service repair manual

1. Issued 01Sep 08
S5PW0027E01 EN-US
30SR
35SR
ACERA
TIER 4
COMPACT CRAWLER EXCAVATOR
SERVICE MANUAL

2. SERVICE MANUAL
30SR ACERA
35SR ACERA
COMPACT CRAWLER EXCAVATOR
TIER 4
Service Manual Number S5PW0027E01 EN-US
Issued 09-2008

3. CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer
Revision History
Issue Issue Date Applicable Machine Remarks
First Edition Issued 09-2008
30SR ACERA
35SR ACERA
COMPACT CRAWLER EXCAVATOR
Issued 09-2008
Book/Form Number 5-17060 EN-US
Copyright © 2008. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PW0027E01

4. IIssued 09-2008 Bur
30SR ACERA & 35SR ACERA SERVICE MANUAL
TABLE OF CONTENTS
SECTION 1
SAFETY AND GENERAL INFORMATION
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: 5-17080 EN-US
CHAPTER 1
GENERAL PRECAUTIONS FOR MAKING REPAIRS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: 5-17090 EN-US
CHAPTER 2
SPECIFICATIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: 5-17100 EN-US
CHAPTER 3
ATTACHMENT DIMENSIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: 5-17110 EN-US
SECTION 2
MAINTENANCE
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: 5-17120 EN-US
CHAPTER 1
TOOLS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: 5-17130 EN-US
CHAPTER 2
STANDARD MAINTENANCE TIME TABLE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: 5-17140 EN-US
CHAPTER 3
MAINTENANCE STANDARD AND TEST PROCEDURE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: 5-17150 EN-US
SECTION 3
SYSTEMS
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: 5-17160 EN-US
CHAPTER 1
HYDRAULIC SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: 5-17170 EN-US
CHAPTER 2
ELECTRICAL SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: 5-17180 EN-US
CHAPTER 3
COMPONENT SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: 5-17190 EN-US
SECTION 4
DISASSEMBLY AND ASSEMBLY
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: 5-17200 EN-US
CHAPTER 1
ATTACHMENTS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: 5-17210 EN-US
CHAPTER 2
UPPER STRUCTURE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: 5-17220 EN-US
5-17060 EN-US

5. 30SR ACERA
II Issued 09-2008 Bur 5-17060 EN-US
CHAPTER 3
TRAVEL SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Book/Form Number: 5-17230 EN-US
SECTION 5
TROUBLESHOOTING
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
Book/Form Number: 5-17240 EN-US
CHAPTER 1
TROUBLESHOOTING (HYDRAULIC SYSTEM)
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Book/Form Number: 5-17250 EN-US
CHAPTER 2
TROUBLESHOOTING (ELECTRICAL SYSTEM)
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Book/Form Number: 5-17260 EN-US
CHAPTER 3
TROUBLESHOOTING (ENGINE)
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Book/Form Number: 5-17270 EN-US
SECTION 6
ENGINE
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
Book/Form Number: 5-17280 EN-US
CHAPTER 1
ENGINE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Book/Form Number: 5-17290 EN-US

6. SAFETY
0-III5-17070 EN-US Issued 09-2008 Bur
GENERAL SAFETY INFORMATION
1. Most accidents, which occur during operation,
are due to neglect of precautionary measures
and safety rules. Sufficient care should be taken
to avoid these accidents. Erroneous operation,
lubrication or maintenance services are very
dangerous and may cause injury or death of
personnel. Therefore all precautionar y
measures, NOTES, DANGERS, WARNINGS
and CAUTIONS contained in the manual and on
the machine should be read and understood by
all personnel before starting any work with or on
the machine.
2. Operation, inspection, and maintenance should
be carefully carried out, and safety must be given
the first priority. Messages of safety are indicated
with marks. The safety information contained in
the manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
3. Messages of safety appear in the manual and on
the machine : All messages of safety are
identified by either word of DANGER, WARNING
and CAUTION.
DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury and is represented as follows:
WARNING- Indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury and is represented as
follows:
CAUTION- Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. It may also be used to
alert against possible damage to the machine
and its components and is represented as
follows:
4. It is very difficult to forecast every danger that
may occur during operation. However, safety can
be ensured by fully understanding proper
operating procedures for this machine according
to methods recommended by Manufacturer.
5. While operating the machine, be sure to perform
work with great care, so as not to damage the
machine, or allow accidents to occur.
6. Continue studying the manual until all Safety,
Operation and Maintenance procedures are
completely understood by all persons working
with the machine.
WARNING
Do not operate or perform any maintenance on this
machine until all instructions found in the
OPERATOR’S MANUAL and this MANUAL have been
thoroughly read and understood.
Improper operation or maintenance of this machine
may cause accidents and could result in serious
injury or death.
Always keep the manual in storage.
If it is missing or damaged, place an order with an
authorized our Distributor for a replacement.
If you have any questions, please consult an
authorized our Distributor.
DANGER
WARNING
CAUTION

