service repair workshop manual

1. Issued 01Jul 08
Revised 01Nov 08
Replaces 87728507 NA
S5YT0006E03 EN-US
70SR
ACERA
TIER 4
CRAWLER EXCAVATOR
SERVICE MANUAL

2. SERVICE MANUAL
70SR ACERA
CRAWLER EXCAVATOR
TIER 4
Service Manual Number S5YT0006E03 EN-US
Issued 11-2008

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 07-2008 70SR ACERA CRAWLER EXCAVATOR
Second Edition 11-2008 70SR ACERA CRAWLER EXCAVATOR
Issued 11-2008
Book/Form Number 5-14171 EN-US
Copyright © 2008. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5YT0006E03

4. IIssued 11-2008 Bur
70SR ACERA SERVICE MANUAL
TABLE OF CONTENTS
SECTION 1
SAFETY AND GENERAL INFORMATION
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: 5-14190 EN-US
CHAPTER 1
GENERAL PRECAUTIONS FOR MAKING REPAIRS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: 5-14200 EN-US
CHAPTER 2
SPECIFICATIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: 5-14211 EN-US
CHAPTER 3
ATTACHMENT DIMENSIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: 5-14220 EN-US
SECTION 2
MAINTENANCE
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: 5-14230 EN-US
CHAPTER 1
TOOLS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: 5-14241 EN-US
CHAPTER 2
STANDARD MAINTENANCE TIME TABLE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: 5-14250 EN-US
CHAPTER 3
MAINTENANCE STANDARD AND TEST PROCEDURE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: 5-14260 EN-US
SECTION 3
SYSTEMS
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: 5-14271 EN-US
CHAPTER 1
MECHATRO CONTROL SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: 5-14281 EN-US
CHAPTER 2
HYDRAULIC SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: 5-14291 EN-US
CHAPTER 3
ELECTRIC SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: 5-14300 EN-US
CHAPTER 4
COMPONENTS SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Book/Form Number: 5-14310 EN-US
CHAPTER 5
AIR CONDITIONING SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Book/Form Number: 5-14320 EN-US
CHAPTER 6
CAB INTERFERENCE PREVENTION SYSTEM (OPTION FOR OFFSET SPECIFICATION)
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Book/Form Number: 5-17840 EN-US
5-14171 EN-US

5. 70SR ACERA
II Issued 11-2008 Bur 5-14171 EN-US
SECTION 4
DISASSEMBLY AND ASSEMBLY
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
Book/Form Number: 5-14330 EN-US
CHAPTER 1
ATTACHMENTS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Book/Form Number: 5-14340 EN-US
CHAPTER 2
UPPER STRUCTURE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Book/Form Number: 5-14350 EN-US
CHAPTER 3
TRAVEL SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Book/Form Number: 5-14360 EN-US
SECTION 5
TROUBLESHOOTING
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
Book/Form Number: 5-14370 EN-US
CHAPTER 1
TROUBLESHOOTING BY ERROR CODES
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Book/Form Number: 5-14380 EN-US
CHAPTER 2
TROUBLESHOOTING BY TROUBLE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Book/Form Number: 5-14390 EN-US
SECTION 6
ENGINE
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
Book/Form Number: 5-14400 EN-US
CHAPTER 1
ENGINE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Book/Form Number: 5-14410 EN-US

