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New Holland E135BSR ROPS Tier III Service Manual

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SERVICE MANUAL
SERVICE MANUAL
SERVICE MANUAL
ROPS Tier III
ROPS Tier III
ROPS Tier III
Midi Crawler Excavator
Midi Crawler Excavator
Crawler Excavator
E80BMSR
E135BSR
E70BSR
Print No. 84365679
Print No. 84396007A
Print No. 84365680

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  • Page 1 SERVICE MANUAL SERVICE MANUAL SERVICE MANUAL E80BMSR E70BSR E135BSR ROPS Tier III ROPS Tier III ROPS Tier III Midi Crawler Excavator Midi Crawler Excavator Crawler Excavator Print No. 84365679 Print No. 84396007A Print No. 84365680...
  • Page 2 E135BSR WORKSHOP MANUAL ENGLISH Print No. 84396007A Edition 09/2010 English - Printed in Italy Find manuals at https://best-manuals.com...
  • Page 3 Find manuals at https://best-manuals.com...
  • Page 4 NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. Read this manual carefully for correct information Strada di Settimo, 323 about repair procedures.
  • Page 5 If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical device used for controlling the equipment. NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. COPYRIGHT BY Product Support - Documentation Centre Strada di Settimo, 323 - 10099 S.
  • Page 6 SAFETY PRECAUTIONS Find manuals at https://best-manuals.com...
  • Page 7 GENERAL SAFETY INFORMATION 3) CAUTION- Indicates a potentially hazardous situation which, if not avoided, may result in mi- nor or moderate injury. It may also be used to alert against possible damage to the machine Do not operate or perform any maintenance on this and its components and is represented as fol- machine until all instructions found in the OPERA- lows:...
  • Page 8 SAFETY PRECAUTIONS stands, capable of supporting the machine, before performing any disassembly. The proper and safe lubrication and maintenance Do not operate this machine unless you have for this machine, recommended by Manufacturer, read and understand the instructions in the OP- are outlined in the OPERATOR’S MANUAL for the ERATOR’S MANUAL.
  • Page 9 (13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera- you understand how to use them before performing tion.
  • Page 10 INDEX NHK-EUR E135BSRLC Book Code No. Index 25 1 Title Distribution Year–Month S5YN0129E01 OUTLINE 2010-07 S5YY0215E01 SPECIFICATIONS 2010-07 S5YY0315E01 ATTACHMENT DIMENSIONS 2010-07 S5YY1115E01 TOOLS 2010-07 S5YY1215E01 STANDARD MAINTENANCE 2010-07 TIME SCHEDULE S5YY1315E01 MAINTENANCE STANDARD 2010-07 AND TEST PROCEDURE S5YY2115E01 MECHATRO CONTROL 2010-07 SYSTEM S5YY2215E01...
  • Page 11 NOTE: This Manual is prepared as a technical material in This Manual may be properly revised due to the im- which the information necessary for the maintenance provement of products, modification of specifications, and repairing services of our hydraulic excavators are etc.

  • Page 12: Table Of Contents

    1. OUTLINE 1. OUTLINE TABLE OF CONTENTS GENERAL PRECAUTIONS FOR MAKING REPAIRS ........1-3 1.1.1 PREPARATION BEFORE DISASSEMBLING ..........1-3 1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ......1-3 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ..1-4 1.1.4 ELECTRICAL EQUIPMENT ................ 1-6 1.1.5 HYDRAULIC PARTS ...................
  • Page 13 1. OUTLINE Issue Data of Issue Applicable Machines Remarks SK200-8 : YN12-56001~ S5YN0129E01 First Edition December, 2008 SK210LC-8 : YQ12-08001~ (SE Asia & Oceania)  SK460-8 : LS11-02501~  February, 2009 SK480LC-8 : YS11-02001~ (SE Asia & Oceania)  E385B : LC11-08501~ ...

  • Page 14: General Precautions For Making Repairs

    1. OUTLINE GENERAL PRECAUTIONS FOR MAKING REPAIRS 1.1.1 PREPARATION BEFORE DISASSEMBLING Read Operator's Manual before disassembling (1) Knowledge of operating procedure Read Operator's Manual carefully to understand the operating procedure. (2) Cleaning machines Clean machines of soil, mud, and dust before carrying into the service shop. Carrying a soiled machine into the service shop, causes making less efficient work and damage of parts.

  • Page 15: Disassembling And Assembling Hydraulic Equipment

    1. OUTLINE 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT (1) Removing hydraulic equipment assy 1. Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and take out the filter. 2. Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground. 3.
  • Page 16 1. OUTLINE (5) Installing hydraulic equipment 1. Confirm hydraulic oil and lubrication oil. 2. Air release is required in the following cases ; a. Change of hydraulic oil b. Replacement of parts on suction pipe side c. Removing and attaching hydraulic pump d.