7. 0-IV Issued 09-2008 Bur 5-17070 EN-US
SAFETY PRECAUTIONS
The serviceman or mechanic may be unfamiliar with
many of the systems on this machine. This makes it
important to use caution when performing service
work. A knowledge of the system and or components
is important before the removal or disassembly of
any component.
Because of the size of some of the machine compo-
nents, the serviceman or mechanic should check the
weights noted in this manual. Use proper lifting proce-
dures when removing any components. Weight of
components table is shown in the section ; SPECIFI-
CATIONS.
The following is a list of basic precautions that must
always be observed.
1. Read and understand all Warning plates and
decal on the machine before Operating,
Maintaining or Repairing this machine.
2. Always wear protective glasses and protective
shoes when working around machines. In
particular, wear protective glasses when using
hammers, punches or drifts on any part of the
machine or attachments. Use welders gloves,
hood/goggles, apron and the protective clothing
appropriate to the welding job being performed.
Do not wear loose fitting or torn clothing.
Remove all rings from fingers, loose jewelry,
confine long hair and loose clothing before
working on this machinery.
3. Disconnect the battery and hang a Do Not
Operate tag in the Operators Compartment.
Remove ignition keys.
4. If possible, make all repairs with the machine
parked on a firm level surface. Block the machine
so it does not roll while working on or under the
machine. Hang a Do Not Operate tag in the
Operators Compartment.
5. Do not work on any machine that is supported
only by lift, jacks or a hoist. Always use blocks or
jack stands, capable of supporting the machine,
before performing any disassembly.
6. Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
7. Lower the bucket, dozer, or other attachments to
the ground before performing any work on the
machine. If this cannot be done, make sure the
bucket, dozer, ripper or other attachment is
blocked correctly to prevent it from dropping
unexpectedly.
8. Use steps and grab handles when mounting or
dismounting a machine. Clean any mud or debris
from steps, walkways or work platforms before
using. Always face to the machine when using
steps, ladders and walkways. When it is not
possible to use the designed access system,
provide ladders, scaffolds, or work platforms to
perform safe repair operations.
9. To avoid back injury, use a hoist when lifting
components which weigh 20kg (45lbs) or more.
Make sure all chains, hooks, slings, etc., are in
good condition and are the correct capacity. Be
sure hooks are positioned correctly. Lifting eyes
are not to be side loaded during a lifting
operation.
10. To avoid burns, be alert for hot parts on
machines which have just been stopped and hot
fluids in lines, tubes and compartments.
11. Be careful when removing cover plates.
Gradually back off the last two capscrews or nuts
located at opposite ends of the cover or device
and carefully pry cover loose to relieve any
spring or other pressure, before removing the
last two capscrews or nuts completely.
12. Be careful when removing filler caps, breathers
and plugs on the machine. Hold a rag over the
cap or plug to prevent being sprayed or splashed
by liquids under pressure. The danger is even
greater if the machine has just been stopped
because fluids can be hot.
WARNING
The proper and safe lubrication and maintenance for
this machine, recommended by Manufacturer, are
outlined in the OPERATOR’S MANUAL for the
machine.
Improper performance of lubrication or maintenance
procedures are dangerous and could result in injury
or death. Read and understand the MANUAL before
performing any lubrication or maintenance.
WARNING
Do not operate this machine unless you have read
and understand the instructions in the OPERATOR’S
MANUAL. Improper machine operation is dangerous
and could result in injury or death.

