Bobcat E45 Compact Excavator Service Manual 6989437 (01-20) – PDF DOWNLOAD

Description

Bobcat E45 Compact Excavator Service Manual 6989437 (01-20) – PDF DOWNLOAD

FILE DETAILS:

Bobcat E45 Compact Excavator Service Manual 6989437 (01-20) – PDF DOWNLOAD

Language : English
Pages :1101
Downloadable : Yes
File Type : PDF

DESCRIPTION:

S/N AG3G11001 & Above
S/N AHHC11001 & Above
S/N B3NM11001 & Above
S/N B3NR11001 & Above

Bobcat E45 Compact Excavator Service Manual 6989437 (01-20) – PDF DOWNLOAD

FOREWORD

This manual is for the Bobcat excavator mechanic. It provides necessary servicing and adjustment procedures for the Bobcat excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

•  The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Bobcat E45 Compact Excavator Service Manual 6989437 (01-20) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
EXCAVATOR IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 23
Procedure 23
LIFTING THE EXCAVATOR 25
Procedure 25
OPERATOR CAB (ROPS / TOPS) 27
Description 27
Cab Door 28
Front Window 29
Front Wiper 30
Window Washer Reservoir 30
Right Side Windows 31
OPERATOR CANOPY (ROPS / TOPS) 33
Description 33
TRANSPORTING THE EXCAVATOR ON A TRAILER 35
Loading And Unloading 35
Fastening 36
TAILGATE 37
Opening And Closing 37
Adjusting The Latch 37
RIGHT SIDE COVER 39
Opening And Closing 39
SERVICE SCHEDULE 41
Maintenance Intervals 41
AIR CLEANER SERVICE 43
Daily Check 43
Replacing Filter Elements 43
CAB FILTERS (S/N AG3G11001 – AG3G13999 AND AHHC11001 – AHHC12999) 45
Cleaning And Maintenance 45
CAB FILTERS (S/N AG3G14000 & ABOVE, AHHC13000 & ABOVE, B3NM11001 & ABOVE AND B3NR11001 & ABOVE) 47
Cleaning And Maintenance 47
ENGINE COOLING SYSTEM 49
Cleaning 49
Checking Level 50
Removing And Replacing Coolant 51
FUEL SYSTEM 53
Fuel Specifications 53
Biodiesel Blend Fuel 53
Filling The Fuel Tank 54
Fuel Filters 55
Draining The Fuel Tank 55
Removing Air From The Fuel System 56
ENGINE LUBRICATION SYSTEM 57
Checking And Adding Engine Oil 57
Engine Oil Chart 57
Removing And Replacing Oil And Filter 58
HYDRAULIC SYSTEM 59
Checking And Adding Hydraulic Oil 59
Hydraulic / Hydrostatic Fluid Chart 60
Removing And Replacing The Hydraulic Filters 60
Removing And Replacing The Hydraulic Fluid 62
LUBRICATING THE EXCAVATOR (EARLIER MODELS) 65
Lubrication Locations 65
LUBRICATING THE EXCAVATOR (LATER MODELS) 69
Lubrication Locations 69
PIVOT PINS 73
Inspection And Maintenance 73
TRAVEL MOTOR 75
Checking And Adding Oil 75
Removing And Replacing Oil 75
SPARK ARRESTER MUFFLER 77
Cleaning Procedure 77
EMERGENCY EXIT 79
Right Side Rear Window 79
Front Window 79
SEAT BELT 81
Inspection And Maintenance 81
CONTROL CONSOLE LOCKOUTS 83
Inspection And Maintenance 83
TOWING THE EXCAVATOR 85
Procedure 85
REMOTE START TOOL KIT – MEL1563 87
Remote Start Tool – MEL1563 87
Service Tool Harness Communicator – MEL1566 89
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 91
Description 91
Remote Start Tool (Service Tool) – 7022042 92
Excavator Service Tool Harness – 6689747 93
Computer Service Tool Harness – 6689746 94
HYDRAULIC SYSTEM 95
HYDRAULIC / HYDROSTATIC SCHEMATICS 101
