A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• MAINTENANCE SAFETY
• CONTENTS
• FOREWORD
• FOREWORD
• SAFETY INSTRUCTIONS
• FIRE PREVENTION
• Maintenance
• Operation
• Electrical
• Hydraulic System
• Fueling
• Starting
• Spark Arrestor Exhaust System
• Welding And Grinding
• Fire Extinguishers
• SERIAL NUMBER LOCATIONS
• Excavator Serial Number
• Engine Serial Number
• DELIVERY REPORT
• EXCAVATOR IDENTIFICATION
• SAFETY & MAINTENANCE
• LIFTING AND BLOCKING THE EXCAVATOR
• Procedure
• LIFTING THE EXCAVATOR
• Procedure
• OPERATOR CAB (ROPS / TOPS)
• Emergency Exit
• Cab Door
• Front Window
• Front Wiper
• Window Washer Reservoir
• Right Side Window
• TRANSPORTING THE EXCAVATOR ON A TRAILER
• Loading And Unloading
• Fastening
• TAILGATE
• Opening And Closing
• Adjusting The Latch
• RIGHT SIDE COVER
• Opening And Closing
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Daily Check
• Replacing The Filters
• CAB FILTERS
• Cleaning And Maintenance
• ENGINE COOLING SYSTEM
• Cleaning
• Checking Level
• Removing And Replacing Coolant
• FUEL SYSTEM
• Fuel Specifications
• Biodiesel Blend Fuel
• Filling The Fuel Tank
• Fuel Filters
• Draining The Fuel Tank
• Removing Air From The Fuel System
• ENGINE LUBRICATION SYSTEM
• Checking And Adding Engine Oil
• Engine Oil Chart
• Removing And Replacing Oil And Filter
• HYDRAULIC SYSTEM
• Checking And Adding Hydraulic Fluid
• Hydraulic / Hydrostatic Fluid Chart
• Removing And Replacing Hydraulic Filters
• Removing And Replacing Hydraulic Fluid
• LUBRICATION OF THE HYDRAULIC EXCAVATOR
• Lubrication Locations
• PIVOT PINS
• Inspection And Maintenance
• TRAVEL MOTOR
• Checking And Adding Oil
• Removing And Replacing Oil
• SPARK ARRESTOR MUFFLER
• Cleaning Procedure
• ALTERNATOR BELT
• Belt Adjustment
• Belt Replacement
• AIR CONDITIONING COMPRESSOR BELT
• Belt Adjustment
• Belt Replacement
• SEAT BELT
• Inspection And Maintenance
• CONTROL CONSOLE LOCKOUTS
• Inspection And Maintenance
• TOWING THE EXCAVATOR
• Procedure
• REMOTE START TOOL KIT – MEL1563
• Remote Start Tool – MEL1563
• Service Tool Harness Control – MEL1565
• Service Tool Harness Communicator – MEL1566
• REMOTE START TOOL (SERVICE TOOL) KIT – 7003031
• Description
• Remote Start Tool (Service Tool) – 7003030
• Excavator Service Tool Harness – 6689747
• Computer Service Tool Harness – 6689746
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATIC
• HYDRAULIC SYSTEM INFORMATION
• Glossary Of Hydraulic / Hydrostatic Symbols
• Troubleshooting The Hydraulic Circuit
• Troubleshooting The Cylinder Circuit
• Troubleshooting The Swing (Upperstructure Slew) Circuit
• Troubleshooting The Travel Circuit
• CYLINDER (BOOM) (S/N AG3G11007 & ABOVE, AHHC11006 & ABOVE)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (BOOM) (S/N AG3G11006 & BELOW, AHHC11006 & BELOW)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (ARM)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (BOOM SWING)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (BUCKET)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (BLADE)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (CLAMP)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• CYLINDER (ANGLE BLADE)
• Testing
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• VALVE (MAIN RELIEF)
• Testing And Adjusting
• VALVES (PORT RELIEF)
• Testing And Adjusting Port Relief Valve Pressure
• VALVES (CROSS PORT RELIEF)
• Testing
• Removal And Installation
• VALVE (PRESSURE REDUCING)
• Testing And Adjusting
• HYDRAULIC CONTROL VALVE
• Description
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• Inlet Valve Section Disassembly And Assembly
• Boom Swing Valve Section Disassembly And Assembly
• Slew Valve Section Disassembly And Assembly
• Blade Valve Section Disassembly And Assembly
• Right And Left Travel Valve Section Disassembly And Assembly
• Angle Blade, Boom, Auxiliary, Arm and Bucket Valve Section Disassembly And Assembly
• HYDRAULIC PUMP
• Hydraulic Pump Work Sheet
• Pump Testing
• Removal And Installation
• Coupler Removal And Installation
• Hydraulic Pump Startup
• Torque Limiter Assembly Parts Identification