6. SAFETY
0-III5-14180 NA Issued 11-2008 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 11-2008 Bur 5-14180 NA
SAFETY PRECAUTIONS
The serviceman or mechanic may be unfamiliar with
many of the systems on this machine. This makes it
important to use caution when performing service
work. A knowledge of the system and or components
is important before the removal or disassembly of
any component.
Because of the size of some of the machine compo-
nents, the serviceman or mechanic should check the
weights noted in this manual. Use proper lifting proce-
dures when removing any components. Weight of
components table is shown in the section ; SPECIFI-
CATIONS.
The following is a list of basic precautions that must
always be observed.
1. Read and understand all Warning plates and
decal on the machine before Operating,
Maintaining or Repairing this machine.
2. Always wear protective glasses and protective
shoes when working around machines. In
particular, wear protective glasses when using
hammers, punches or drifts on any part of the
machine or attachments. Use welders gloves,
hood/goggles, apron and the protective clothing
appropriate to the welding job being performed.
Do not wear loose fitting or torn clothing.
Remove all rings from fingers, loose jewelry,
confine long hair and loose clothing before
working on this machinery.
3. Disconnect the battery and hang a Do Not
Operate tag in the Operators Compartment.
Remove ignition keys.
4. If possible, make all repairs with the machine
parked on a firm level surface. Block the machine
so it does not roll while working on or under the
machine. Hang a Do Not Operate tag in the
Operators Compartment.
5. Do not work on any machine that is supported
only by lift, jacks or a hoist. Always use blocks or
jack stands, capable of supporting the machine,
before performing any disassembly.
6. Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
7. Lower the bucket, dozer, or other attachments to
the ground before performing any work on the
machine. If this cannot be done, make sure the
bucket, dozer, ripper or other attachment is
blocked correctly to prevent it from dropping
unexpectedly.
8. Use steps and grab handles when mounting or
dismounting a machine. Clean any mud or debris
from steps, walkways or work platforms before
using. Always face to the machine when using
steps, ladders and walkways. When it is not
possible to use the designed access system,
provide ladders, scaffolds, or work platforms to
perform safe repair operations.
9. To avoid back injury, use a hoist when lifting
components which weigh 20kg (45lbs) or more.
Make sure all chains, hooks, slings, etc., are in
good condition and are the correct capacity. Be
sure hooks are positioned correctly. Lifting eyes
are not to be side loaded during a lifting
operation.
10. To avoid burns, be alert for hot parts on
machines which have just been stopped and hot
fluids in lines, tubes and compartments.
11. Be careful when removing cover plates.
Gradually back off the last two capscrews or nuts
located at opposite ends of the cover or device
and carefully pry cover loose to relieve any
spring or other pressure, before removing the
last two capscrews or nuts completely.
12. Be careful when removing filler caps, breathers
and plugs on the machine. Hold a rag over the
cap or plug to prevent being sprayed or splashed
by liquids under pressure. The danger is even
greater if the machine has just been stopped
because fluids can be hot.
WARNING
The proper and safe lubrication and maintenance for
this machine, recommended by Manufacturer, are
outlined in the OPERATOR’S MANUAL for the
machine.
Improper performance of lubrication or maintenance
procedures are dangerous and could result in injury
or death. Read and understand the MANUAL before
performing any lubrication or maintenance.
WARNING
Do not operate this machine unless you have read
and understand the instructions in the OPERATOR’S
MANUAL. Improper machine operation is dangerous
and could result in injury or death.

