remove knob (1), from lever (2).

2. Remove three screws and crown washers (3), attaching housing (4).

3. Remove housing (4).

4. Open access door (5).

5. Place reversing switch (1), in the “B” position.

6. Remove four screws and crown washers (2), attaching housing (3).

NOTE: In some instances the floor mat may have to be taken out for clearance in removing the housing (3).

7. Remove housing (3), by sliding to the right so that lever (4), can side through the slot, and reversing switch (1), can slide through the circular opening.

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SECTION 10 - OPERATOR’S PLATFORM

8. Remove screws (1), and brackets (2), attaching lever (3), on the inside of the seat base. Brackets are accessible through access door.

9. Remove right lever (3).

10. If ball tap (17), is to be replaced, lower the bucket and dozer blade to the ground.

11. Make sure the hydraulic system is not under pressure.

12. Remove pin (1), attaching clevis (2), to lever (3).

13. Remove screws (4), nuts (5), and washers (6), then remove lever (3).

14. Loosen jam nut (8), then remove clevis (2), from threaded rod (7).

15. Remove pin (9), attaching clevis (10), to link (11).

16. Remove jam nuts (8) and (12), from threaded rod (7).

17. Remove screw (13), washers (14) and (15), link (11), and washer (16), from ball tap (17).

18. If ball tap (17), requires replacement, remove screws (18), and washers (19), attaching ball tap (17), to bracket (20).

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SECTION 10 - OPERATOR’S PLATFORM

19. Disconnect the two hydraulic fittings from the ball tap (17), plug hoses and remove ball tap.

20. Remove pin (1), attaching clevis (2), to threaded rod (3).

21. Remove pin (4), attaching clevis (5), to threaded rod (3).

22. Remove clevis (5), and jam nuts (6), from rod (7).

23. Slide washer (8), pipe and spring (9), and washer (10), off threaded rod.

24. Remove nut (11), and washer (12), from threaded rod (7), and remove rod from bracket (13).

25. Remove clevis (2), from threaded rod (14).

26. Remove pin (16), from clevis (15), and remove clevis from lever (19).

27. Remove jam nut (17) and (18), from threaded rod (14).

Installation 1. Attach threaded rod (14), to clevis (15).

2. Attach clevis (2), to threaded rod (14).

3. Attach threaded rod (7), to bracket (13), with nut (11), and washer (12).

4. Slide washer (10), pipe and spring (9), onto threaded rod (7).

5. Slide washer (8), onto threaded rod (7), and put jam nuts (6), onto threaded rod (7).

6. Attached clevis (5), to threaded rod (7).

7. Attach clevis (5), to threaded rod (3), with pin (4).

8. Attach clevis (2), to threaded rod (3), with pin (1).

9. Place adjusting nuts (17) and (18), on cable (14), on each side of bracket.

10. Attach clevis (15), to lever (19), with pin (16).

10-45

SECTION 10 - OPERATOR’S PLATFORM

11. If ball tap (17), was removed, attach ball tap (17), to bracket with screws (18), and washers (19).

12. Apply sealant to hydraulic fittings, then connect hydraulic fittings to ball tap (17).

13. Connect link (11), to ball tap (17), with screw (13), and washers (14), (15), and (16).

14. Connect clevis (10), to link (11), and secure with pin (9).

15. Install jam nut (12), on threaded rod (7).

16. Screw threaded rod (7), into clevis (10), and tighten jam nut (12), against clevis (10).

17. Install jam nut (8), on threaded rod (7).

18. Screw clevis (2), onto rod (7), and tighten jam nut (8), against clevis (2).

19. Install lever (3), into housing and attach with nuts (5), washers (6), and screws (4).

20. Attach clevis (2), to lever (3), with pin (1).

21. Attach lever (3), to panel under seat with brackets (2), and screws (1) (two places).

22. If hydraulic reservoir was drained, refill reservoir.

23. Check operation of lever. If lever does not fully cutoff hydraulic fluid, adjust rod length by readjusting position of clevises on threaded rod.

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SECTION 10 - OPERATOR’S PLATFORM

EC45 Removal 1. Remove knob (1), from lever, (2).

2. Remove three screws and crown washers (3), attaching housing (4).

3. Remove housing (4).

4. Open access door (5).

5. Place reversing switch (1), in the “B” position.

6. Remove four screws and crown washers (2), attaching housing (3).

NOTE: In some instances the floor mat may have to be taken out for clearance in removing the housing (3).

7. Remove housing (3), by sliding to the right so that lever (4), can slide through the slot, and reversing switch (1), can slide through the circular opening.

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SECTION 10 - OPERATOR’S PLATFORM

8. Remove screws (1), and brackets (2), attaching lever (3), on the inside of the seat base. Brackets are accessible through access door.

9. Remove right lever (3).

10. If ball tap (17), is to be replaced, lower the bucket and dozer blade to the ground.

11. Make sure the hydraulic system is not under pressure.

12. Remove pin (1), attaching clevis (2), to lever (3).

13. Remove screws (4), nuts (5), and washers (6), then remove lever (3).

14. Loosen jam nut (8), then remove clevis (2), from threaded rod (7).

15. Remove pin (9), attaching clevis (10), to link (11).

16. Remove jam nuts (8) and 12, from threaded rod (7).

17. Remove screw (13), washers (14) and 15, link (11), and washer (16), from ball tap (17).

18. If ball tap (17), requires replacement, remove screws (18), and washers (19), attaching ball tap (17), to bracket (20).

19. Disconnect the two hydraulic fittings from the ball tap (17), plug hydraulic hoses, and remove ball tap.

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SECTION 10 - OPERATOR’S PLATFORM

Installation 1. If ball tap (17), was removed, attach ball tap (17), to bracket with screws (18), and washers (19).

2. Apply sealant to hydraulic fittings, then connect hydraulic fittings to ball tap (17).

3. Connect link (11), to ball tap (17), with screw (13), and washers (14), (15), and (16).

4. Connect clevis (10), to link (11), and secure with pin (9).

5. Install jam nut (12), on threaded rod (7).

6. Screw threaded rod (7), into clevis (10), and tighten jam nut (12), against clevis (10).

7. Install jam nut (8), on threaded rod (7).

8. Screw clevis (2), onto rod (7), and tighten jam nut (8), against clevis (2).

9. Install lever (3), into housing and attach with nuts (5), washers (6), and screws (4).

10. Attach clevis (2), to lever (3), with pin (1).

11. Attach lever (3), to panel under seat with brackets (2), and screws (1) (two places).

12. Check operation of lever. If lever does not fully cutoff hydraulic fluid, adjust rod length by readjusting position of clevises on threaded rod.

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SECTION 10 - OPERATOR’S PLATFORM

Remote Control The remote controls are hydraulic valves and are covered in Section 7, Hydraulic System of this manual.

Reversing Lever The reversing levers are hydraulic valves and are covered in Section 7, Hydraulic System of this manual.