8. SAFETY
0-V5-17070 EN-US Issued 09-2008 Bur
13. Always use the proper tools that are in good
condition and that are suited for the job at hand.
Be sure you understand how to use them before
performing any service work.
14. Install all fasteners with the same part number.
Do not use a lesser quality fastener if
replacements are necessary.
15. Repairs which require welding should be
performed only with the benefit of the appropriate
reference information and by personnel
adequately trained and knowledgeable in
welding procedures. Determine type of metal
being welded and select correct welding
procedure and electrodes, rods or wire to provide
a weld metal strength equivalent at least to that
of the parent metal. Make sure to disconnect
battery before any welding procedures are
attempted.
16. Do not damage wiring during removal
operations. Reinstall the wiring so it is not
damaged nor will be damaged in operation of the
machine by contacting sharp corners, or by
rubbing against some object or hot surface. Do
not connect wiring to a line containing fluid.
17. Be sure all protective devices including guards
and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution and replace the guard or
shield after repair is completed.
18. The maintenance and repair work while holding
the bucket raised is dangerous due to the
possibility of a falling attachment. Don’t fail to
lower the attachment and place the bucket to the
ground before starting the work.
19. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks
with your hands. Very small (pinhole) leaks can
result in a high velocity oil stream that will be
invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use card-
board or paper to locate pinhole leaks.
20. Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat,
vibration or rubbing against other parts during
operation. Shields that protect against oil spray
onto hot exhaust components in event of a line,
tube or seal failure must be installed correctly.
21. Do not operate a machine if any rotating part is
damaged or contacts any other part during
operation. Any high speed rotating component
that has been damaged or altered should be
checked for balance before reusing.
22. Be careful when servicing or separating the
tracks (crawlers). Chips can fly when removing
or installing a track (crawlers) pin. Wear safety
glasses and long sleeve protective clothing.
Tracks (crawlers) can unroll very quickly when
separated. Keep away from front and rear of
machine. The machine can move unexpectedly
when both tracks (crawlers) are disengaged from
the sprockets. Block the machine to prevent it
from moving.

9. 0-VI Issued 09-2008 Bur 5-17070 EN-US
NOTE:
This Manual is prepared as a technical material in
which the information necessary for the maintenance
and repairing services of our hydraulic excavators
are collected, and is categorized into 6 Sections,
Safety and General Information, Maintenance,
System, Disassembly, Troubleshooting, and Engine.
The Section Safety and General information
describes the specifications for entire machine
and material, which are instructive for
replacement and repairing of attachments.
The Section Maintenance describes the material,
which is helpful for maintenance service and
adjustments for entire machine.
The Section System describes the operating
system like hydraulic system, electric system,
components, and so on.
The Section Disassembly describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
The Section Troubleshooting describes how to
find the fault equipment.
The Section Engine describes the engines
making use of the "Service Manual" provided by
the suppliers.
This Manual may be properly revised due to the
improvement of products, modification of
specifications, etc. And there are cases where the
system on actual machine and a part of the contents
of this manual may differ due to the variations of
specification by countries. For the section in which
the description is hardly understood, contact our
distributor.
The number is assigned to every part handled in this
Manual on account of the description, but the parts,
which cannot be supplied as service parts are
contained. Therefore, the order must be placed with
respective formal number with due confirmation on
the Parts Manual for applicable machine.

10. CHAPTER 2 - UPPER STRUCTURE
2-55-17220 EN-US Issued 09-2008 Bur
SECTION 4 - DISASSEMBLY AND ASSEMBLY
UPPER STRUCTURE
PREFACE
1. This manual describes all the procedures from removing to installing, arranging them by item.
2. This Manual consists of first part; Removing and Installing, and second part; Disassembling and Assembling.
3. The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
4. The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
5. Please be aware that procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
Specification of Tightening Torque
Tightening torque is indicated as follows, for example:
Tightening torque: 100 Nm (83 pound-ft)
NOTE: Tolerance is ± 10% unless otherwise noted. Refer to chapter on "Tools" for standard tightening torque.