HYDRAULIC SYSTEM INFORMATION 109
Glossary Of Hydraulic / Hydrostatic Symbols 109
Troubleshooting The Hydraulic Circuit 112
Troubleshooting The Cylinder Circuit 113
Troubleshooting The Swing (Upperstructure Slew) Circuit 114
Troubleshooting The Travel Circuit 115
CYLINDER (BOOM) (S/N AG3G11007 & ABOVE, AHHC11007 & ABOVE, B3NM11001 & ABOVE AND B3NR11001 & ABOVE) 117
Testing 117
Removal And Installation 119
Parts Identification 122
Disassembly 123
Assembly 126
CYLINDER (BOOM) (S/N AG3G11006 & BELOW, AHHC11006 & BELOW) 131
Testing 131
Removal And Installation 133
Parts Identification 136
Disassembly 137
Assembly 140
CYLINDER (ARM) 145
Testing 145
Removal And Installation 147
Parts Identification 149
Disassembly 150
Assembly 152
CYLINDER (BOOM SWING) 157
Testing 157
Removal And Installation 159
Parts Identification 161
Disassembly 162
Assembly 164
CYLINDER (BUCKET) 167
Testing 167
Removal And Installation 169
Parts Identification 171
Disassembly 172
Assembly 174
CYLINDER (BLADE) 177
Testing 177
Removal And Installation 179
Parts Identification 180
Disassembly 181
Assembly 183
CYLINDER (CLAMP) 187
Testing 187
Removal And Installation 188
Parts Identification 190
Disassembly 191
Assembly 194
CYLINDER (ANGLE BLADE) 199
Testing 199
Removal And Installation 200
Parts Identification 202
Disassembly 203
Assembly 205
CYLINDER (EXTENDABLE ARM) 209
Testing 209
Parts Identification 211
Disassembly 212
Assembly 214
VALVE (MAIN RELIEF) 219
Testing And Adjusting 219
VALVE (PORT RELIEF) 221
Testing And Adjusting Port Relief Valve Pressure 221
VALVE (CROSS PORT RELIEF) 223
Testing 223
Removal And Installation 226
VALVE (PRESSURE REDUCING) 227
Testing And Adjusting 227
HYDRAULIC CONTROL VALVE 229
Description 229
Removal And Installation 229
Parts Identification 233
Disassembly And Assembly 234
Inlet Valve Section Disassembly And Assembly 238
Boom Swing Valve Section Disassembly And Assembly 242
Slew Valve Section Disassembly And Assembly 245
Blade Valve Section Disassembly And Assembly 249
Right And Left Travel Valve Section Disassembly And Assembly 253
Angle Blade, Boom, Auxiliary, Arm And Bucket Valve Section Disassembly And Assembly 255
HYDRAULIC PUMP 259
Hydraulic Pump Work Sheet 259
Pump Testing 262
Removal And Installation 271
Coupler Removal And Installation 272
Hydraulic Pump Startup 273
Torque Limiter Assembly Parts Identification 274
Torque Limiter Assembly Removal And Installation 275
Torque Limiter Valve Assembly Disassembly And Assembly 275
Pump Control Parts Identification 276
Pump Control Removal And Installation 277
Pump Control Disassembly And Assembly 277
Parts Identification 282
Disassembly And Assembly 283
MANIFOLD ASSEMBLY / ACCUMULATOR (WITHOUT ANGLE BLADE) 291
Description 291
Removal And Installation 291
Parts Identification 293
Disassembly And Assembly 294
MANIFOLD ASSEMBLY / ACCUMULATOR (WITH ANGLE BLADE) 301
Description 301
Removal And Installation 301
Parts Identification 303
Disassembly And Assembly 304
TRAVEL MOTOR 311
Removal And Installation 311
Parts Identification Hydraulic Motor 312
Parts Identification Gear Reduction Hub 313
Disassembly 314
Assembly 324