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SECTION 10 - OPERATOR’S PLATFORM

Ar ticulation P edal Pedal The articulation pedal is located at the left side of the operator’s platform and is accessible by removing the front access panel.

EC15/EC25/EC35 Removal 1. Remove the front access panel below the pedal (1), to access mounting hardware (2), and cable (3).

2. Remove pin (1), and disengage yoke (2), from pedal (3).

3. Remove screws and washers (4), and remove pedal (3).

4. If bracket (6), or hinge (5), need to be replaced, remove screws (11), washers (12), nuts (9), and washer (10), then remove bracket (6), attached to hinge (5).

5. Separate bracket (6), from hinge (5), by removing screws (7), and washers (8).

6. Loosen nuts (13), and slide cable (14), out of bracket.

7. Loosen nuts (15), to free cable (14), from bracket (19).

8. Remove pin (16), from yoke (17), and disconnect yoke (17), from valve (18).

10-51

SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Slide cable (14), through front access and attach yoke (17), to valve (18), with pin (16).

2. Place nuts (15), on each side of bracket (19), and tighten nuts to bracket.

3. Place nuts (13), on each side of support bracket and tighten nuts.

4. If bracket (6), and hinge (5), were removed, install as described in steps 5 and 6.

5. Attach bracket (6), to hinge (5), with two screws (7), and washers (8).

6. Attach hinge (5), to machine with screws (11), washers (12), on top of hinge (5), and washers (10), and nuts (9), under floor.

7. Attach pedal (3), to bracket (6), with screws and washers (4).

8. Attach yoke (2), to pedal (3), with pin (1).

9. Install front access plate.

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SECTION 10 - OPERATOR’S PLATFORM

EC45 Removal 1. Remove the six screws (1), and take off left side panel (2), to gain access to articulation pedal (3).

2. Lower the bucket and dozer blade to the ground.

3. Make sure the hydraulic system is not under pressure.

4. Remove hydraulic fitting (1), from side of pedal assembly and plug hoses.

5. Remove hydraulic fittings (2), from bottom of pedal assembly and plug hoses.

6. Remove four screws and washers (3).

7. Note orientation of pedal then lift pedal out of machine.

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SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Set pedal into pedal opening on machine.

2. Attach pedal to machine with four screws and washers (3).

3. Apply sealant to hydraulic fittings (2), and attach hydraulic fittings to bottom of the pedal.

4. Apply sealant to hydraulic fittings (1), and attach hydraulic fittings to side of the pedal.

5. Install left access panel with the six screws.

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SECTION 10 - OPERATOR’S PLATFORM

Left Crawler Control Pedal EC15/EC25/EC35 The left crawler control pedal has a lever arm attached, which allows the pedal to be operated by the left foot or by the left hand.

Removal 1. Remove front access panel (1), by removing the eight screws (2), to access the left crawler pedal (3).

2. Remove nut (1), attaching angle joint (2), to pedal (3).

3. Remove nut (9), and washer (8), attaching pedal stud (4), to hinge (5).

4. If hinge (5), needs to be removed, remove screws (6), and washers (7).

5. If linkage to the control valve (10), needs to be removed, remove angle joint (2).

6. Unscrew threaded rod (11), from clevis (12).

7. Remove jam nuts (13) and (14), from threaded rod (11).

8. Remove pin (15), and remove clevis (12), from reversing lever (16).

9. Remove reversing lever (16), from links (17), by removing cotter pins (18), and clevis pins (19).

10. Remove links (17), from valve (10), by removing cotter pin (20), and clevis pin (21).

10-55

SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Attach links (17), to valve (10), with clevis pin (21), and cotter pin (20).

2. Attach reversing lever (16), to links (17), with clevis pins (19), and cotter pins (18).

3. Install jam nuts (13) and (14), on threaded rod (11).

4. Attach clevis (12), on threaded rod (11).

5. Attach clevis (12), to reversing lever (16), with pin (15).

6. Attach angle joint (2), to threaded rod (11).

7. If previously removed, attach hinge (5), with screws (6), and washers (7).

8. Attach left crawler pedal stud (4), to hinge (5), with washer (8), and nuts (9).

9. Attach angle joint (2), to pedal (3), with nut (1).

10. Adjust linkage by adjusting position of angle joint (2), and clevis (12).

11. When properly adjusted, lock angle joint (2), in place with jam nut (13), and lock clevis (12), in place with jam nut (14).

10-56

SECTION 10 - OPERATOR’S PLATFORM

EC45 Removal 1. Access to the hydraulic pedal is obtained by removing left side access panel (2).

2. Remove six screws (1), and remove access panel (2).

3. Lower the bucket and dozer blade to the ground.

4. Make sure the hydraulic system is not under pressure.

5. Remove lever (1), from pedal (2), by removing two screws (5), and washers (6).

6. Remove hydraulic fittings (7), from side of pedal (2), and plug hoses.

7. Remove hydraulic fittings (8), from bottom of pedal (2), and plug hoses.

8. Note the position of the pedal (2), then remove four screws (3), and washers (4), and remove pedal (2), from the machine.

10-57

SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Attach pedal (2), to machine with four screws (3), and washers (4).

2. Apply sealant to hydraulic fittings (8), then connect hydraulic fittings (8), to bottom of pedal (2).

3. Apply sealant to hydraulic fittings (7), then connect hydraulic fittings (7), to side of pedal (2).

4. Attach lever (1), to pedal (2), with two screws (5), and washers (6).

5. Attach left side access panel (2), to upper carriage with six screws (1).

10-58

SECTION 10 - OPERATOR’S PLATFORM

Right Crawler Control Pedal EC15/EC25/EC35 The right crawler control pedal has a lever arm attached that allows the pedal to be operated by the right foot or by the right hand.

Removal 1. Remove front access panel (1), by removing the eight screws (2), to access the right crawler pedal (3).

2. Remove nut (1), attaching angle joint (2), to pedal (3).

3. Remove nuts (9), and washer (8), attaching pedal stud (4), to hinge (5).

4. If hinge (5), needs to be removed, remove screws (6), and washers (7).

5. If linkage to the control valve (10), needs to be removed, remove angle joint (2), from threaded rod (11).

6. Unscrew threaded rod (11), from clevis (12).

7. Remove jam nuts (13) and 14, from threaded rod (11).

8. Remove pin (15), and remove clevis (12), from valve (10).

10-59

SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Install jam nuts (13) and (14), on threaded rod (11).

2. Attach clevis (12), on threaded rod (11).

3. Attach clevis (12), to valve (10), using pin (15).

4. Attach angle joint (2), to threaded rod (11).

5. If previously removed, attach hinge (5), with screws (6), and washers (7).

6. Attach left crawler pedal studs (4), to hinge (5), with washers (8), and nuts (9).

7. Attach angle joint (2), to pedal (3), with nut (1).

8. Adjust linkage by adjusting position of angle joint (2), and clevis (12).

9. When properly adjusted, lock angle joint (2), in place with jam nut (13), and lock clevis (12), in place with jam nut (14).