11. 2-6 Issued 09-2008 Bur 5-17220 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
REMOVING AND INSTALLING
CANOPY / CAB
Canopy Removal
(1)Remove the floor mats (5) and (8).
(2)Removing handrail (A3)
Loosen the sems-bolt M10× 40 (A9) and M16× 100
(A6) to remove the handrail (A3).
(3)Removing canopy assembly
1. Disconnect the light harness (B1) that runs inside
the support (A2) and is connected to the main
harness with a connector.
2. Loosen one capscrew M16× 65 (A4) and eight
capscrews M12× 55 (A7) to remove the canopy.
Canopy weight : 85 kg (187 lbs)
GRAPHIC_ID Figure 1
8 5
(4)Install the canopy in reverse order of the removal.
Tighten the capscrews at the torque specified
below :
M10 : Tightening torque: 46 Nm (34 pound-ft)
M12 : Tightening torque: 79 Nm (59 pound-ft)
M16 : Tightening torque: 191 Nm (141 pound-ft)
GRAPHIC_ID Figure 2
B2
A7
B1
HARNESS
OUTLETA2
A8
A4
A3
A5
Cab Removal (Option)
Cab removal preparation
(1) Remove the floor mats (6) and (7).
(2) Removing cab harness connector
1) Respectively disconnect 6P connectors of cab
harness and cab connecting harness, 2P
connector of washer motor, 3P connector of
radio (optional) and so on. (See ELECTRICAL
SYSTEM)
GRAPHIC_ID Figure 3

12. 2-75-17220 EN-US Issued 09-2008 Bur
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
Cab removal
(1)Remove the fuel filler cap (A2) and rubber cover
(20).
(2)Removing cover installed on rear of cab
Loosen three sems-bolt M6× 25 (12) for installing
the cover (13).
(3)Removing cab mounting screws
Loosen six capscrews for mounting the cab.
Two capscrews (1) M16× 100
One capscrew (2) M16× 50
Two capscrews (3) M12× 50
One capscrew (24) M12× 40
An extension tool about 1 m (3ft-3.4in) long is
required for removing the capscrew item 1 (with
mark *).
GRAPHIC_ID Figure 4
1213
B
VIEW B
12
3
A2
20
(4)Lifting cab
1. Loosen the sems-bolt M10× 20 (C6) to remove
the seat belt assembly (C2) in advance to
prevent it from interfering with the cab during
lifting.
1. Put slings through the lifting eyes on the cab top
and lift up.
Cab weight : 250 kg (550 lbs)
GRAPHIC_ID Figure 5
(5)Installing cab
Install the cab in reverse order of the removal.
In the fastening position of the capscrew (24), it
is necessary to adjust the clearance with shims
as shown in Fig. 5.
Tighten screws to the torque specified below.
M6 : Tightening torque: 4.4 Nm (3.3 pound-ft)
M10 : Tightening torque: 46 Nm (34 pound-ft)
M12 : Tightening torque: 79 Nm (59 pound-ft)
M16 : Tightening torque: 191 Nm (141 pound-ft)
GRAPHIC_ID Figure 6
A
C2
C6

13. 2-8 Issued 09-2008 Bur 5-17220 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
Cab Door Adjustment
(1)When the door is opened and the door is fixed in the place, proper rebound of the rubber stopper in three places
shown in right figure is needed.
For this rebound adjust the pushing depth of rubber from 0.6 to 1mm (0.02 to 0.04in) (In terms of screw rotation,
the depth is equivalent from half turn to three-fourths turn).
After this adjustment, the force for door release becomes about 98 to 118 N (22 to 27 lb.).
Tightening torque of rubber stopper lock nut: 35 to 42 Nm (26 to 31 pound-ft).
pushing
depth
SECTION C-C
RUBBER STOPPER 3 PLACES