TRAVEL MOTOR (S/N AG3G16000 & ABOVE) 337
Removal And Installation 337
Parts Identification Hydraulic Motor 338
Parts Identification Gear Reduction Hub 339
Disassembly 340
Assembly 348
SWIVEL JOINT 357
Removal And Installation 357
Parts Identification Angle Blade Swivel (S/N AG3G11001 – AG3G14543, AHHC11001 – AHHC13622) 359
Parts Identification Angle Blade Swivel (S/N AG3G14544 – AG3G14767, AHHC13623 & Above) 360
Parts Identification Angle Blade Swivel (S/N AG3G14768 & Above) 361
Parts Identification Straight Blade Swivel (S/N AG3G11001 – AG3G14542, AHHC11001 – AHHC13622) 362
Parts Identification Straight Blade Swivel (S/N AG3G14543 – AG3G14767, AHHC13623 & Above) 363
Parts Identification Straight Blade Swivel (S/N AG3G14768 & Above) 364
Disassembly And Assembly 365
SWING MOTOR 367
Removal And Installation 367
Parts Identification 369
Disassembly And Assembly 370
SWING MOTOR (DRIVE CARRIER) 379
Removal And Installation 379
Parts Identification 380
Disassembly And Assembly 381
CONTROL PATTERN SELECTOR VALVE 387
Removal And Installation 387
Parts Identification 388
Disassembly And Assembly 389
RIGHT CONTROL LEVER (JOYSTICK) (S/N AG3G11001 – AG3G13999 AND AHHC11001 – AHHC12999) 391
Testing 391
Handle Removal And Installation 392
Joystick Assembly Removal And Installation 394
Parts Identification 395
Disassembly 396
Assembly 401
RIGHT CONTROL LEVER (JOYSTICK) (S/N AG3G14001 & ABOVE, AHHC13001 & ABOVE, B3NM11001 & ABOVE AND B3NR11001 & ABOVE) 405
Testing 405
Handle Removal And Installation 406
Joystick Assembly Removal And Installation 408
Parts Identification 409
Disassembly 410
Assembly 414
LEFT CONTROL LEVER (JOYSTICK) (S/N AG3G11001 – AG3G13999 AND AHHC11001 – AHHC12999) 419
Testing 419
Handle Removal And Installation 420
Joystick Assembly Removal And Installation 422
Parts Identification 423
Disassembly 424
Assembly 429
LEFT CONTROL LEVER (JOYSTICK) (S/N AG3G14001 & ABOVE, AHHC13001 & ABOVE, B3NM11001 & ABOVE AND B3NR11001 & ABOVE) 433
Testing 433
Handle Removal And Installation 434
Joystick Assembly Removal And Installation 436
Parts Identification 437
Disassembly 438
Assembly 442
HYDRAULIC FILTER MOUNT 447
Removal And Installation 447
HYDRAULIC RESERVOIR 449
Removal And Installation 449
OIL COOLER 451
Removal And Installation 451
DIRECT TO TANK VALVE 453
Removal And Installation 453
BLADE CONTROL LEVER 455
Handle Removal And Installation 455
Removal And Installation 457
Parts Identification 459
Disassembly And Assembly 460
CASE DRAIN FILTER MOUNT 465
Removal And Installation 465
TRAVEL CONTROL VALVE 467
Removal And Installation 467
Parts Identification 468
Disassembly And Assembly 469
REMOVING AIR FROM THE HYDRAULIC SYSTEM 475
Procedure 475
MANIFOLD (HYDRAULIC X-CHANGE) (EARLIER MODELS) 477
Removal And Installation 477
Parts Identification 478
Disassembly And Assembly 479
MANIFOLD (HYDRAULIC X-CHANGE) (LATER MODELS) 483
Removal And Installation 483
Parts Identification 484
Disassembly And Assembly 485
MANIFOLD (PIN GRABBER) 491
Removal And Installation 491
Parts Identification 492
Disassembly And Assembly 493
SECONDARY AUXILIARY VALVE (EARLIER MODELS) 495
Removal And Installation 495
Parts Identification 497