• Torque Limiter Assembly Removal And Installation
• Torque Limiter Valve Assembly Disassembly And Assembly
• Pump Control Parts Identification
• Pump Control Removal And Installation
• Pump Control Disassembly And Assembly
• Parts Identification
• Disassembly And Assembly
• MANIFOLD ASSEMBLY / ACCUMULATOR (WITHOUT ANGLE BLADE)
• Description
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• MANIFOLD ASSEMBLY / ACCUMULATOR (WITH ANGLE BLADE)
• Description
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• TRAVEL MOTOR
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• SWIVEL JOINT
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• SWING MOTOR
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• SWING MOTOR (DRIVE CARRIER)
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• CONTROL PATTERN SELECTOR VALVE
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• RIGHT CONTROL LEVER (JOYSTICK)
• Testing
• Handle Removal And Installation
• Joystick Assembly Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• LEFT CONTROL LEVER (JOYSTICK)
• Testing
• Handle Removal And Installation
• Joystick Assembly Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• HYDRAULIC FILTER MOUNT
• Removal And Installation
• HYDRAULIC RESERVOIR
• Removal And Installation
• OIL COOLER
• Removal And Installation
• DIRECT TO TANK VALVE
• Removal And Installation
• BLADE CONTROL LEVER
• Handle Removal And Installation
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• CASE DRAIN FILTER MOUNT
• Removal And Installation
• TRAVEL CONTROL VALVE
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• REMOVING AIR FROM THE HYDRAULIC SYSTEM
• Procedure
• HYDRAULIC X-CHANGE MANIFOLD
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• SECONDARY AUXILIARY VALVE
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• VALVE (BOOM LOCK) (S/N AHHC11001 & ABOVE)
• Removal And Installation
• VALVE (ARM LOCK) (S/N AHHC11001 & ABOVE)
• Removal And Installation
• UNDERCARRIAGE
• BLADE
• Removal And Installation
• BLADE (ANGLE)
• Removal And Installation
• Cutting Edge Removal And Installation
• TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK)
• Description
• Track Lug Height
• Checking Tension
• Adjusting Tension
• Track Removal And Installation
• Idler Removal And Installation
• Idler Parts Identification
• Track Idler Disassembly
• Track Idler Assembly
• Track Tensioner Removal And Installation
• Track Tensioner Cylinder Parts Identification
• Track Tensioner Disassembly And Assembly
• Roller Removal And Installation
• Sprocket Removal And Installation
• TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK)
• Description
• Checking Tension
• Adjusting Tension
• Track Removal And Installation
• Steel Track Installation
• Idler Removal And Installation
• Idler Parts Identification
• Track Idler Disassembly
• Track Idler Assembly
• Track Tensioner Disassembly And Assembly
• Track Tensioner Cylinder Parts Identification
• Track Tensioner Disassembly And Assembly
• Roller Removal And Installation
• Sprocket Removal And Installation
• Guide Plate Removal And Installation
• TRACK MAINTENANCE
• Track Damage Identification
• SWING CIRCLE GEAR
• Swing Bearing Removal
• Swing Bearing Installation
• UPPERSTRUCTURE AND SWING SECTION
• UPPERSTRUCTURE
• Removal
• Installation
• ROPS CANOPY
• Removal And Installation
• CAB
• Removal And Installation
• Door Removal And Installation
• Front Window Removal And Installation
• Right Side Rear Sliding Window Removal And Installation
• Right Side Front Sliding Window Removal And Installation
• Right Side Front And Rear Sliding Window Weather Strip Removal And Installation
• Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation
• Glass Removal
• Glass Installation
• SEAT
• Removal And Installation
• Seat Mount Removal And Installation
• RIGHT CONSOLE
• Console Cover Removal And Installation
• LEFT CONSOLE
• Lower Console Cover Removal And Installation
• Upper Console Cover Removal And Installation
• Compression Spring Removal And Installation
• Lock Lever Removal And Installation
• Console Removal And Installation