8. SAFETY
0-V5-14180 NA Issued 11-2008 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 11-2008 Bur 5-14180 NA
NOTE:
This Manual is prepared as a technical material in
which the information necessary for the maintenance
and repairing services of our hydraulic excavators
are collected, and is categorized into 6 Sections,
Safety and General Information, Maintenance,
System, Disassembly, Troubleshooting, and Engine.
The Section Safety and General information
describes the specifications for entire machine
and material, which are instructive for
replacement and repairing of attachments.
The Section Maintenance describes the material,
which is helpful for maintenance service and
adjustments for entire machine.
The Section System describes the operating
system like hydraulic system, electric system,
components, and so on.
The Section Disassembly describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
The Section Troubleshooting describes how to
find the fault equipment.
The Section Engine describes the engines
making use of the "Maintenance 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. 2-6 Issued 11-2008 Bur 5-14350 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
REMOVING AND INSTALLING
OPERATOR SEAT
Removal
1. Preparation for removal
A. Remove the head rest (A1-1) of the operator’s
seat (A1) to ease handling.
B. Move the whole control stand to its foremost
position.
C. Move the operator’s seat to its forward end.
D. Incline the reclining seat as forward as
possible.
2. Remove operator’s seat. (Include upper rail.)
A. With the above-mentioned condition, remove
two cap screws (B2) M8× 20 from the upper
rail. Then move the control stand to its
rearmost end and remove two capscrews (B2)
M8× 20.
B. Remove the operator’s seat. [about 28kg (62
lbs).]
Carry out the following operations as required.
C. Remove seat belt (C1).
D. Remove armrest (A3)(A4).
E. Remove bracket assy (1), rail (7).
GRAPHIC_ID Figure 1
A1
A1-1
B2
C1
C2
C1
7
C2
1
Installation
Install it in reverse procedure of removing according
to the tightening torque table.
Reference : Movement on rail
Upper rail …… Fixed on lower surface of seat
[Forward 80mm (0.26in), backward 80mm
(0.26in)]
Lower rail …… Fixed on seat stand.
[Forward 60mm (0.19in), backward 60mm
(0.19in)]
Amount of adjustment of seat height
[Up; 23mm (0.07in), down; 37mm (0.16in)]
Suspension stroke
[Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]
GRAPHIC_ID Figure 2
Tightening position
Allen wrench
Hex (mm)
Tightening torque
Nm (pound-ft)
Capscrew (B2) 6 23.5 (17.3)
Sems bolt (C2) 17 46.1 (34)
Capscrew (A5) 13 23 (17)
Sems bolt (A6) 13 23 (17)
A6
A3
A5
A1
A2
A5
A4

11. 2-75-14350 EN-US Issued 11-2008 Bur
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
CAB
Removal
1. Remove floor mat.
2. Remove cover assy (A29)
A. Loosen 2 machine screw (A17) M6× 16.
B. Loosen 2 machine screw (A39) M6× 45.
C. Disconnect each connector for both speakers.
Then remove cover assy (A29).
3. Remove the harness connector (See Electric
System)
A. Disconnect connectors of cab harness (CN-
605) and (CN-519) at rear right of cab.
B. Disconnect antenna cable coming from
backside of tuner at rear left of cab.
4. Remove the plastic tube for the window washer
from the rear left of cab.
GRAPHIC_ID Figure 3
)!'
)%
)% )!'
) '
5. Remove the right panel of cab
A. Remove 2 caps (A12) loosen 2 sems bolts
(A16) M6× 30 and 1 sems bolt (A15) M6× 16.
And right panels (A2) and (A2-3) are freed.
B. Lift cover (A1) upwards and remove it. (Fixed
with 3 clows and 2 clips)
C. Unfix 3 harness clips (A2-3E) of inside on
right panel (A2-3). And free the harnesses
connected to key switch.
D. With harnesses are connected condition,
install key switch cover (A1) to bracket (A29)
of rear cab temporally.
E. Disconnect harness connectors of work light
switch on right panel (A2-3), air conditioner
panel and cigarette lighter, and remove right
panel (A2-3) and (A2-3). (See Chapter 23)
F. Loosen sems bolts (A20) M6× 16 and (A19)
M6× 45 one each, and remove front panel (A3)
with air conditioner duct.
GRAPHIC_ID Figure 4
A12
A12
A15 A2
A16
A2-3E
A2-3
A2-3E
A2-2
B1
B2
A1
A20
A3
A19
A3-3

12. 2-8 Issued 11-2008 Bur 5-14350 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
GRAPHIC_ID Figure 5
Front A3
A1
FUSE
RELAY BOX
ASSY
6. Remove cab attaching bolt
5 capscrews (A1) M12× 65 (Mark ■) and 1
capscrew (A3) M12× 30. (Mark ▲)
7. Slinging cab
A. Remove two plastic plugs at the front of the
ceiling of the cab. Then place a wire sling with
eye rings and a hook around the cab, as
shown in Fig 7.
B. Then lift up slowly avoiding interference with
surroundings.
Wire with hook ;
Length 1.5m (4ft 11in)× Dia. 8mm
(0.315in)× 3pcs.
Weight of cab ; Approx. 250kg (550 lbs)
GRAPHIC_ID Figure 6
A1
A3
Installation
Install it in reverse order of removing according to
the Tightening torque Table.
GRAPHIC_ID Figure 7
Tightening position
Allen wrench
Hex (mm)
Tightening torque
Nm (pound-ft)
Capscrew (B2) 6 23.5 (17.3)
Sems bolt (C2) 17 46.1 (34)
Capscrew (A5) 13 23 (17)
Sems bolt (A6) 13 23 (17)
EYE BOLT
M10