Disassembly And Assembly 498
SECONDARY AUXILIARY VALVE (LATER MODELS) 503
Removal And Installation 503
Parts Identification 505
Disassembly And Assembly 506
VALVE (BOOM LOCK) 509
Removal And Installation 509
VALVE (ARM LOCK) 511
Removal And Installation 511
UNDERCARRIAGE 513
BLADE 515
Removal And Installation 515
BLADE (ANGLE) 517
Removal And Installation 517
Cutting Edge Removal And Installation 518
TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) 519
Description 519
Track Lug Height 519
Checking Tension 520
Adjusting Tension 521
Track Removal And Installation 523
Idler Removal And Installation 524
Idler Parts Identification 525
Idler Disassembly 526
Idler Assembly 528
Track Tensioner Removal And Installation 531
Track Tensioner Parts Identification 532
Track Tensioner Disassembly And Assembly 533
Roller Removal And Installation 535
Sprocket Removal And Installation 536
TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) 537
Description 537
Checking Tension 538
Adjusting Tension 539
Track Removal 541
Track Installation 543
Idler Removal And Installation 544
Idler Parts Identification 545
Idler Disassembly 546
Idler Assembly 548
Track Tensioner Removal And Installation 551
Track Tensioner Parts Identification 552
Track Tensioner Disassembly And Assembly 553
Roller Removal And Installation 555
Sprocket Removal And Installation 556
Guide Plate Removal And Installation 556
TRACK MAINTENANCE 557
Track Damage Identification 557
SWING CIRCLE GEAR 569
Swing Bearing Removal 569
Swing Bearing Installation 570
UPPERSTRUCTURE AND SWING SECTION 571
UPPERSTRUCTURE 575
Removal 575
Installation 577
ROPS CANOPY 579
Removal And Installation 579
CAB 583
Removal And Installation 583
Door Removal And Installation 586
Front Window Removal And Installation (Earlier Model) 587
Front Window Removal And Installation (Later Model) 588
Front Window Disassembly And Assembly (Later Model) 589
Front Window Adjustment (Later Model) 590
Right Side Rear Sliding Window Removal And Installation 592
Right Side Front Sliding Window Removal And Installation 592
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation 593
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation 593
Glass Removal 593
Glass Installation 594
SEAT 601
Removal And Installation 601
Seat Mount Removal And Installation 602
RIGHT CONSOLE (S/N AG3G11001 – AG3G13999 AND AHHC11001 – AHHC12999) 603
Console Cover Removal And Installation 603
RIGHT CONSOLE (S/N AG3G14000 & ABOVE, AHHC13000 & ABOVE, B3NM11001 & ABOVE AND B3NR11001 & ABOVE) 609
Console Cover Removal And Installation 609
LEFT CONSOLE 615
Lower Console Cover Removal And Installation 615
Upper Console Cover Removal And Installation 616
Compression Spring Removal And Installation 619
Lock Lever Removal And Installation 621
Console Removal And Installation 621
LEFT UPPERSTRUCTURE COVER 623
Removal And Installation 623
RIGHT UPPERSTRUCTURE COVER 625
Removal And Installation 625
COUNTERWEIGHT 627
Removal And Installation 627
Long Arm Counterweight Removal And Installation 630
TRAVEL LEVERS AND PEDALS 631
Removal And Installation 631
Disassembly And Assembly 632
FLOOR MAT 633