  • Page 17: Electrical Equipment

    1. OUTLINE 1.1.4 ELECTRICAL EQUIPMENT (1) The disassembly of electrical equipment is not allowed. (2) Handle equipment with care so as not to drop it or bump it. (3) Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire. (4) Check that connector is connected and locked completely.

  • Page 18: Hydraulic Parts

    1. OUTLINE 1.1.5 HYDRAULIC PARTS (1) O-ring • Check that O-ring is free from flaw and has elasticity before fitting. • Even if the size of O-ring is equal, the usage differs, for example in dynamic and static sections, the rubber hardness also differs according to the pressure force, and also the quality differs depending on the materials to be seated.

  • Page 19: International Unit System

    1. OUTLINE INTERNATIONAL UNIT SYSTEM Introduction Base units Table 1-1 Although this manual uses the SI units system. Outline of Derived units SI units system is described here. of base units Supplemen Given hereinunder are an excerpt of the units that are Table 1-3 tary units SI units...
  • Page 20 1. OUTLINE (5) Prefixes of SI (6) Unit Conversion Table Table1-5 Table1-6 PREFIX QUANTITIES REMARKS POWER DESIGNATION SIGN Mass Giga Force 1kgf=9.807N Mega Torque kgf•m N•m 1kgf•m=9.807N•m Kilo Pressure kgf/cm 1kgf/cm =0.098MPa Hecto Motive power 1PS=0.7355kW Deca Revolution r.p.m 1r.p.m=1min –1 –1 Deci...
  • Page 21 1. OUTLINE 1-10...
  • Page 22 2. SPECIFICATIONS 2. SPECIFICATIONS TABLE OF CONTENTS NAME OF COMPONENTS .................. 2-3 GENERAL DIMENSIONS ..................2-4 2.2.1 E135BSRLC [4.68m(15ft-4in) + 2.84m(9ft-4in) Long Arm + 0.38m3 (0.50cu-yd) Bucket] ......................2-4 WEIGHT OF COMPONENTS ................2-5 TRANSPOTATION ....................2-7 2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ......2-7 2.4.2 DIMENSIONS OF ATTACHMENT ...............
  • Page 23 2. SPECIFICATIONS Issue Date of Issue Applicable Machines Remarks S5YY0215E01 First Edition July, 2010 E135BSRLC : YH06-08001~ (NHK-EUR)

  • Page 24: Name Of Components

    2. SPECIFICATIONS NAME OF COMPONENTS BUCKET CYLINDER MONITOR PANEL ARM CYLINDER CONTROL VALVE OIL COOLER SWING MOTOR FUEL TANK IDLER LINK RADIATOR BUCKET LINK HYD TANK BOOM GUARD MUFFLER BOOM CYLINDER HYD PUMP SHOE BUCKET FRONT IDLER IDLER ADJUST SLEWING BEARING LOW ROLLER UPP ROLLER ENGINE...

  • Page 25: General Dimensions

    2. SPECIFICATIONS GENERAL DIMENSIONS 2.2.1 E135BSRLC [4.68m(15ft-4in) + 2.84m(9ft-4in) Long Arm + 0.38m (0.50cu-yd) Bucket] 7,110 mm (23'-4") 2,490 mm (8'-2") 1,490 mm (4'-11") 600 mm (12.6") 3,040 mm (9'-11") 2,590 mm (8'-6") 3,750 mm (12'-4") 7,500 mm (24'-7)

  • Page 26: Weight Of Components

    2. SPECIFICATIONS WEIGHT OF COMPONENTS Unit ; kg (lb) Item / Model E135BSRLC Fully equipped weight 14,700 (32,410) 1. Upper frame assy (Assembly of following :) 7,560 (16,670) 1.1 Upper frame 1,420 (3,131) 1.2 Counter weight 3,400 (7,500) Counter weight (Semi-weighted) Counter weight (weighted) 1.3 Cab 395 (871)
  • Page 27 2. SPECIFICATIONS Unit ; kg (lb) Item / Model E135BSRLC 4. Lubricant and water (Assembly of following :) 334 (736) 4.1 Hydraulic oil 137 (302) 4.2 Engine oil 16 (35) 4.3 Fuel 167 (368) 4.4 Water 14 (31) Marks * show dry weight.

