Professional Documents
Culture Documents
Fiat Kobelco E30sr E35sr Evolution Workshop Manual
Fiat Kobelco E30sr E35sr Evolution Workshop Manual
WORKSHOP MANUAL
ENGLISH
Print n. 604.13.250.00
29002 60413250
Edition: 01/2003
Français - Printed in Italy
Printed by Studio ti
0-1
This is the cut pages sample. Download all 672 page(s) at: ManualPlace.com
INTRODUCTION
TO THE READER
• This manual has been written for a skilled - For any question or comment, or in case you
technician, in order to give him the information notice a mistake in this manual content,
necessary to repair this machine. please contact:
0-3
INTRODUCTION
AVOID ACCIDENTS
ATTENTION
0-4
INDEX
INDEX
SPECIFICATIONS
MAINTENANCE
Section 11 - Tools
Section 12 - Standard maintenance time table
Section 13 - Maintenance standards and test procedures
SYSTEM
DISASSEMBLING
TROUBLESHOOTING
ENGINE
Section 51 - Engine
29002 60413250
0-5
SAFETY PRECAUTIONS
0-6
SAFETY PRECAUTIONS
The following is a list of basic precautions that 8. Use steps and grab handles when mounting or
must always be observed. dismounting a machine. Clean any mud or debris
from steps, walkways or work platforms before
1. Read and understand all Warning plates and using. Always face the machine when using
decal on the machine before Operating, steps, ladders and walkways. When it is not
Maintaining or Repairing this machine. possible to use the designed access system,
provide ladders, scaffolds, or work platforms to
2. Always wear protective glasses and protective perform safe repair operations.
shoes when working around machines. In
particular, wear protective glasses when using 9. To avoid back injury, use a hoist when lifting
hammers, punches or drifts on any part of the components which weigh 23kg (50lbs) or more.
machine or attachments. Use welders gloves, Make sure all chains, hooks, slings, etc., are in
hood/goggles, apron and the protective clothing good condition and are the correct capacity. Be
appropriate to the welding job being performed. sure hooks are positioned correctly. Lifting eyes
Do not wear loose fitting or torn clothing. Remove are not to be side loaded during a lifting operation.
all rings from fingers, loose jewelry, confine long
hair and loose clothing before working on this 10. To avoid burns, be alert for hot parts on machines
machinery. which have just been stopped and hot fluids in
lines, tubes and compartments.
3. Disconnect the battery and hang a “Do Not
Operate” tag in the Operators Compartment. 11. Be careful when removing cover plates. Gradually
Remove ignition keys. back off the last two capscrews or nuts located at
opposite ends of the cover or device and carefully
4. If possible, make all repairs with the machine pry cover loose to relieve any spring or other
parked on a level, hard surface. Block the machine pressure, before removing the last two capscrews
so it does not roll while working on or under the or nuts completely.
machine. Hang a “Do Not Operate” tag in the
Operators Compartment. 12. Be careful when removing filler caps, breathers
and plugs on the machine. Hold a rag over the
5. Do not work on any machine that is supported cap or plug to prevent being sprayed or splashed
only by lift, jacks or a hoist. Always use blocks or by liquids under pressure. The danger is even
jack stands, capable of supporting the machine, greater if the machine has just been stopped
before performing any disassembly. because fluids can be hot.
6. Relieve all pressure in air, oil or water systems 15. Repairs which require welding should be
before any lines, fittings or related items are performed only with the benefit of the appropriate
disconnected or removed. Always make sure all reference information and by personnel
raised components are blocked correctly and be adequately trained and knowledgeable in welding
alert for possible pressure when disconnecting procedures. Determine type of metal being
any device from a system that utilizes pressure. welded and select correct welding procedure
and electrodes, rods or wire to provide a weld
7. Lower the bucket, dozer, or other attachments to metal strength equivalent at least to that of the
the ground before performing any work on the parent metal. Make sure to disconnect battery
29002 60413250
machine. If this cannot be done, make sure the before any welding procedures are attempted.
bucket, blade, ripper or other attachment is
blocked correctly to prevent it from dropping
unexpectedly.
0-7
SAFETY PRECAUTIONS
16. Do not damage wiring during removal 23. Do not breathe dust generating when cleaning
operations. Reinstall the wiring so it is not parts such as radiators: their inhalation can be
damaged nor will be damaged in operation of harmful for your health.
the machine by contacting sharp corners, or by
rubbing against some object or hot surface. Do
not connect wiring to a line containing fluid.
0-8
E30SR EVOLUTION
E35SR EVOLUTION
TABLE OF CONTENTS
1-1
PRELIMINARY REMARKS
specified.
6) If it is hard to remove a part according to the WARNING
procedure, do not try it by force but investigate the Operation of the hydraulic equipment without filling
hydraulic oil or lubricant or without performing air bleeding
cause.
will result in damage to the equipment.
7) Place the removed parts in order and attach tags
to facilitate the reassembling.
8) Note the location and quantity of parts commonly 3) Perform air bleeding of the hydraulic pump and
applied to multiple locations. slewing motor after loosening the upper drain plug,
starting the engine and keep it in low idle condi-
(3) Inspecting parts tion. Complete the air bleeding when seeping of
1) Ensure that the disassembled parts are free from hydraulic oil is recognized, and tightly plug.
seizure, interference and uneven contact. 4) Perform air bleeding of the travel motor and the
2) Measure and record wear condition of parts and hydraulic cylinders by running the engine for more
clearance. than 5 minutes at low speed without load.