Removal And Installation 633
FUEL TANK 635
Removal And Installation (Canopy Equipped Excavator) 635
Removal And Installation (Cab Equipped Excavator) 636
Fuel Tank Fitting Removal And Installation 636
HORN 637
Removal And Installation 637
SWING FRAME 639
Removal And Installation 639
Boom Swing Frame Hose Routing 642
Bushing Removal 643
Bushing Installation 644
BOOM 645
Removal And Installation 645
STANDARD AND LONG ARM 647
Removal And Installation 647
Arm To Boom Bushing Removal And Installation 648
Arm To Bucket And Bucket Link Bushing Removal And Installation 649
ARM (EXTENDABLE) 651
Removal And Installation 651
Arm To Boom Bushing Removal And Installation 652
Arm To Bucket Bushing Removal And Installation 653
Disassembly And Assembly 654
Shimming Procedure 661
BUCKET 663
Bucket Teeth Removal And Installation 663
Bucket Side Cutting Edge Removal And Installation 664
CLAMP 665
Removal And Installation 665
TAILGATE 667
Removal And Installation 667
Latch Removal And Installation 668
X-CHANGE 669
Removal And Installation 669
Disassembly 670
Assembly 671
X-CHANGE (HYDRAULIC) (EARLIER MODELS) 673
Removal And Installation 673
Parts Identification 675
Disassembly 676
Assembly 681
Expansion Plug Installation 689
X-CHANGE (HYDRAULIC) (LATER MODELS) 691
Removal And Installation 691
Parts Identification 693
Disassembly 694
Assembly 700
Expansion Plug Installation 708
QUICK COUPLER (KLAC™ SYSTEM) 709
Troubleshooting 709
Daily Inspection 709
Removal And Installation 710
Parts Identification 712
Disassembly 713
Assembly 715
QUICK COUPLER (LEHNHOFF® SYSTEM) 717
Troubleshooting 717
Daily Inspection 717
Removal (MS03 And MS08) 718
Installation (MS03 And MS08) 719
Parts Identification (MS03) 720
Disassembly And Assembly (MS03) 721
Parts Identification (MS08) 722
Disassembly (MS08) 723
Assembly (MS08) 726
QUICK COUPLER (PIN GRABBER) 731
Troubleshooting 731
Daily Inspection 732
Removal And Installation 733
Parts Identification 734
Disassembly And Assembly 735
RIGHT SIDE COVER (EARLIER MODELS) 737
Removal And Installation 737
Latch Removal And Installation 738
Latch Adjustment 739
RIGHT SIDE COVER (LATER MODELS) 741
Removal And Installation 741
Latch Removal And Installation 742
Latch Adjustment 742
TOOL BOX 745
Removal And Installation 745
ELECTRICAL SYSTEM AND ANALYSIS 747
ELECTRICAL SCHEMATICS 747
ELECTRICAL SYSTEM INFORMATION 762
Troubleshooting Chart 762
Description 763
Fuse And Relay Location / Identification 763
BATTERY 766
Servicing 766
Removing And Installing 767
Using A Booster Battery (Jump Starting) 768
ALTERNATOR 770
Belt Adjustment 770
Belt Replacement 770
Charging System Inspection 772
Alternator Voltage Testing 773
Low Voltage Testing 773
High Voltage Testing 774
Removal And Installation 775
Parts Identification 777
STARTER 778
Testing 778
Removal And Installation 779
Parts Identification 780
LIGHTS 782
Removal And Installation 782
Boom Light Removal And Installation 783
Boom Light Bulb Replacement 783
MAGNETIC LOCKOUT SENSOR 784
Removal And Installation 784
FUEL LEVEL SENDER 786
Removal And Installation 786
Testing 787
DIAGNOSTIC SERVICE CODES (S/N AG3G11001 – AG3G13999 AND AHHC11001 – AHHC12999) 788