  • Page 28: Transpotation

    2. SPECIFICATIONS TRANSPOTATION 2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER (1) 4.68m (15ft-4in) Boom+2.84m (9ft-4in) Long Arm+0.38m3 (0.50cu-yd) Bucket Item/Shoe type 600mm (23.6in) LC Width : mm (ft-in) 2,590 (8'6") Weight: kg (lbs) 14,700kg (32,410 lbs) 7,070 mm (23'-2") 3,480 mm (11'-5") 1,100 mm (3'-7")

  • Page 29: Dimensions Of Attachment

    2. SPECIFICATIONS 2.4.2 DIMENSIONS OF ATTACHMENT (1) BOOM Item / Type 4.68m (15ft-4in) Boom Length X Height X Width 4.84 X 1.42 X 0.60 L X H X W: m (ft-in) (15'11" X 4'8" X 1'12") Weight: kg (lbs) 1,350 (2,975) (2) ARM AND BUCKET 2.84m (9ft-4in) Arm + Item / Type...
  • Page 30 2. SPECIFICATIONS (4) Bucket Type Hoe bucket 1.19 X 1.07 X 0.70 Length X Height X Width 1.19 X 1.07 X 0.70 1.19 X 1.07 X 0.80 (3'11" X 3'6" X 2'4") L X H X W: m (ft-in) (3'11" X 3'6" X 2'4") (3'11"...

  • Page 31: Specifications And Performance

    2. SPECIFICATIONS SPECIFICATIONS AND PERFORMANCE 2.5.1 SPEED AND CLIMBING CAPABILITY Item / Model E135BSRLC Swing speed : min-1 {rpm} 11.5 {11.5} Travel speed (1-speed/2-speed) : km/h 3.4 / 5.6 (2.1 / 3.5) (mile/h) Gradeability : % (degree) 70 (35) 2.5.2 ENGINE Engine model MITSUBISHI D04FR-74kW...

  • Page 32: Type Of Crawler

    2. SPECIFICATIONS TYPE OF CRAWLER Overall width of crawler Ground pressure Shape Shoe width mm (in) mm (ft-in) kPa (psi) Grouser shoe 600 (23.6) 2,590 (8'6") 36 (5.22) 700 (27.6) 2,690 (8'10") 32 (4.64) Use 600mm (23.6") grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.) 2-11...

  • Page 33: Type Of Bucket

    2. SPECIFICATIONS TYPE OF BUCKET Outer width mm (ft-in) Heaped Availability Weight W or W/O Number Struck capacity With side Without side of face (cu•yd) of tooth side cutter kg (lbs) shovel (cu•yd) cutter cutter 0.20 0.24 (0.31) 590 (1'11") 500 (1'7.7") Hoe bucket (0.26)

  • Page 34: Combinations Of Attachment

    2. SPECIFICATIONS COMBINATIONS OF ATTACHMENT Bucket Available Arm Heaped capacity Struck 2.38m (7ft-10in) Arm 2.84m (9ft-4in) Type (cu•yd) (cu•yd) (STD) Arm (Long) 0.24 (0.31) 0.20 (0.26) 0.31 (0.41) 0.23 (0.30) 0.38 (0.50) 0.28 (0.37) Hoe bucket 0.45 (0.59) 0.35 (0.46) 0.50 (0.65) 0.38 (0.50) 0.57 (0.75)

  • Page 35: Engine Specification

    2. SPECIFICATIONS ENGINE SPECIFICATION 2.9.1 SPECIFICATIONS Applicable machine E135BSRLC Engine model MITSUBISHI D04FR-74kW Water-cooled, 4 cycle 4 cylinder direct injection type diesel Type engine with inter cooler turbo-charger Number of mm (in) 4 X 102 X 130 (4.02 X 5.12) cylinderXBoreXStroke Total displacement cc (cu-in)

  • Page 36: Engine Characteristic Curve

    2. SPECIFICATIONS 2.9.2 ENGINE CHARACTERISTIC CURVE Condition to be measured: The net value is indicated, measuring without cooling fan. ENGINE SPEED (min Fuel consumption volume Fuel consumption rate X kW X Load factor ( ) 0.835 X 1000 233g/kW . h X 74kW X 0.835 X 1000 : Standard load factor...
  • Page 37 2. SPECIFICATIONS 2-16...
  • Page 38 3. ATTACHMENT DIMENSIONS 3. ATTACHMENT DIMENSIONS TABLE OF CONTENTS BOOM ........................3-3 3.1.1 BOOM DIMENSIONAL DRAWING .............. 3-3 3.1.2 BOOM MAINTENANCE STANDARD ............3-4 ARM ........................3-6 3.2.1 ARM DIMENSIONAL DRAWING ..............3-6 3.2.2 ARM MAINTENANCE STANDARD ............. 3-7 BUCKET ......................3-10 3.3.1 BUCKET DIMENSIONAL DRAWING ............
  • Page 39 3. ATTACHMENT DIMENSIONS Issue Date of Issue Applicable Machines Remarks S5YY0315E01 First Edition July, 2010 E135BSRLC : YH06-08001~ (NHK-EUR)

  • Page 40: Boom

    3. ATTACHMENT DIMENSIONS BOOM 3.1.1 BOOM DIMENSIONAL DRAWING SECTION X-X Boom dimensional drawings 4.68M(15ft-4in) BOOM YY02B00371F1 NAME DIMENSIONS: mm (ft-in) Boom length 4,680 (15'4") Boom foot width 575 (22.6") Boom end inner width 274 (10.8") Boom end outer width 386 (15.2") Height of boom cylinder rod pin 952 (37.5") Height of arm cylinder (head side) pin...