10. Attach front access panel (1), with eight screws (2).

10-60

SECTION 10 - OPERATOR’S PLATFORM

EC45 Removal Access to the hydraulic pedal is obtained by remove left side access panel (2).

1. Remove six screws (1), and remove access panel (2).

2. Lower the bucket and dozer blade to the ground.

3. Make sure the hydraulic system is not under pressure.

4. Remove lever (1), from pedal (2), by removing two screws (5), and washers (6).

5. Remove hydraulic fittings (7), from side of pedal (2), and plug hoses.

6. Remove hydraulic fittings (8), from bottom of pedal (2), and plug hoses.

7. Note the position of the pedal (2), then remove four screws (3), and washers (4), and remove pedal (2), from the machine.

10-61

SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Attach pedal (2), to machine with four screws (3), and washers (4).

2. Apply sealant to hydraulic fittings (8), then connect hydraulic fittings (8), to bottom of pedal (2).

3. Apply sealant to hydraulic fittings (7), then connect hydraulic fittings (7), to side of pedal (2).

4. Attach lever (1), to pedal (2), with two screws (5), and washers (6).

5. Attach left side access panel (2), to upper carriage with six screws (1).

10-62

SECTION 10 - OPERATOR’S PLATFORM

Optional Control Pedal EC15/EC25/EC35 Removal 1. Remove front access panel (1), by removing the eight screws (2), to access the optional control pedal (3).

2. Remove nut (1), attaching angle joint (2), to pedal (3).

3. Remove nut (9), and washer (8), attaching pedal stud (4), to hinge (5).

4. If hinge (5), needs to be removed, remove screws (6), and washers (7).

5. If linkage to the control valve (10), needs to be removed, remove angle joint (2), from threaded rod (11).

6. Unscrew threaded rod (11), from clevis (12).

7. Remove jam nuts (13) and 14, from threaded rod (11).

8. Remove pin (15), and clevis (12), from valve (10).

10-63

SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Install jam nuts (13) and (14), on threaded rod (11).

2. Attach clevis (12), to threaded rod (11).

3. Attach clevis (12), to valve (10), with pin (15).

4. Attach angle joint (2), to threaded rod (11).

5. If previously removed, attach hinge (5), with screws (6), and washers (7).

6. Attach optional control pedal stud (4), to hinge (5), with washer (8), and nuts (9).

7. Attach angle joint (2), to pedal (3), with nut (1).

8. Adjust linkage by adjusting position of angle joint (2), and clevis (12).

9. When properly adjusted, lock angle joint (2), in place with jam nut (13), and lock clevis (12), in place with jam nut (14).

10. Attach front access panel (1), with eight screws (2).

10-64

SECTION 10 - OPERATOR’S PLATFORM

EC45 Removal Access to the hydraulic pedal is obtained by remove left side access panel (2).

1. Remove six screws (1), and remove access panel (2).

2. Lower the bucket and dozer blade to the ground.

3. Make sure the hydraulic system is not under pressure.

4. Remove hydraulic fittings (4), from side of pedal (1), and plug hoses.

5. Remove hydraulic fittings (5), from bottom of pedal (1), and plug hoses.

6. Note the position of the pedal (1), then remove four screws (2), and washers (3), and remove pedal (1), from the machine.

10-65

SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Attach pedal (1), to machine with four screws (2), and washers (3).

2. Apply sealant to hydraulic fittings (5), then connect hydraulic fittings (5), to bottom of pedal (1).

3. Apply sealant to hydraulic fittings (4), then connect hydraulic fittings (4), to side of pedal (1).

4. Attach left side access panel (2), with six screws (1).

10-66

SECTION 10 - OPERATOR’S PLATFORM

Dozer Blade Control Lever EC15/EC25/EC35 Removal 1. Remove front access panel (1), by removing the eight screws (2), to access the dozer blade control lever (3).

2. Remove nut (1), attaching angle joint (2), to lever (3).

3. Remove screws (4), nuts (8), and washers (9), attaching lever (3), to hinge (5).

4. If hinge (5), needs to be removed, remove screws (6), and washers (7).

5. If linkage to the control valve (10), needs to be removed, remove angle joint (2), from threaded rod (11).

6. Unscrew threaded rod (11), from clevis (12).

7. Remove jam nuts (13) and (14), from threaded rod (11).

8. Remove pin (15), and clevis (12), from valve (10).

10-67

SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Install jam nuts (13) and (14), on threaded rod (11).

2. Attach clevis (12), to threaded rod (11).

3. Attach clevis (12), to valve (10), with pin (15).

4. Attach angle joint (2), to threaded rod (11).

5. If previously removed, attach hinge (5), with screws (6), and washers (7).

6. Attach dozer control lever (3), to hinge (5), with screw (4), washers (9), and nuts (8).

7. Attach angle joint (2), to pedal (3), with nut (1).

8. Adjust linkage by adjusting position of angle joint (2), and clevis (12).

9. When properly adjusted, lock angle joint (2), in place with jam nut (13), and lock clevis (12), in place with jam nut (14).

10. Install front access cover (1), and attach with eight screws (2).

10-68

SECTION 10 - OPERATOR’S PLATFORM

EC45 Removal 1. Remove six screws (1), and remove access panel (2).

2. Lower the bucket and dozer blade to the ground.

3. Make sure the hydraulic system is not under pressure.

4. Remove hydraulic fittings (4), from side of pedal (1), and plug hoses.

5. Note the position of the pedal (1), then remove four screws (2), and washers (3), and remove pedal (1), from the machine.

10-69

SECTION 10 - OPERATOR’S PLATFORM

Installation 1. Attach pedal (1), to machine with four screws (2), and washers (3).

2. Apply sealant to hydraulic fittings (4), then connect hydraulic fittings (4), to side of pedal (1).

3. Install side access cover and attach with eight screws.

10-70

SECTION 10 - OPERATOR’S PLATFORM

Upper Carr iage Loc k Bolt Carriage Lock EC15 The upper carriage lock bolt, locks the upper and lower carriage so that the upper carriage cannot be moved until the lock bolt is released to the upper position.

Removal 1. Slide lock bolt (1), out of bracket (2).

2. Pull up on lock bolt to remove lower end (3), from upper carriage.

Installation 1. Drop lower end (3), through tube in upper carriage.