Service Codes List 788
DIAGNOSTIC SERVICE CODES (S/N AG3G14000 & ABOVE, AHHC13000 & ABOVE, B3NM11001 & ABOVE AND B3NR11001 & ABOVE) 790
Viewing Service Codes 790
Number Codes List 791
DELUXE INSTRUMENT PANEL SETUP (S/N AG3G11001 – AG3G13999 AND AHHC11001 – AHHC12999) 794
Passwords 794
Password Entry (For Starting And Operating The Machine) 794
Changing The Operator Password 794
Password Lockout Feature 795
Job Clock 795
RPM 795
Maintenance Clock 796
CONTROL PANEL SETUP (S/N AG3G14000 & ABOVE, AHHC13000 & ABOVE, B3NM11001 & ABOVE AND B3NR11001 & ABOVE) 798
Panel Setup (Deluxe Instrument Panel) 798
Password Setup (Keyless Start Panel) 804
Password Lockout Feature 805
Password Setup (Deluxe Instrument Panel) 806
Maintenance Clock 808
INSTRUMENT PANEL / CONTROLLER (S/N AG3G11001 – AG3G13999 AND AHHC11001 – AHHC12999) 810
Removal And Installation 810
INSTRUMENT PANEL (S/N AG3G14000 & ABOVE, AHHC13000 & ABOVE, B3NM11001 & ABOVE AND B3NR11001 & ABOVE) 812
Removal And Installation 812
CONTROLLER (S/N AG3G14000 & ABOVE, AHHC13000 & ABOVE, B3NM11001 & ABOVE AND B3NR11001 & ABOVE) (GATEWAY AND AUXILIARY) 814
Description 814
Gateway Controller Removal And Installation 814
Auxiliary Controller Removal And Installation 815
KEY SWITCH 816
Removal And Installation 816
WIPER MOTOR 818
Removal And Installation 818
MOTION ALARM SYSTEM 820
Description 820
Inspecting 820
Adjusting Switch Position 821
SERVICE PC (LAPTOP COMPUTER) 822
Connecting The Remote Start Tool 822
Connecting Remote Start Tool (Service Tool) 822
Operation 823
SHUT-OFF SWITCH 824
Description 824
Removal And Installation 825
TRAVEL MOTOR AUTO-SHIFT 828
Auto-Shift Drive System (If Equipped) 828
Troubleshooting 829
AUTO IDLE PRESSURE SENSOR 832
Description 832
Removal And Installation 833
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS 834
Description 834
Controller Removal And Installation 834
Antenna Removal And Installation 836
Procedure 838
ENGINE SERVICE 840
ENGINE INFORMATION 844
Description 844
Specifications 845
Crankshaft Re-Grind Data 851
Torque For Kubota® Metric Bolts 852
Troubleshooting 853
Removal And Installation 854
Compression Checking 863
ENGINE SPEED CONTROL 864
Removal And Installation 864
Auto Idle Description 865
Auto Idle Controller Removal And Installation 866
Calibration 867
Actuator Removal And Installation (Earlier Model) 870
Actuator Removal And Installation (Later Model) 873
MUFFLER 874
Removal And Installation 874
AIR CLEANER 876
Housing Removal And Installation 876
ENGINE COOLING SYSTEM 878
Radiator Removal And Installation 878
Fan Removal And Installation 882
Water Pump Removal And Installation 883
Water Pump Disassembly And Assembly 883
Thermostat Housing Removal And Installation 884
Thermostat – Checking 884
LUBRICATION SYSTEM 886
Oil Pan Removal And Installation 886
Oil Pump Removal And Installation 887
Oil Pump Inspection 887
Engine Oil Pressure – Testing 888
FUEL SYSTEM 890
Fuel Shutoff Solenoid – Checking 890
Fuel Shut-off Solenoid Removal And Installation 891
Fuel Injection Pump – Checking 892
Fuel Injection Pump Removal And Installation 893
Fuel Injection Pump – Timing 896