  • Page 41: Boom Maintenance Standard

    3. ATTACHMENT DIMENSIONS 3.1.2 BOOM MAINTENANCE STANDARD (1) Clearance of pin and bushing on boom section Clearance of pin and bushing on boom section Unit : mm (in) Standard value Clearance Sym- Bushing Repaira Item Pin part No. Remedy Pin dia. Standard Service Pin dia.
  • Page 42 3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the boom cylinder installation section SECTION C-C SECTION D-D SECTION A-A SECTION B-B Clearance in thrust direction on the boom cylinder installation section Unit : mm (in) Clearance X adjusted with shim Basic size Pin length (total of both sides)

  • Page 43: Arm

    3. ATTACHMENT DIMENSIONS 3.2.1 ARM DIMENSIONAL DRAWING VIEW J SECTION X-X SECTION Z-Z SECTION Y-Y ARM DIMENSIONAL DRAWING YY12B00378F1 2.84m (9ft-4in) ARM Unit : mm (ft-in) Code NAME DIMENSION Code NAME DIMENSION Arm length 2,840 (9'4") Bracket inner width 110 (4.33") Distance between pins of boss R641.5 (25.3") Bracket inner width...

  • Page 44: Arm Maintenance Standard

    3. ATTACHMENT DIMENSIONS 3.2.2 ARM MAINTENANCE STANDARD (1) Clearance of pin and bushing D, D' Clearance of pin and bushing on arm section Unit : mm (in) Standard dimensions Clearance Item Pin part No. Remedy Pin dia. Bushing i.d. Standard Service Repairable Pin dia.
  • Page 45 3. ATTACHMENT DIMENSIONS (2) Clearance of arm and cylinder installing sections in thrust direction D, D' D, D' SECTION A-A SECTION C-C SECTION F-F SECTION E-E X4' L4' SECTION B-B SECTION D-D SECTION G-G Clearance of arm and cylinder installing sections in thrust direction...
  • Page 46 3. ATTACHMENT DIMENSIONS Unit : mm (in) Clearance X adjusted with shim Basic size Pin length (total of both sides) Sec. Item Remedy Standard Repairable Size Service limit No. Length value level (9.86) A-A Arm point Bucket (9.92) 0.6~1.0 (0.05) (15.4) (0.024~0.04) Link side...

  • Page 47: Bucket

    3. ATTACHMENT DIMENSIONS BUCKET 3.3.1 BUCKET DIMENSIONAL DRAWING (1) Hoe bucket Bucket dimensional drawing NAME NAME Distance between pin and bracket Inner width of bucket bottom Distance between bucket pin and tooth end Bucket outer width of front side Inner width of bucket top end Pitch between teeth Inner width of bracket Pitch between teeth...

  • Page 48: Bucket Dimensional Table

    3. ATTACHMENT DIMENSIONS 3.3.2 BUCKET DIMENSIONAL TABLE Unit : mm (ft-in) Type Normal digging [STD] 0.24 0.31 0.38 0.45 0.57 0.70 Capacity 0.50 (0.22) m (0.27) m (0.33) m (0.40) m (0.50) m (0.60) m (0.45) m YY61B00079F YY61B00080F YY61B00081F YY61B00075F Part No.

  • Page 49: Lug Section Dimensional Drawing

    3. ATTACHMENT DIMENSIONS 3.3.3 LUG SECTION DIMENSIONAL DRAWING Roughness of counterbore bottom surface is to be 100S or less in range of diameter 39mm. BOSS And M16 bolt is to be installed. (3 places) 2418P26832 (1.10) Apply rust prevention oil (0.748) BOSS SHIM...

  • Page 50: Boss Section Dimensional Drawing

    3. ATTACHMENT DIMENSIONS 3.3.4 BOSS SECTION DIMENSIONAL DRAWING (0.197") 15 (0.591") DETAIL A Dimension of boss section Unit : mm (ft-in) Capacity of Type of Part No. of Part No. øA øB øC øD øG bucket bucket bucket of boss (cu•yd) [STD] 0.50 (0.45)
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