2. Slide lock bolt (1), into slot in bracket (3).

10-71

SECTION 10 - OPERATOR’S PLATFORM

THIS P A GE INTENTIONALL Y LEFT BLANK PA INTENTIONALLY

10-72

EC15, EC25, EC35, EC45 CRAWLER EXCAVATOR SERVICE MANUAL CONTENTS SECTION 00 - GENERAL INFORMATION SECTION 6 - ELECTRICAL SYSTEM SECTION 7 - HYDRAULIC SYSTEM SECTION 10 - OPERATOR’S PLATFORM

SECTION 11 - TRACTION/UNDERCARRIAGE

©1999 NEW HOLLAND CONSTRUCTION

SECTION 11 - TRACTION/UNDERCARRIAGE

THIS PAGE INTENTIONALLY LEFT BLANK

11-2

SECTION 11 - TRACTION/UNDERCARRIAGE

SECTION 11 TRACTION/UNDERCARRIAGE Contents General ............................................................................................................................................. 11-6 Rules for Safety at Work................................................................................................................ 11-7 Personnel ................................................................................................................................... 11-7 Tools ........................................................................................................................................... 11-7 Securing the Working Equipment ............................................................................................... 11-7 Hydraulic and Lubricating System ............................................................................................. 11-8 Conversions or Modifications to the Machine ............................................................................ 11-8 Returning to Operation ............................................................................................................... 11-8 Removal and Installation ................................................................................................................... 11-9 Dozer Blade Cylinder .................................................................................................................... 11-9 EC15 .......................................................................................................................................... 11-9 Removal ................................................................................................................................. 11-9 Installation ............................................................................................................................. 11-10 EC25/EC35/EC45 .................................................................................................................... 11-11 Removal ............................................................................................................................... 11-11 Installation ............................................................................................................................. 11-12 Dozer Blade ................................................................................................................................. 11-13 EC15 ........................................................................................................................................ 11-13 Removal ............................................................................................................................... 11-13 Installation ............................................................................................................................. 11-13 EC25/EC35 .............................................................................................................................. 11-14 Removal ............................................................................................................................... 11-14 Installation ............................................................................................................................. 11-14 EC45 ........................................................................................................................................ 11-15 Removal ............................................................................................................................... 11-15 Installation ............................................................................................................................. 11-15 Rubber Track ............................................................................................................................... 11-16 EC15 ........................................................................................................................................ 11-16 Removal ............................................................................................................................... 11-16 Installation ............................................................................................................................. 11-17 EC25/EC35 .............................................................................................................................. 11-18 Removal ............................................................................................................................... 11-18 Installation ............................................................................................................................. 11-19

11-3

SECTION 11 - TRACTION/UNDERCARRIAGE

EC45 ........................................................................................................................................ 11-20 Removal ............................................................................................................................... 11-20 Installation ............................................................................................................................. 11-21 Steel Track ................................................................................................................................... 11-22 EC15 ........................................................................................................................................ 11-22 Removal ............................................................................................................................... 11-22 Installation ............................................................................................................................. 11-23 EC25/EC35 .............................................................................................................................. 11-24 Removal ............................................................................................................................... 11-24 Installation ............................................................................................................................. 11-25 EC45 ........................................................................................................................................ 11-26 Removal ............................................................................................................................... 11-26 Installation ............................................................................................................................. 11-27 Idler .............................................................................................................................................. 11-28 EC15/EC25/EC35 .................................................................................................................... 11-28 Removal ............................................................................................................................... 11-28 Installation ............................................................................................................................. 11-28 EC45 ........................................................................................................................................ 11-28 Removal ............................................................................................................................... 11-28 Installation ............................................................................................................................. 11-28 Lower Track Roller ....................................................................................................................... 11-29 EC15/EC25/EC35 .................................................................................................................... 11-29 Removal ............................................................................................................................... 11-29 Installation ............................................................................................................................. 11-29 EC45 ........................................................................................................................................ 11-29 Removal ............................................................................................................................... 11-29 Installation ............................................................................................................................. 11-29 Upper Track Rollers (EC45 Only) ................................................................................................ 11-30 Removal ................................................................................................................................... 11-30 Installation ................................................................................................................................ 11-30 Sprocket Gear ............................................................................................................................. 11-30 Removal ................................................................................................................................... 11-30 Installation ................................................................................................................................ 11-30 Travel Motor ................................................................................................................................. 11-31 EC15 ........................................................................................................................................ 11-31 Removal ............................................................................................................................... 11-31 Installation ............................................................................................................................. 11-32 EC25/EC35 .............................................................................................................................. 11-33 Removal ............................................................................................................................... 11-33 Installation ............................................................................................................................. 11-34

11-4

SECTION 11 - TRACTION/UNDERCARRIAGE

EC45 ........................................................................................................................................ 11-35 Removal ............................................................................................................................... 11-35 Installation ............................................................................................................................. 11-36 Disassembly and Assembly ........................................................................................................... 11-37 Lower Track Roller ....................................................................................................................... 11-37 EC15 ........................................................................................................................................ 11-37 Disassembly ......................................................................................................................... 11-37 Assembly .............................................................................................................................. 11-37 EC25/EC35 .............................................................................................................................. 11-38 Disassembly ......................................................................................................................... 11-38 Assembly .............................................................................................................................. 11-38 EC45 ........................................................................................................................................ 11-38 Upper Track Roller Assembly (EC45 Only) ................................................................................. 11-39 Disassembly ............................................................................................................................ 11-39 Assembly ................................................................................................................................. 11-39 Idler .............................................................................................................................................. 11-40 EC15 ........................................................................................................................................ 11-40 Disassembly ......................................................................................................................... 11-40 Assembly .............................................................................................................................. 11-40 EC25/EC35 .............................................................................................................................. 11-41 Disassembly ......................................................................................................................... 11-41 Assembly .............................................................................................................................. 11-41 Travel Motor ................................................................................................................................. 11-41

11-5

SECTION 11 - TRACTION/UNDERCARRIAGE

GENERAL This hydraulic excavator has been built in accordance with state-of-the-art standards and the recognized safety rules.

However, operating the machine if a fault is suspected or has occurred, or carrying out repair work unprofessionally, may endanger the lives of persons in contact with it, or damage the machine and other property.

The hydraulic excavator must be stopped immediately if any damage is suspected or occurs to ensure that the safety of the operator, other personnel at the place of use, or of other material property is not compromised.

All components are carefully coordinated. Trouble-free operation and a long service life can only be achieved with original spare parts.

11-6

SECTION 11 - TRACTION/UNDERCARRIAGE

Rules for Safety at Work

WARNING Personnel The machine must not be started by unauthorized personnel.

Observe the accident prevention regulations.

A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn.

For climbing on or off the machine, use the handrails provided for this purpose.

Always keep steps and platforms in a non-slip state.

Remove any oil, grease, earth, clay, snow, ice, and other foreign matter immediately.

The hydraulic excavator may be operated, serviced, or repaired only by specially trained and authorized personnel with the appropriate technical knowledge.

WARNING Securing the Working Equipment

If such knowledge is lacking, detailed instructions must be given by experienced personnel.

The personnel must have read and understood the operator’s manual and, in particular, the chapter “Safety Instructions”.

Only such persons may start up the machine during repair work in order to adjust the attachments.

Incorrect operation of the machine or the attachments may result in life-threatening situations.

During all work, always observe the start-up and shut-down procedures described in the operator’s manual.

Wear a safety helmet, safety footwear, and gloves.