13. 2-95-14350 EN-US Issued 11-2008 Bur
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
BATTERY
Removing
1. Open left hand cover (1).
A. Open it with starter key.
B. Open left hand cover (1).
C. Fix it with stay.
2. Remove battery cover (A1)
Loosen 3 sems bolts (A6) M10 and remove
battery cover (A1).
GRAPHIC_ID Figure 8
1
3. Remove battery cable
A. Remove cable (4) [between the earth and
battery (–)].
(Always remove (-) terminal first and install it
at last.)
B. Cable (5) [between battery (+) and (-)]
C. Cable (3) [between battery (+) and battery
relay].
IMPORTANT: Follow the battery removal order.
Start removing battery from grounding side, and
finish attaching to grounding side. If this order is
missed, short-circuits may occur.
GRAPHIC_ID Figure 9
3
22
4
5
4. Remove battery (B1)
A. Loosen 2 capscrews (A3) M10× 225.
B. Remove plate (A2).
C. Remove battery (B1).
GRAPHIC_ID Figure 10
A6
A1
A2
B1
A3
A4
A5

14. 2-10 Issued 11-2008 Bur 5-14350 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
Install
1. Install the battery in the reverse order of
removing.
Hold down plate (A2) against battery (B1), and
tighten capscrew (A3).
Tightening torque : 10.8 Nm (8.0 pound-ft)
2. Installing grounding cable
Install grounding cable (4) last. Especially care
must be taken that the grounding face is free
from painting, rust, etc.
GUARD
Preparation for Removal
1. Remove guard in the following procedure.
Remove these equipments according to the
order of items (2), (4), (3), (5), and (1).
(2) All the locked equipment, open them using starter
key.
GRAPHIC_ID Figure 11
31
4 2
5
Remove Guard
1. Remove panel assy (2-1)
A. Unlock panel assy (2-1) and open it.
B. Remove 2 sems-bolts M12 × 25.
C. Remove panel assy (2-1).
Weight : 13 kg (29 lbs)
GRAPHIC_ID Figure 12
2-1
2-2
2-2

15. 2-115-14350 EN-US Issued 11-2008 Bur
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
2. Removing cover assy (2-5)
A. Remove 2 sems-bolts (2-2) M12 × 25 and 2
sems-bolts (2-13) M12 × 30.
B. Removing cover assy (2-5).
Weight : 7 kg (15 lbs)
GRAPHIC_ID Figure 13
2-13 2-5
2-2
2-2
3. Remove panel assy (2-4)
A. Remove 3 sems-bolts (2-2) M12 × 25.
B. Remove panel assy (2-4).
Weight : 8 kg (18 lbs)
GRAPHIC_ID Figure 14
2-4
2
2 2
4. Remove panel assy (2-3)
A. Remove 2 sems-bolts (2-8) M12 × 40.
B. Remove a sems-bolt (2-14) M12 × 20.
C. Remove 2 sems-bolts (2-2) M12 × 25.
D. Remove panel assy (2-3).
Weight : 14 kg (31 lbs)
GRAPHIC_ID Figure 15
2-2
2-3
2-14
2-8 2-8
2-2