Fuel Camshaft Removal And Installation 898
Fuel Camshaft Governor 899
Fuel Injector Removal And Installation 900
Fuel Injector Nozzle Pressure – Checking 902
Nozzle Spray Condition 903
Valve Seat Tightness 903
CYLINDER HEAD 904
Glow Plugs – Testing 904
Glow Plugs Removal And Installation 905
Valve Clearance Adjustment 906
Valve Timing – Checking 906
Cylinder Head Removal And Installation 907
Cylinder Head Disassembly And Assembly 910
Cylinder Head – Servicing 911
Cylinder Head Top Clearance 911
Valve Guide – Checking 912
Valve Guide Removal And Installation 913
Reconditioning The Valve And Valve Seat 914
Valve Spring 915
Valve Tappets 916
Rocker Arm And Shaft – Checking 917
Push Rod Alignment – Checking 917
CRANKSHAFT AND PISTONS 918
Piston And Connecting Rod Removal And Installation 918
Piston And Connecting Rod – Servicing 920
Cylinder Bore – Checking 922
Connecting Rod Alignment 923
Crankshaft Gear Removal And Installation 924
Crankshaft And Bearings Removal And Installation 925
Crankshaft And Bearings – Servicing 928
CAMSHAFT AND TIMING GEARS 932
Timing Gearcase Cover Removal And Installation 932
Timing Gears Backlash – Checking 935
Idle Gear And Camshaft Removal And Installation 936
Camshaft – Servicing 938
Idle Gear And Shaft – Servicing 939
FLYWHEEL AND HOUSING 940
Hydraulic Pump Coupler Removal And Installation 940
Flywheel Removal And Installation 942
Flywheel Ring Gear 942
FLYWHEEL RPM SENSOR 944
Description 944
Removal 944
Installation 944
HEATING, VENTILATION AND AIR CONDITIONING S/N AG3G11001 – AG3G13999 AND AHHC11001 – AHHC12999 946
AIR CONDITIONING SYSTEM FLOW 948
Description 948
Chart 949
Components 950
Safety Equipment 954
REGULAR MAINTENANCE 956
Cab Filters 956
Air Conditioning Compressor Belt Adjustment 957
Air Conditioning Compressor Belt Replacement 957
Condenser 958
Air Conditioning Lubrication 958
Evaporator / Heater Coil 958
Air Conditioning Service Chart 959
TROUBLESHOOTING 960
Blower Motor Does Not Operate 960
Blower Motor Operates Normally, But Air Flow Is Insufficient 960
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 960
The Compressor Operates Improperly Or Not At All 960
Gauge Pressure Related Troubleshooting 961
Temperature / Pressure Chart 962
Poor A/C Performance 963
HVAC Repair And Leaks 963
Electrical System 964
Engine Coolant Bypassing The Heater Valve 966
SYSTEM CHARGING AND RECLAMATION 968
Refrigerant Identification 968
Reclamation And Charging With Recovery / Charging Unit 970
COMPRESSOR 972
Removal And Installation 972
Oil 974
Oil Check 975
CONDENSER 978
Removal And Installation 978
RECEIVER / DRIER 980
Receiver / Drier Removal And Installation 980
Pressure Relief Valve Removal And Installation 981
Pressure Switch Removal And Installation 981
EVAPORATOR / HEATER UNIT 982
Removal And Installation 982
THERMOSTAT 984
Description 984
Removal And Installation 985
EXPANSION VALVE 988
Removal And Installation 988
EVAPORATOR COIL 990
Removal And Installation 990
HEATER COIL 992
Removal And Installation 992
BLOWER FAN 994
Removal And Installation 994
HEATER VALVE 996
Removal And Installation 996
HVAC DUCT 998
Removal And Installation 998