Before carrying out repair work on the machine, the attachments must be secured against inadvertent and unauthorized starting, e.g.: by placing chocks under tracks and by resting the working equipment on the ground.

Rest the working equipment on the ground in such a way that no movements can be made when mechanical or hydraulic connections are detached.

Secure any equipment or component which is to be mounted or dismantled or whose position is to be changed, using hoists or appropriate slinging/supporting devices to prevent them from moving, slipping, or falling inadvertently.

Systems and units, e.g.: pipes, hoses, etc., must be properly depressurized before being opened.

Wear close fitting clothing when working on the machine.

Protective devices on moving machine parts may be opened or removed only when the drive unit is stationary and protected against inadvertent starting.

Loose or wide garments may catch on machine parts and result in injury.

Before returning to service, all protective devices must be refitted.

Tools

Before carrying out repair work, the machine and the equipment must be secured against inadvertent starting, e.g.: by placing chocks under the tracks and by resting the working equipment on the ground.

Tools such as hoists, slings, trestles, and other devices, must be in a reliable safe state.

Metal splinters may cause injury when attachment bolts are being driven in or out.

11-7

SECTION 11 - TRACTION/UNDERCARRIAGE

WARNING Hydraulic and Lubricating System Always observe the safety regulations applicable to the product when handling oils, greases, and other chemical substances.

Unused but open bores at pipelines and hose connections must be closed in a pressure-tight manner.

WARNING Conversions or Modifications to the Machine Unauthorized conversions or modifications of the hydraulic excavator are forbidden for reasons of safety.

The nominal pressure of pressure relief valves must not be modified.

Use collected hydraulic oil to refill the hydraulic system refill only through return-flow filters.

Dispose of waste oil in an environmentally safe manner.

Observe the correct working sequence when fitting or replacing components or equipment.

CAUTION Returning to Operation Prior to returning the machine for operation:

When the machine is at operating temperature, the consumables are at least at the same temperature. Precautions must therefore be taken to prevent burning or scalding.

-

Grease all lubricating points.

-

Check all oil levels and make the necessary corrections.

Be careful when handling acids, e.g., battery acid. Acid splashes may injure the eye, and the skin.

-

Carry out functional checks of all repaired components.

-

Check all functions of the excavator during a test run. Release the hydraulic excavator for operation only after all functions have been found to work perfectly.

Do not smoke when handling flammable liquids.

Be careful with open flames and unprotected light.

Not only fuel but also other consumables often have a low flash point and catch fire easily.

11-8

SECTION 11 - TRACTION/UNDERCARRIAGE

REMOVAL AND INSTALLATION WARNING SECURE ANY EQUIPMENT OR COMPONENT WHICH IS TO BE MOUNTED OR DISMANTLED OR WHOSE POSITION IS TO BE CHANGED, USING HOISTS OR APPROPRIATE SLINGING/SUPPORTING DEVICES TO PREVENT THEM FROM MOVING, SLIPPING, OR FALLING INADVERTENTLY. Dozer Blade Cylinder EC15 The dozer blade cylinder is located under the shield (1), and is attached between the dozer blade (2), and the undercarriage (3).

Removal 1. Start machine and lower bucket and dozer blade to the ground.

2. Turn off machine and remove key.

3. Remove cover (1), by removing two screws (2), and washers (3).

4. Disconnect two hydraulic fittings from cylinder (4), and plug hydraulic lines.

5. Remove nut (5), and screw (6), from pin (7).

6. Drive out pin (7), attaching cylinder (4), to dozer blade (8).

7. Remove nut (9), and screw (10), from pin (11).

8. Drive out pin (11), attaching cylinder (4), to undercarriage (12).

9. Remove dozer cylinder from machine.

10. Refer to Hydraulic System, Section 7 of this manual for disassembly of dozer cylinder.

11-9

SECTION 11 - TRACTION/UNDERCARRIAGE

Installation 1. Attach dozer cylinder (4), to undercarriage (12), with pin (11).

2. Secure pin (11), with screw (10), and nut (9).

3. Attach dozer cylinder (4), to dozer blade (8), with pin (7).

4. Secure pin (7), with screw (6), and nut (5).

5. Apply sealant on hydraulic fittings.

6. Attach hydraulic fittings to hydraulic cylinder (4).

7. Torque screws (6) and 10, to 159 lb-in. (18 Nm).

8. Attach cover (1), with screws (2), and washers (3).

9. Torque screws (2), to 46 lb-ft (63 Nm).

10 Start engine and operate dozer blade. Make sure there are no leaks at the hydraulic fittings.

11-10

SECTION 11 - TRACTION/UNDERCARRIAGE

EC25/EC35/EC45 The dozer blade cylinder (1), is attached between the dozer blade (2), and the undercarriage (3).

Removal 1. Start machine and lower bucket and dozer blade to the ground.

2. Turn off machine and remove key.

3. Disconnect two hydraulic fittings (3), from cylinder (4), and plug hydraulic lines.

4. Remove nuts (5), and screws (6), from pins (7).

5. Drive out pin (7), attaching cylinder (4), to dozer blade (1).

6. Drive out pin (7), attaching cylinder (4), to undercarriage (2).

7. Remove dozer cylinder from machine.

8. Refer to Hydraulic System, Section 7 of this manual for disassembly of dozer cylinder.

11-11

SECTION 11 - TRACTION/UNDERCARRIAGE

Installation 1. Attach dozer cylinder (4), to undercarriage (2), with pin (7).

2. Secure pin (7), with screw (6), and nut (5).

3. Attach dozer cylinder (4), to dozer blade (1), with pin (7).

4. Secure pin (7), with screw (6), and nut (5).

5. Apply sealant on hydraulic fittings (3).

6. Attach hydraulic fittings (3), to hydraulic cylinder (4).

7. Torque screws (6), to 159 lb-in. (18 Nm).

8. Start engine and operate dozer blade. Make sure there are no leaks at the hydraulic fittings.

11-12

SECTION 11 - TRACTION/UNDERCARRIAGE

Dozer Blade EC15 Removal 1. Start machine and lower bucket and dozer blade to the ground.

2. Turn off machine and remove key.

3. Remove nut (3), and screw (5), from pin (4).

4. Drive out pin (4), attaching cylinder (2), to dozer blade (1).

5. Remove nut (7), and screw (6), from pin (8).

6. Drive out pin (8), attaching dozer blade (1), to undercarriage (12).

7. Remove nut (10), and screw (9), from pin (11).

8. Drive out pin (11), attaching dozer blade (1), to undercarriage (12).

9. Remove dozer blade from machine.

Installation 1. Attach dozer blade (1), to undercarriage (12), with pins (8) and 11.

2. Secure pin (8), with screw (6), and nut (7).

3. Secure pin (11), with screw (9), and nut (10).

4. Attach dozer cylinder (2), to dozer blade (1), with pin (5).

5. Secure pin (5), with screw (4), and nut (3).

6. Torque screws (4), 6 and 9, to 159 lb-in. (18 Nm).

11-13

SECTION 11 - TRACTION/UNDERCARRIAGE

EC25/EC35 Removal 1. Start machine and lower bucket and dozer blade to the ground.