16. 2-12 Issued 11-2008 Bur 5-14350 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
5. Remove cover assy (4-2)
A. Remove a sems-bolt (4-9) M12 × 30.
B. Remove a sems-bolt (4-7) M12 × 20.
C. Remove cover assy (4-2).
Weight : 1 kg (2 lbs)
6. Remove cover assy (4-1)
A. Remove 3 sems-bolts (4-7) M12 × 20.
B. Remove cover assy (4-1).
Weight : 3 kg (7 lbs)
GRAPHIC_ID Figure 16
4-9
4-7
4-1
4-7
4-2
7. Remove hood assy (3-2)
A. Unlock hood assy (3-2) and open it.
B. Remove 4 sems-bolts (3-12) M12 × 20.
C. Remove hood assy (3-2).
Weight : 17 kg (37 lbs)
GRAPHIC_ID Figure 17
3-12
3-2
8. Remove hood assy (3-1)
A. Remove 4 sems-bolts (3-13) M12 × 25.
B. Remove hood assy (3-1).
Weight : 15 kg (33 lbs)
9. Remove covers (3-3), (3-4)
A. Remove a sems-bolt (3-13) M12 × 25.
B. Remove cover assy (3-3).
C. Remove a sems-bolt (3-13) M12 × 25.
D. Remove cover (4).
Weight : 10 kg, 4 kg (22 lbs, 9 lbs) GRAPHIC_ID Figure 18
3-13
3-13
3-1
3-13
3-3
3-13
3-4

17. 2-135-14350 EN-US Issued 11-2008 Bur
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
10. Remove left hand cover (5-1)
A. Open cover assemblies (5-1) and remove the
couplers from harness (1) for swing flasher.
B. Remove 2 sems-bolts (5-4) M12 × 25 and
remove left hand cover (5-1).
11. Remove right hand cover (5-2)
A. Open cover assemblies (5-2) and remove the
couplers from harness (2) for swing flasher.
B. Remove 2 sems-bolts (5-4) M12 × 25 and
remove right hand cover (5-2).
GRAPHIC_ID Figure 19
5-1
5-2
5-4
5-4
1
2
MACHINE FRONTI
VIEW I
12. Remove bracket (1-5)
Remove 2 sems-bolts (1-8) M12 × 25 and
remove bracket (1-5).
GRAPHIC_ID Figure 20
1-8
1-5
1-8

18. 2-14 Issued 11-2008 Bur 5-14350 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
13. Remove guard assy (1-2)
A. Remove 2 sems-bolts (1-9) M12 × 30.
B. Remove the sems-bolt (1-8) M12 × 25
attaching support (1-3).
C. Remove guard assy (1-2).
Weight : 7 kg (15 lbs)
14. Remove pillar (1-4)
A. Remove 2 sems-bolts (1-8) M12 × 25.
B. Remove pillar (1-4).
Weight : 7 kg (15 lbs)
GRAPHIC_ID Figure 21
1-4
1-8
1-8
1-13
1-8
1-9
1-9
1-2
15. Remove guard assy (1-1)
A. Remove 4 sems-bolts (1-8) M12 × 25.
B. Remove guard assy (1-1).
Weight : 20 kg (44 lbs)
GRAPHIC_ID Figure 22
1-8
1-8
1-1
Installation
1. Installing is done in the reverse order of
removing.
2. Tightening torque
M12 79.4 Nm (58.6 pound-ft)

19. CHAPTER 2 - UPPER STRUCTURE
2-155-14350 EN-US Issued 11-2008 Bur
SECTION 4 - DISASSEMBLY AND ASSEMBLY
UNDER COVER
Removal
1. Remove under cover (1,2,3,4,5,6)
A. Remove sems-bolts (7) M12 × 25.
B. Remove covers.
GRAPHIC_1D Figure 23
Installation
1. Install under cover (1,2,3,4,5,6)
Tightening torque : 80 Nm (59 pound-ft)
7
6
5
7
7
4
3
7
7
1
7
2