14. 2-95-17220 EN-US Issued 09-2008 Bur
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
Guard (Cover)
Removal
Fig. 7 shows the method for removing the cover of
the canopy.
GRAPHIC_ID Figure 7
4
1
5
3
2
A
B
C
D
E
G
(1)Removing hood assembly (2)
Unlock and open the hood assembly (2). Loosen
two capscrews M12× 30 (37) of the hinge section
(2-8) to remove the hood (2).
GRAPHIC_ID Figure 8
37
2
2-8

15. 2-10 Issued 09-2008 Bur 5-17220 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
(2)Removing cover assembly (3)
Loosen two M8× 20 sems-bolts (21) and one
M8× 25 sems-bolt to remove the cover assembly
(3).
GRAPHIC_ID Figure 9
21
3
21
45
(3)Removing cover assembly (4)
Loosen three M10× 30 sems-bolts (19) to remove
the cover assembly (4).
(4)Removing cover assembly (5)
Loosen four M10× 30 sems-bolts (19) to remove the
cover assembly (5).
GRAPHIC_ID Figure 10
19
19
19
5
19
19
19
194
(5)Removing cover assembly (1)
1. Unlock the cover (1-8) to open the cover
assembly (1).
2. Loosen two M12 nuts (31) to remove the cover
assembly (1).
GRAPHIC_ID Figure 11
31
1-8
1

16. 2-115-17220 EN-US Issued 09-2008 Bur
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
Installation
Install the above assemblies in reverse order of the removal.
Tighten the capscrews to the torque specified
below :
M8 : Tightening torque: 24 Nm (18 pound-ft)
M10 : Tightening torque: 46 Nm (34 pound-ft)
(Exclude item 19 with * mark)
M12 : Tightening torque: 79 Nm (59 pound-ft)
M16 : Tightening torque: 191 Nm (141 pound-ft)
ltem 19 with * mark : Tightening torque:
19.6~24.5 Nm (15~18pound-ft)

17. 2-12 Issued 09-2008 Bur 5-17220 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
FLOOR PLATE ASSEMBLY
Remove floor plate together with the travel pilot valve assembly and the swing pedal in one piece.
Floor Plate Removal Preparation
(1)Remove the floor mats (5) and (8).
(2)Remove the canopy or cab.
(3)Remove the covers (2) and (4) as well as the
plates (3).
(4)Remove the cover assembly (5) of the deck under
the floor.
(5)Disconnect electrical wiring for travel 2-speed
selector switch from the connector portion.
If this machine was equipped with the travel alarm,
disconnect the connectors of electric wirings of
four pressure switches on travel pilot valve.
GRAPHIC_ID Figure 12
WARNING
In advance, disconnect the negative terminal of the
battery to prevent danger of short circuit, etc.
The figure is for the standard canopy.
4
3
1
2
8 5
(6)Removing travel pilot piping (prior to this work,
release the pressure in the piping)
Disconnect hoses of the travel pilot valve (A10) at
the valve side position marked with * and then
plug their openings.
Attach a tag recording the valve connecting port
to each of the disconnected hoses. For
installation, tighten the hose fittings at the
following torque :
NOTE: Take care of the tightening torque as the pilot
valve is made of aluminum. GRAPHIC_ID Figure 13
Tightening Torque
Nm (pound-ft)
Thread size
(PF)
Spanner
used
(mm)
O-ring type
fitting
30° flare type
fitting
1/4 19 26.5 (20) 29.4 (22)
A10
TANK
T
1
2
3
4
P
S/V
A2
C/V
Pb7
C/V
Pa7
C/V
Pa6
C/V
Pb6
(7)Removing cable of swing pedal
1. Loosen four M8× 20 sems-bolts (B11) to pull out
the support (B1) upward.
2. Pull out the pin (B6) and loosen the adjusting nut
to disconnect the control cable (B4).
GRAPHIC_ID Figure 14
NUT
B1
123
B4
B11
B6