2. Turn off machine and remove key.

3. Remove nut (3), and screw (5), from pin (4).

4. Drive out pin (4), attaching cylinder (2), to dozer blade (1).

5. Remove nuts (7), and screws (6), from pins (8).

6. Drive out pin (8), attaching left side of dozer blade (1), to undercarriage (10), and remove washer (9).

7. Drive out pin (8), attaching right side of dozer blade (1), to undercarriage (10), and remove washer (9).

8. Remove dozer blade from machine.

Installation 1. Attach dozer blade (1), to left side of undercarriage (10), with pin (8), and washer (9).

2. Attach dozer blade (1), to right side of undercarriage (10), with pin (8), and washer (9).

3. Secure pins (8), with screws (6), and nuts (7).

4. Attach dozer cylinder (2), to dozer blade (1), with pin (4).

5. Secure pin (4), with screw (5), and nut (3).

6. Torque screws (5) and 6, to 159 lb-in. (18 Nm).

11-14

SECTION 11 - TRACTION/UNDERCARRIAGE

EC45 Removal 1. Start machine and lower bucket and dozer blade to the ground.

2. Turn off machine and remove key.

3. Remove nut (3), and screw (5), from pin (4).

4. Drive out pin (4), attaching cylinder (2), to dozer blade (1).

5. Remove nuts (7), and screws (6), from pins (8).

6. Drive out pin (8), attaching left side of dozer blade (1), to undercarriage (9).

7. Drive out pin (8), attaching right side of dozer blade (1), to undercarriage (9).

8. Remove dozer blade from machine.

Installation 1. Attach dozer blade (1), to left side of undercarriage (9), with pin (8).

2. Attach dozer blade (1), to right side of undercarriage (9), with pin (8).

3. Secure pins (8), with screws (6), and nuts (7).

4. Attach dozer cylinder (2), to dozer blade (1), with pin (4).

5. Secure pin (4), with screw (5), and nut (3).

6. Torque screws (5) and 6, to 159 lb-in. (18 Nm).

11-15

SECTION 11 - TRACTION/UNDERCARRIAGE

Rubber Track EC15 Removal 1. Swing the upper carriage by 90 degrees to clear the track.

2. Lift one side of the machine until the crawler is free.

3. Remove the two screws (2), attaching the cover (1), to the roller carrier (3).

4. Slowly loosen the valve (2), with the grease nipple (1). Let the grease drain out so that the idler can be moved, removing tension on the track.

5. Tighten valve.

6. Remove grease and dispose of grease according to regulations.

WARNING TRACK IS VERY HEAVY. BE SURE AREA IS CLEAR BEFORE REMOVING. 7. With the help of another person, remove track (2), from inside using a mounting bar (1). Using extreme care, let the track fall off slowly from the machine.

11-16

SECTION 11 - TRACTION/UNDERCARRIAGE

Installation 1. Install track around drive gear and idler gear.

2. Connect hand grease gun to grease nipple (2), via coupling and re-tension the crawler track. The sag of the crawler track between crawler roller and crawler track should be 0.6 to 0.79 inch (15-20 mm).

3. Move crawler track and check the crawler tension again.

NOTE: When a new track is installed, the tension should be checked 2-3 times the first day and readjust if necessary.

4. Attach cover (1), to roller carrier (3), with two screws (2).

11-17

SECTION 11 - TRACTION/UNDERCARRIAGE

EC25/EC35 Removal 1. Swing the upper carriage by 90 degrees to clear the track.

2. Lift one side of the machine until the crawler is free.

3. Remove the two screws (2), attaching the cover (1), to the roller carrier (3).

4. Slowly loosen the valve (2), with the grease nipple (1). Let the grease drain out so that the idler can be moved, removing tension on the track.

5. Tighten valve.

6. Remove grease and dispose of grease according to regulations.

WARNING TRACK IS VERY HEAVY. BE SURE AREA IS CLEAR BEFORE REMOVING. 7. With the help of another person, remove track (2), from inside using a mounting bar (1). Using extreme care, let the track fall off slowly from the machine.

11-18

SECTION 11 - TRACTION/UNDERCARRIAGE

Installation 1. Install track around drive gear and idler gear.

2. Connect hand grease gun to grease nipple (1), via coupling and re-tension the crawler track. The sag of the crawler track between crawler roller and crawler track should be 1.0 to 1.38 inch (25-35 mm).

3. Move crawler track and check the crawler tension again.

NOTE: When a new track is installed, the tension should be checked 2-3 times the first day and readjust if necessary.

4. Attach cover (1), to roller carrier (3), with two screws (2).

11-19

SECTION 11 - TRACTION/UNDERCARRIAGE

EC45 Removal 1. Slew the upper carriage by 90 degrees.

2. Lift one side of the machine until the crawler is free.

3. Remove the two screws (2), attaching the cover (1), to the roller carrier (3).

4. Slowly loosen the valve (2), with the grease nipple. Let the grease drain out so that the idler can be moved, removing tension on the track.

5. Tighten valve.

6. Remove grease and dispose of grease according to regulations.

WARNING TRACK IS VERY HEAVY. BE SURE AREA IS CLEAR BEFORE REMOVING. 7. With the help of another person, remove track (2), from inside using a mounting bar (1). Using extreme care, let the track fall off slowly from the machine.

11-20

SECTION 11 - TRACTION/UNDERCARRIAGE

Installation 1. Install track around drive gear and idler gear and rollers.

2. Connect hand grease gun to grease nipple on valve (2), via coupling and re-tension the crawler track. Correct tension is when indicator (1), is flush with the edge of the cylinder (3).

3. Move crawler track and check the crawler tension again.

NOTE: When a new track is installed, the tension should be checked 2-3 times the first day and readjust if necessary.

4. Attach cover (1), to roller carrier (3), with two screws (2).

11-21

SECTION 11 - TRACTION/UNDERCARRIAGE

Steel Track EC15 Removal 1. Swing the upper carriage by 90 degrees to clearn the track.

2. Lift one side of the machine until the crawler is free.

3. Remove the two screws (2), attaching the cover (1), to the roller carrier (3).

4. Slowly loosen the valve (2), with the grease nipple (1). Let the grease drain out so that the idler can be moved removing tension on the steel track.

5. Remove cotter pin (1), from pin (2).

6. Remove pin (2), to open the steel track (3).

7. Remove track from machine.

8. Tighten valve.

9. Remove grease and dispose of grease according to regulations.

11-22

SECTION 11 - TRACTION/UNDERCARRIAGE

Installation 1. Install track around drive gear at rollers and idler gear.

2. Attach the ends of the steel track (3), with the pin (2), and cotter pin (1).

3. Connect hand grease gun to grease nipple (1), via coupling and re-tension the crawler track. The sag of the crawler track between crawler roller and crawler track should be 1.0 to 1.38 inches (25-35 mm).