HEATING, VENTILATION AND AIR CONDITIONING S/N AG3G14000 & ABOVE, AHHC13000 & ABOVE, B3NM11001 & ABOVE AND B3NR11001 & ABOVE 1000
AIR CONDITIONING SYSTEM FLOW 1002
Description 1002
Chart 1003
Components 1004
Safety Equipment 1008
REGULAR MAINTENANCE 1010
Cab Filters 1010
Air Conditioning Compressor Belt Adjustment 1011
Air Conditioning Compressor Belt Replacement 1011
Condenser 1012
Air Conditioning Lubrication 1012
Evaporator / Heater Coil 1012
Air Conditioning Service Chart 1014
TROUBLESHOOTING 1016
Blower Motor Does Not Operate 1016
Blower Motor Operates Normally, But Air Flow Is Insufficient 1016
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 1016
The Compressor Operates Improperly Or Not At All 1016
Gauge Pressure Related Troubleshooting 1017
Temperature / Pressure Chart 1018
Poor A/C Performance 1019
HVAC Repair And Leaks 1019
Electrical System 1020
Engine Coolant Bypassing The Heater Valve 1022
SYSTEM CHARGING AND RECLAMATION 1024
Refrigerant Identification 1024
Reclamation And Charging With Recovery / Charging Unit 1026
COMPRESSOR 1028
Removal And Installation 1028
Oil 1030
Oil Check 1031
CONDENSER 1034
Removal And Installation 1034
RECEIVER / DRIER 1036
Receiver / Drier Removal And Installation 1036
Pressure Relief Valve Removal And Installation 1037
Pressure Switch Removal And Installation 1037
EVAPORATOR / HEATER UNIT 1038
Removal And Installation 1038
THERMOSTAT 1040
Description 1040
Removal And Installation 1041
EXPANSION VALVE 1044
Removal And Installation 1044
EVAPORATOR COIL 1046
Removal And Installation 1046
HEATER COIL 1048
Removal And Installation 1048
BLOWER FAN 1050
Removal And Installation 1050
HEATER VALVE 1052
Removal And Installation 1052
HVAC DUCT 1054
Removal And Installation 1054
SPECIFICATIONS 1056
EXCAVATOR SPECIFICATIONS 1058
Machine Dimensions 1058
Machine Dimensions (Standard Arm) 1059
Machine Dimensions (Long Arm) 1060
Machine Dimensions (Extendable Arm) 1061
Machine Dimensions (Angle Blade) 1062
Rated Lift Capacity (Standard Arm) 1063
Rated Lift Capacity (Standard Arm With Additional Counterweight) 1064
Rated Lift Capacity (Long Arm) 1065
Rated Lift Capacity (Extendable Arm) 1066
Performance 1067
Controls 1067
Engine 1068
Hydraulic System 1069
Hydraulic Cylinders 1070
Hydraulic Cycle Times 1070
Drive System 1070
Slew System 1070
Undercarriage 1070
Electrical 1071
Capacities 1071
Tracks 1071
Ground Pressure 1072
TORQUE SPECIFICATION FOR BOLTS 1074
Torque For General SAE Bolts 1074
Torque For General Metric Bolts 1075
HYDRAULIC CONNECTION SPECIFICATIONS 1076
O-ring Face Seal Connection 1076
Straight Thread O-ring Fitting 1076
Tubelines And Hoses 1077
Flare Fitting 1077
O-ring Flare Fitting 1078
Port Seal Fitting 1080
Push To Connect Fittings 1081
HYDRAULIC FLUID SPECIFICATIONS 1084
Specifications 1084
CONVERSIONS 1086
Decimal And Millimeter Equivalent Chart 1086
U S To Metric Conversion Chart 1087
SERVICE TOOLS REQUIRED 1088
Remote Start Tools 1088
Hydraulic Tools 1089
Engine Tools 1092
Electrical Tools 1094
General Tools 1094
HVAC Tools 1095
ALPHABETICAL INDEX 1096
SERVICE SCHEDULE SYMBOLS 1100

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.M