18. 2-135-17220 EN-US Issued 09-2008 Bur
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
(8)Removing N&B solenoid piping (prior to this work,
release the pressure in the piping)
Disconnect hoses of the N&B solenoid valve (B5)
at the valve side position marked with * and then
plug their openings.
Attach a tag recording the valve connecting port
to each of the disconnected hoses. For
installation, tighten the hose fittings to the
following torque :
NOTE: Take care of the tightening torque as the pilot
valve is made of aluminum.
GRAPHIC_ID Figure 15
Tightening Torque
Nm (pound-ft)
Thread size
(PF)
Spanner
used
(mm)
O-ring type
fitting
30° flare type
fitting
1/4 19 36.3 (26.8) 29.4 (22)
B5
Pb4
P
P
T
A
B
T
Pa4
C/V
C/V
S/V
S/V
Removal
(1)Remove the M8× 20 sems-bolt (6).
(2)Remove the floor plate assembly (1).
GRAPHIC_ID Figure 16
6
1
Th fi i f th t d d
Assembly
(1)Assemble the floor plate in reverse order of the
disassembly.
Sems-bolt (6) M8 :
Tightening torque : 23.5 Nm (17 pound-ft)

19. 2-14 Issued 09-2008 Bur 5-17220 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
BATTERY
Removal Preparation
(1)Remove the floor mats (5) and (8).
(2)Remove the cover (4).
(3)Remove the cover assembly (5) of the lower left
side
GRAPHIC_ID Figure 17
4
8 5
Removal
(1) Disconnect the negative side terminal of the
cable.
(2) Then, disconnect the positive side terminal of the
cable
(3)Loosen the M8 nut (7) to remove the plate (5) and
the rod (4).
(4)Take out the battery (1) holding the straps
attached to it. GRAPHIC_ID Figure 18
WARNING
Follow the removal procedure of battery cable. Firstly
disconnect the grounding side cable. Connect the
grounding side finally. Failure to do so may result in
dangerous situation due to spark.
1
62
4
4
7
7
5
Installation
Install the battery in reverse order of the removal.
Nut (7) M8 :
Tightening torque : 3.5 Nm (2.6 pound-ft)

20. 2-155-17220 EN-US Issued 09-2008 Bur
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
COUNTERWEIGHT
Removal Preparation
1)Remove the cover assemblies (1), (3), (4) and (5)
as well as the hood assembly (2).
(2) Lifting tools preparation
Lifting jigs for counterweight (see Tool list)
Two M20× 35 screws (A)
Wire rope (Nylon sling)
GRAPHIC_ID Figure 19
A
Lifting jig
for counterweight
SLING
SCREW(A)
Removal
(1)Remove the plate (9) and attach the lifting jigs for
counterweight.
(2)Put a rope through the lifting lugs and temporarily
lift up the counterweight so that the rope is not
slack.
Counterweight weight :
370 kg (820 lbs) for 30SR Acera
665 kg (1,470 lbs) for 35SR Acera
(3)Loosen one M20× 90 capscrew (2) and two
M20× 65 capscrews (3).
(4) Remove the shims (5), (6) and (7).
(5) Remove counterweight (1).
GRAPHIC_ID Figure 20
3
4
2
3
4
9
9
1
5
6
7
5
6
7
5
6
7
Installation
(1)Install the counterweight in reverse order of the
removal.
(2)Reinstall the shims (5), (6), and (7).
(3)Lifting counterweight
Make sure that all the three fixing bolts can be
manually screwed.
(4)Apply Loctite #262 on the capscrews (2) and (3)
and tighten them together with the washer (4).
Tightening torque : 373 Nm (275 pound-ft)
(5)Remove lifting jigs.
GRAPHIC_ID Figure 21