4. Move crawler track and check the crawler tension again.

NOTE: When a new track is installed, the tension should be checked 2-3 times the first day and readjust if necessary.

5. Attach cover (1), to roller carrier (3), with two screws (2).

11-23

SECTION 11 - TRACTION/UNDERCARRIAGE

EC25/EC35 Removal 1. Swing the upper carriage by 90 degrees to clear the track.

2. Lift one side of the machine until the crawler is free.

3. Remove the two screws (2), attaching the cover (1), to the roller carrier (3).

4. Slowly loosen the valve (2), with the grease nipple (1). Let the grease drain out so that the idler can be moved removing tension on the track.

5. Remove cotter pin (1), from pin (2).

6. Remove pin (2), to open the steel track (3).

7. Remove track from machine.

8. Tighten valve.

9. Remove grease and dispose of grease according to regulations.

11-24

SECTION 11 - TRACTION/UNDERCARRIAGE

Installation 1. Install track around drive gear rollers and idler gear.

2. Attach the ends of the steel track (3), with the pin (2), and cotter pin (1).

3. Connect hand grease gun to grease nipple (2), via coupling and re-tension the crawler track. The sag of the crawler track between crawler roller and crawler track should be 1.0 to 1.38 inches (25-35 mm).

4. Move crawler track and check the crawler tension again.

NOTE: When a new track is installed, the tension should be checked 2-3 times the first day and readjust if necessary.

5. Attach cover (1), to roller carrier (3), with two screws (2).

11-25

SECTION 11 - TRACTION/UNDERCARRIAGE

EC45 Removal 1. Swing the upper carriage by 90 degrees to clear the track.

2. Lift one side of the machine until the crawler is free.

3. Remove the two screws (2), attaching the cover (1), to the roller carrier (3).

4. Slowly loosen the valve (2), with the grease nipple. Let the grease drain out so that the idler can be moved removing tension on the track.

5. Remove track from machine.

6. Tighten valve (2).

7. Remove grease and dispose of grease according to environmental regulations.

11-26

SECTION 11 - TRACTION/UNDERCARRIAGE

Installation 1. Install track around drive gear and idler gear and rollers.

2. Connect hand grease gun to grease nipple on valve (2), via coupling and re-tension the crawler track. Correct tension is when indicator (1), is flush with the edge of the cylinder (3).

3. Move crawler track and check the crawler tension again.

NOTE: When a new track is installed, the tension should be checked 2-3 times the first day and readjust if necessary.

4. Attach cover (1), to roller carrier (3), with two screws (2).

11-27

SECTION 11 - TRACTION/UNDERCARRIAGE

Idler EC15/EC25/EC35 Removal 1. Remove track (1), from machine as previously described.

2. Slide idler assembly (2), out of channel (3), on machine. If idler (2), is to be disassembled, refer to the disassembly procedure in this section.

Installation 1. Carefully slide idler assembly (2), into channel (3).

2. Install track (1), as previously described.

EC45 Removal 1. Remove track (1), from machine as previously described.

2. Slide idler assembly (2), out of channel (3), on machine. If idler (2), is to be disassembled, refer to the disassembly procedure in this section.

Installation 1. Carefully slide idler assembly (2), into channel (3).

2. Install track (1), as previously described.

11-28

SECTION 11 - TRACTION/UNDERCARRIAGE

Lower Track Roller EC15/EC25/EC35 Three rollers are mounted on the bottom edge of the roller carrier on each side of the machine.

Removal 1. Remove the track as previously described.

2. Loosen the nuts and washers (1), on both the inside and outside of the roller carrier (2), and slide the roller assembly out of the “U” shaped slot.

Installation 1. Slide the assembled roller into the “U” shaped slot on the roller carrier (1), with the outer nut (1), and spring washer on the outside of the roller carrier (2), on both the inside and outside surfaces.

2. Secure the roller assembly with nuts (1).

3. Torque nuts (1), to 380 lb-ft (519 Nm).

EC45 Four rollers are mounted on the bottom edge of the roller carrier on each side of the machine.

Removal 1. Remove the track as previously described.

2. Remove the screw (1), and washers on both the inside and outside of the roller carrier (2), and slide the roller assembly out of the roller carrier.

Installation 1. Slide the roller into the roller carrier (2).

2. Apply Loctite to the screws (1), and attach with the screws (1), and washers on both the inside and outside surfaces of the roller carrier (2).

3. Torque screws (1), to 146 lb-ft (200 Nm).

11-29

SECTION 11 - TRACTION/UNDERCARRIAGE

Upper Track Rollers (EC45 Only) One upper track roller is mounted on the top edge of the roller carrier on each side of the machine.

Removal 1. Remove the track as previously described.

2. Loosen the nuts and washers (1), on both the inside and outside of the roller carrier (2), and slide the roller assembly out of the “U” shaped slot.

Installation 1. Slide the assembled roller into the “U” shaped slot on the roller carrier (1), with the outer nut (1), and spring washer on the outside of the roller carrier (2), on both the inside and outside surfaces.

2. Secure the roller assembly with nuts (1).

3. Torque nuts (1), to 358 lb-ft (485 Nm).

Sprocket Gear Removal 1. Remove track (1).

2. Remove bolts and washers (2), attaching sprocket gear (4), to travel motor.

3. Remove sprocket gear (3).

Installation 1. Align mounting holes in sprocket gear (3), with mounting holes in travel gear.

2. Apply Loctite on all bolts (2).

3. Attach sprocket gear (3), to travel motor with bolts and washers (2).

4. Torque bolts (2), to the following values EC15 49 lb-ft (67 Nm) EC25/EC35 73 lb-ft (100 Nm) EC45 73 lb-ft (100 Nm) 5. Install track.

11-30

SECTION 11 - TRACTION/UNDERCARRIAGE

Travel Motor EC15 Removal 1. Remove track.

2. Remove sprocket gear.

3. Remove bolts (1), and washers (2), attaching cover (3), to undercarriage (6).

CAUTION TRAVEL MOTOR IS HEAVY. SUPPORT TRAVEL MOTOR BEFORE REMOVING BOLTS. 4. Unscrew ventilation filter on hydraulic tank to remove pressure from tank.

5. Operate controls several times to remove any pressure in the hydraulic system.

6. Label and disconnect hydraulic lines from travel motor.

7. Plug hydraulic lines.

8. Remove bolts (4), and washers (5), attaching travel motor (7), to undercarriage (6).

9. Remove travel motor.

10. Check hydraulic oil for foreign particles (dirt, abrasion, etc.). If foreign particles are present, clean hydraulic system.

11-31

SECTION 11 - TRACTION/UNDERCARRIAGE

Installation 1. Align travel motor mounting holes (7), with holes in undercarriage (6).