3) If the problem is found in a part, repair or replace it
with a new one.
WARNING
(4) Reassembling hydraulic equipment Do not allow the hydraulic cylinder to bottom on the
1) Turn ON the ventilation fan or open windows to stroke end just after the maintenance.
maintain good ventilation prior to starting the
cleaning of parts.
2) Perform rough and finish cleaning before assem- 5) Perform air bleeding of pilot line by performing a
bling. series of digging, slewing and travel.
3) Remove washing oil by air and apply clean hydrau- 6) Check hydraulic oil level after placing the attach-
lic or gear oil for assembling. ment to the oil check position, and replenish oil if
4) Always replace the removed O-rings, backup rings necessary.
and oil seals with new ones by applying grease in
Checking hydraulic oil level
advance.
5) Remove dirt and moisture from and perform Level gauge Oil level lines
(Level located
degreasing on the surface where liquid gasket to between the two
lines shows
be applied. appropriate
amount of oil)
6) Remove rust preventive agent from the new parts
before use.
7) Fit bearings, bushings and oil seals using special
jigs.
1.4 ELECTRICAL EQUIPMENT
8) Assemble the parts utilizing matching marks.
9) Ensure all the parts are completely assembled after
the work. (1) Do not disassemble electrical equipment.
(5) Installing hydraulic equipment (2) Handle it carefully not to drop and give a shock.
1) Ensure hydraulic oil and lubricant are properly
supplied. (3) Turn the key OFF prior to connecting and discon-
2) Perform air bleeding when: necting work.
a. Hydraulic oil changed
b. Parts of suction side piping replaced (4) Disconnect the connector by holding it and press-
29002 60413250
c. Hydraulic pump installed ing the lock. Do not pull the wire to apply force to
d. Slewing motor installed the caulking portion.
e. Travel motor installed
f. Hydraulic cylinder installed (5) Connect the connector and ensure it is completely
locked.
1-2
PRELIMINARY REMARKS
(6) Turn the key OFF prior to touching the terminal of used depending on the working pressure even
starter or generator. the size of fitting and the total length of the hose
is same.
(7) Remove the ground (earth) terminal of battery • Tighten the fitting at the specified torque. En-
when handling tools around the battery or its relay. sure no kink, tension, interference nor oil leak-
age is recognized.
(8) Do not splash water on the electrical equipment
and connectors during machine washing. 1.6 WELDING REPAIR
(1) Refer repair welding to qualified personnel accord-
(9) Check for moisture adhesion inside the waterproof ing to the appropriate procedure.
connector after pulling it out, since it is hard to
remove moisture from the connector. If moisture (2) Disconnect the ground (earth) cable of the battery
adhesion is found, dry it completely before the before starting the repair. Failure to do so will cause
connection. damage to the electrical equipment.
1-3
PRELIMINARY REMARKS
WARNING
• While towing, do not enter between the machine and
towing vehicle.
• Do not apply a shock load onto the towing rope.
• Do not use eyes on machine lower frame to tow
machine.
• Keep the wire rope horizontally, and perpendicularly to
the crawler frame.
• Tow the machine slowly at low speed mode.
• For the towing of the machine body, provide pads to be
applied to the corner of crawler frame to prevent the
wire rope and crawler frame from any damages.
NOTE:
Do not pull machine utilizing the brackets welded on the
lower plates of the carbody. These brackets are provided
for pulling lightweight objects. See figure for better
reference.
1-4
PRELIMINARY REMARKS
(1) Base Units [ Table 3-1 ] Given hereinafter is an excerpt of the units that
QUANTITY UNIT SYMBOL (5) Prefixes of SI [ Table 3-5 ]
Length metre m MULTIPLI-
PREFIX SYMBOL
Mass kilogram kg CATION FACTORS
Time second s giga G 10 9
Electric current ampere A mega M 10 6
Thermodynamic kilo k 10 3
temperature kelvin K
hecto h 10 2
Amount of substance mol mol deca da 10
Luminous intensity candela cd deci d 10-1
centi c 10-2
(2) Supplementary Units [ Table 3-2 ] milli m 10-3
QUANTITY UNIT SYMBOL micro µ 10-6
Plane angle radian rad nano n 10-9
Solid angle steradian sr pico p 10-12
*
1-5
PRELIMINARY REMARKS
FORCE
1 N=0.10197 kgf
10 50 100 500 1,000 5,000 10,000 20,000 N
TORQUE
1 N · m=0.102 kgf · m
10 50 100 5,000 10,000 20,000 N • m
PRESSSURE
1 MPa=10.197 kgf/cm2
0.1 1 10 100 MPa
29002 60413250
1-6
E30SR EVOLUTION
E35SR EVOLUTION
SECTION 2 SPECIFICATIONS
TABLE OF CONTENTS
1. COMPONENTS NAME
2 1
38
6
5 7
37 4 8
3 10
36
9
11
35 33
12
13
32
34
31
14
30
15
29
28
27 F19193
26
16
25 17
23 18
24 19
22 20
21
2-1
Fiat Kobelco E30sr E35sr Evolution Workshop Manual
Full download: http://manualplace.com/download/fiat-kobelco-e30sr-e35sr-evolution-workshop-manual/
SPECIFICATIONS
2. MACHINE DIMENSIONS
F15945
CAB
29002 60413250
F15946
2-2
This is the cut pages sample. Download all 672 page(s) at: ManualPlace.com