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22. 2-16 Issued 09-2008 Bur 5-17220 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
PUMP
Removal Preparation
(1)Remove the cover assembly (3) and (5).
(2)Remove the counterweight.
(3)Depressurize the hydraulic oil tank and drain the
hydraulic oil.
Spread a vinyl sheet under the pump to prevent
contamination due to oil leakage.
(4)Loosen clip (B38) to remove the filler neck (B1) of
the fuel supply port to improve workability.
Two sems–bolts M8× 20 (B39)
Tightening torque : 23.5 Nm (17 pound-ft)
GRAPHIC_ID Figure 22
*
*!'
*!
Removal
(1)Disconnecting hoses and fittings connected to the
pump
Attach a tag to each hose for identification.
1. Loosen four M12× 35 capscrews (19) to remove
the tube (14).
2. Remove the pilot delivery hose (B23).
3. Remove the main pump delivery hoses (8), (9)
and (10).
(2)Loosen two M12× 30 capscrews (C4) to remove
the pump (C8).
Pump weight : 28 kg (62 lbs)
GRAPHIC_ID Figure 23
C/V
P1
C/V
P2
C/V
P3
A1
A2
A3
14
19
12
10
8
9
25
25
C4C8
Z
A4B23
S/V
P1

23. CHAPTER 2 - UPPER STRUCTURE
2-175-17220 EN-US Issued 09-2008 Bur
SECTION 4 - DISASSEMBLY AND ASSEMBLY
Installation
Install the pump in reverse order of the removal according to the tightening torque and sealant instructions.
(1)Apply grease to the spline part of the pump input
shaft.
Grease : Shell Retinax AM Grease or equivalent
(Molybdenum disulfide extreme pressure
multipurpose grease)
(2)Insert the pump spline part to the coupling.
(3)Fix the pump by the capscrew (C4).
(4)Install the main pump delivery hoses (8), (9), and
(10), and the pilot delivery hose (B23) (See Fig.
23).
(5)Tighten the capscrew (19) to install the suction
tube (14).
(6)When the suction hose (12) is removed, apply
sealant on the inserted portion of the hose and fix
the tube with the clip (25).
Tightening torque: 5.4 Nm (4.0 pound-ft)
(7)Supply the tank with hydraulic oil (approx. 38 liters
(10 gal)).
(8)Loosen the air bleed valve of the pump to release
air from the casing, and fill it with hydraulic oil (See
Fig. 24).
(9)Reinstall each component removed in the above
removal preparation.
(10)After starting the engine, release air (See
Hydraulic Oil Tank Assembly in this chapter.
GRAPHIC_ID Figure 24
Tightening Torque
Nm (pound-ft)
Thread size
(PF)
Spanner
used
(mm)
O-ring type
fitting
30° flare type
fitting
3/8 22 73.5 (54) 49.0 (36)
1/2 27 108 (80) 78.5 (58)

24. 2-18 Issued 09-2008 Bur 5-17220 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
Removal Preparation
(1)Unlock and open the right upper cover (1).
(2)Remove the right lower cover (4).
Spread a vinyl sheet under the control valve to prevent contamination due to oil leakage.
(3)Release the residual pressure in the circuit and the pressure in the hydraulic oil tank.
Removal
(1) Disconnecting hoses
Disconnect all the hoses connecting to the control valve, and attach blind plugs and tags recording the
installation place.
Remove the return hose to the hydraulic oil tank to improve workability.
GRAPHIC_1D Figure 25
MAIN HYDRAULIC HOSE DISCONNECTION
S/J
E
S/J
F
S/J
B
S/J
A
S/J
C
S/M
B
S/M
A
ARM
(R)
ARM
(H)
BUCKET
(H)
BUCKET
(R)
BOOM
(R)
BOOM
(H)
B1B2
B3
B7
B8
B9
B10
A10
A7
A5
A3
A2
A1
A6
SW/CYL
(H)
A17
SEL/V
B8
A10
A10
A18
NB
(R)
B7
A9
A10A15
A12
A5A8 A15
A7
A7
S/J
DB5B6
SW/CYL
(R)
A6
A14
H/P : Hydraulic pump
S/J : Swivel joint
S/M : Slewing motor
8
H/P
A3
H/P
A2
H/P
P1
P2
P3
9
10
A1
21
23
24
COOLER OIL
(UPPER)
S/M
MHYDRAULIC TANK
T2
Dr1
T1
B4
A4