2. Apply Loctite to bolts (4).

3. Attach travel motor (7), to undercarriage (6), with bolts (4), and washers (5).

4. Torque bolts (4), to 49 lb-ft (67 Nm).

5. Apply sealant to hydraulic line fittings.

6. Attach hydraulic lines to travel motor.

7. Attach cover (3), to undercarriage (6), with bolts (1), and washers (2).

8. Check hydraulic oil level and add oil if necessary.

9. Close ventilation filter on hydraulic oil tank.

11-32

SECTION 11 - TRACTION/UNDERCARRIAGE

EC25/EC35 Removal 1. Remove track.

2. Remove sprocket gear.

3. Remove screws (1), and washers (2), attaching cover (3), to undercarriage (4).

4. Remove cover (3).

5. Unscrew ventilation filter on hydraulic tank to remove pressure from tank.

6. Operate controls several times to remove any pressure in the hydraulic system.

7. Label and disconnect hydraulic lines from travel motor.

8. Plug hydraulic lines.

CAUTION TRAVEL MOTOR IS HEAVY. SUPPORT TRAVEL MOTOR BEFORE REMOVING BOLTS. 9. Remove bolts (1), attaching travel motor (2), to undercarriage (3).

10. Remove travel motor.

11. Check hydraulic oil for foreign particles (dirt, abrasion, etc.). If foreign particles are present, clean hydraulic system.

11-33

SECTION 11 - TRACTION/UNDERCARRIAGE

Installation 1. Align travel motor mounting holes (2), with holes in undercarriage (3).

2. Apply Loctite to bolts (1).

3. Attach travel motor (2), to undercarriage (3), with bolts (1).

4. Torque bolts (1) to 78 lb-ft (107 Nm).

5. Apply sealant to hydraulic line fittings.

6. Attach hydraulic lines to travel motor.

7. Attach cover (3), to undercarriage (4), with screws (1), and washers (2) 8. Check hydraulic oil level and add oil if necessary.

9. Shut ventilation filter on hydraulic oil tank.

11-34

SECTION 11 - TRACTION/UNDERCARRIAGE

EC45 Removal 1. Remove track.

2. Remove sprocket gear.

3. Remove screws (1), and washers (2), attaching cover (3), to undercarriage (4).

4. Remove cover (3).

5. Unscrew ventilation filter on hydraulic tank to remove pressure from tank.

6. Operate controls several times to remove any pressure in the hydraulic system.

7. Label and disconnect hydraulic lines from travel motor.

8. Plug hydraulic lines.

CAUTION TRAVEL MOTOR IS HEAVY. SUPPORT TRAVEL MOTOR BEFORE REMOVING BOLTS. 9. Remove bolts (1), attaching travel motor (2), to undercarriage (3).

10. Remove travel motor.

11. Check hydraulic oil for foreign particles (dirt, abrasion, etc.). If foreign particles are present, clean hydraulic system.

11-35

SECTION 11 - TRACTION/UNDERCARRIAGE

Installation 1. Align travel motor mounting holes (2), with holes in undercarriage (3).

2. Apply Loctite to bolts (1).

3. Attach travel motor (2), to undercarriage (3), with bolts (1).

4. Torque bolts (1), to 139 lb-ft (190 Nm).

5. Apply sealant to hydraulic line fittings.

6. Attach hydraulic lines to travel motor.

7. Attach cover (3), to undercarriage (4), with screws (1), and washers (2).

8. Check hydraulic oil level and add oil if necessary.

9. Close ventilation filter on hydraulic oil tank.

11-36

SECTION 11 - TRACTION/UNDERCARRIAGE

DISASSEMBLY AND ASSEMBLY Lower Track Roller EC15 Disassembly 1. Remove the lower track roller from the undercarriage as previously described.

2. Remove nuts (9), spring washers (8), and washers (7), (rubber track) or 7A, (steel track).

3. Remove snap rings (6), and seal rings (5).

4. Remove snap rings (4), and bearings (3).

5. Remove pin (2), from track roller (1).

Assembly 1. Install pin (2), in track roller (1).

2. Install bearings (3), and snap rings (4).

3. Install seal rings (5), and snap rings (6).

4. Install washers for rubber track (7) or steel track (7A), spring washers (8), and nuts (9).

5. Install lower roller assembly onto undercarriage as previously described.

11-37

SECTION 11 - TRACTION/UNDERCARRIAGE

EC25/EC35 Disassembly 1. Remove the lower track roller from the undercarriage as previously described.

2. Remove nuts (1), and washers (2).

3. For steel tracks, remove washers (10).

4. Remove snap rings (3), and covers (4).

5. Remove seal rings (5).

6. Remove snap rings (6), and bearings (7), 7. Remove shaft (8), from track roller (9).

Assembly 1. Install shaft (8), into track roller (9).

2. Install bearings (7), and snap rings (6).

3. Install seal rings (5).

4. Install covers (4), and snap rings (3).

5. For steel tracks, install washers (10).

6. Install washers (2), and nuts (1).

7. Install lower roller assembly onto undercarriage as previously described.

EC45 The lower track rollers are not serviceable.

Remove and replace as previously described.

11-38

SECTION 11 - TRACTION/UNDERCARRIAGE

Upper Track Roller Assembly (EC45 Only) Disassembly 1. Remove the upper track roller from the undercarriage as previously described.

2. Remove nuts (1), and washers (2).

3. Remove snap rings (3), and covers (4).

4. Remove seal rings (5).

5. Remove snap rings (6), and bearings (7), 6. Remove shaft (8), from track roller (9).

Assembly 1. Install shaft (8), in track roller (9).

2. Install bearings (7), and snap rings (6).

3. Install seal rings (5).

4. Install covers (4), and snap rings 3.

5. Install washers (2), and nuts (1).

6. Install upper track roller assembly onto undercarriage as previously described.

11-39

SECTION 11 - TRACTION/UNDERCARRIAGE

Idler EC15 Disassembly 1. Remove dowel pins (1), from guidance (2).

2. Remove dowel pin (1) from guide (2) and remove the guide (2) from the shaft (7).

3. Remove snap rings (3), and seals (4).

4. Remove snap rings (5), and bearings (6).

5. Remove shaft (7), from idler (8).

Assembly 1. Install shaft (7), in idler (8).

2. Install bearings (6), and snap rings (5).

3. Install seals (4), and snap rings (3).

4. Install guide (2), on shaft (7), and install the dowel pins (1).

11-40

SECTION 11 - TRACTION/UNDERCARRIAGE

EC25/EC35 Disassembly 1. Remove dowel pins (1), from guidance (2).

2. Remove guide (2), from shaft (7).

3. Remove seals (3).

4. Remove snap rings (4), and bearings (5).

5. Remove shaft (7), from idler (6).

Assembly 1. Install shaft (7), in idler (6).

2. Install bearings (5), and snap rings (4).

3. Install seals (3).

4. Install guides (2), on shaft (7), and attach with dowel pins (1).

Travel Motor Disassembly and assembly of the travel motor is described in Hydraulic System, Section 7 of this manual.

11-41

SECTION 11 - TRACTION/UNDERCARRIAGE

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11-42