20. 2-16 Issued 11-2008 Bur 5-14350 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
FUEL TANK
Preparation for Removal
1. Draining fuel (See Fig. 25)
A. Unlock cap (B1) with a starter key and open it.
B. Loosen valve (A10) under the tank.
C. Draining fuel
Capacity of tank : 367L (97gal)
2. Remove panel assy (2-3),(2-4).
3. Remove the connector for fuel level sensor (A4).
(See Fig. 25)
4. Remove fuel hose
A. Loosen clip (12),(17) and draw out hoses (8)
and (26).
B. Put in plugs that match the hose bore.
GRAPHIC_ID Figure 24
.
12,8
27,26
Removal
1. Remove 4 capscrews (A1) M16× 50.
2. Hook the wire to the lifting eye on the fuel tank
assy (B6) and remove the fuel tank.
Weight : 63kg (139 lbs)
3. Remove shim (A3).
Record the shim locations.
GRAPHIC_ID Figure 25
B1
A1
B6
A9A1
A4
A5
A3
A9
A3
A7

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22. 2-175-14350 EN-US Issued 11-2008 Bur
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
Installation
1. Installing is done in the reverse order of
removing.
Tank attaching bolt (A1) M16× 50
Apply Loctite #262
Tightening torque : 191 Nm (140 pound-ft)
IMPORTANT: If the gap (looseness) between tank
mount and frame exceeds 1mm (0.04inch), adjust
the gap with shim (A3) and tighten capscrew (A1) to
install the tank.
2. Tightening torque
No. Name Qty
Tightening torque
Nm (pound-ft)
A1 Capscrew 4 191 (140)
A5 Machine screw 5 1.96 (1.4)
A7 Cock 1 34 (25)

23. 2-18 Issued 11-2008 Bur 5-14350 EN-US
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK
Preparation for Removal
1. Swinging upper structure 45 degrees.
Swing upper structure to make the removal of
suction hose for pump installed under tank
easier.
2. Necessary to remove the hydraulic oil tank.
GRAPHIC_ID Figure 26
3. Bleeding internal air of tank
Press cap by finger to bleed internal air.
IMPORTANT: Keep pressing until the hissing sound
stops.
GRAPHIC_ID Figure 27
Push
(ELEMENT NO.
YN57V00004S002)
4. Remove cover (B1)
A. Remove 6 sems bolts (B10) M10× 25.
B. Remove cover (B1).
C. Remove suction strainer (B4).
5. Remove cover (B2)
A. Remove 6 sems bolts (B10) M10× 25.
B. Remove cover (B2).
C. Remove filter element (B7).
6. Turn the handle of element assy (B7), and
disassemble the removed filter element (B7).
7. Draining hydraulic oil
Place pump in tank and draw up hydraulic oil.
Capacity of tank : 72 L (19gal)
GRAPHIC_ID Figure 28
B5
B10
B11
B12
B1
B4
B14
B10
B2
B13
B15
B7-1
B7-1
B7-3
B7-4
B7-2
B7

24. 2-195-14350 EN-US Issued 11-2008 Bur
CHAPTER 2 - UPPER STRUCTURE
SECTION 4 - DISASSEMBLY AND ASSEMBLY
Removal
1. Draw out the suction hose (1)
Remove 2 clips (9) of the tank side and pull out
hose (1).
GRAPHIC_ID Figure 29
9
1
9
At installing suction hose,
apply PERMATEX to the
inner end of both hoses.
2. Disconnecting the main pipe return hose (7)
3. Remove drain hose (6) of pump
4. Remove drain hose (4) of swing motor
GRAPHIC_ID Figure 30
10
17
4
8
20
13
18
6
26
30
35
20
7
20
PUMP Dr-
TANK
O/C OUT-
TANK
S/M Dr-
TANK
C/V R3-
TANK
5. Disconnecting pilot return hose
A. Remove pilot hose (A1),(A22).
B. Remove pilot hose (A4).
C. Remove pilot hose (A6).
GRAPHIC_ID Figure 31
C/V T2-
TANK
C/V Dr2
TANK
A2
A22
PT T
TANK
S/V T-
TANK
A22
A6
A19
A4