• LEFT UPPERSTRUCTURE COVER
• Removal And Installation
• RIGHT UPPERSTRUCTURE COVER
• Removal And Installation
• COUNTERWEIGHT
• Removal And Installation
• Long Arm Counterweight Removal And Installation
• TRAVEL LEVERS AND PEDALS
• Removal And Installation
• Disassembly And Assembly
• FLOOR MAT
• Removal And Installation
• FUEL TANK
• Removal And Installation (Canopy Equipped Excavator)
• Removal And Installation (Cab Equipped Excavator)
• HORN
• Removal And Installation
• SWING FRAME
• Removal And Installation
• Boom Swing Frame Hose Routing
• Bushing Removal
• Bushing Installation
• BOOM
• Removal And Installation
• STANDARD AND LONG ARM
• Removal And Installation
• Arm To Boom Bushing Removal And Installation
• Arm To Bucket And Bucket Link Bushing Removal And Installation
• BUCKET
• Bucket Teeth Removal And Installation
• Bucket Side Cutting Edge Removal And Installation
• CLAMP
• Removal And Installation
• TAILGATE
• Removal And Installation
• Latch Removal And Installation
• X-CHANGE
• Removal And Installation
• Disassembly
• Assembly
• X-CHANGE (HYDRAULIC)
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• RIGHT SIDE COVER
• Removal And Installation
• Latch Removal And Installation
• Latch Adjustment
• TOOL BOX
• Removal And Installation
• ELECTRICAL SYSTEM & ANALYSIS
• ELECTRICAL SCHEMATICS
• ELECTRICAL SYSTEM INFORMATION
• Troubleshooting Chart
• Description
• Fuse And Relay Location / Identification
• BATTERY
• Servicing
• Removal And Installation
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Belt Adjustment
• Belt Replacement
• Charging System Inspection
• Alternator Voltage Testing
• Low Voltage Testing
• High Voltage Testing
• Removal And Installation
• Parts Identification
• STARTER
• Testing
• Removal And Installation
• Parts Identification
• LIGHTS
• Removal And Installation
• Boom Light Removal And Installation
• Boom Light Bulb Replacement
• MAGNETIC LOCKOUT SENSOR
• Removal And Installation
• FUEL LEVEL SENDER
• Removal And Installation
• Testing
• DIAGNOSTICS SERVICE CODES
• Number Codes List
• DELUXE INSTRUMENT PANEL SETUP
• Passwords
• Password Entry (For Starting And Operating The Machine)
• Changing The Operator Password
• Password Lockout Feature
• Job Clock
• RPM
• INSTRUMENT PANEL / CONTROLLER
• Removal And Installation
• KEY SWITCH
• Removal And Installation
• WIPER MOTOR
• Removal And Installation
• MOTION ALARM SYSTEM (IF EQUIPPED)
• Description
• Inspecting
• Adjusting Switch Position
• SERVICE PC (LAPTOP COMPUTER)
• Connecting The Remote Start Tool
• Connecting Remote Start Tool (Service Tool)
• Operation
• SHUT-OFF SWITCH
• Description
• Removal And Installation
• ENGINE SERVICE
• ENGINE INFORMATION
• Description
• Specifications
• Crankshaft Re-Grind Data
• Torque For Kubota Metric Bolts
• Troubleshooting
• Removal And Installation
• Compression Checking
• ENGINE SPEED CONTROL
• Removal And Installation
• Auto Idle Controller Removal And Installation
• Calibration
• Actuator Removal And Installation
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Housing Removal And Installation
• ENGINE COOLING SYSTEM
• Radiator Removal And Installation
• Fan Removal And Installation
• Water Pump Removal And Installation
• Water Pump Disassembly And Assembly
• Thermostat Housing Removal And Installation
• Thermostat – Checking
• LUBRICATION SYSTEM
• Oil Pan Removal And Installation
• Oil Pump Removal And Installation
• Oil Pump Inspection
• Engine Oil Pressure – Testing
• FUEL SYSTEM
• Fuel Shutoff Solenoid – Checking
• Fuel Shut-off Solenoid Removal And Installation
• Fuel Injection Pump – Checking
• Fuel Injection Pump Removal And Installation
• Fuel Injection Pump – Timing
• Fuel Camshaft Removal And Installation
• Fuel Camshaft Governor
• Fuel Injector Removal And Installation
• Fuel Injector Nozzle Pressure – Checking
• Nozzle Spray Condition
• Valve Seat Tightness
• CYLINDER HEAD
• Glow Plugs – Testing
• Glow Plugs Removal And Installation
• Valve Clearance Adjustment
• Valve Timing – Checking
• Cylinder Head Removal And Installation
• Cylinder Head Disassembly And Assembly
• Cylinder Head – Servicing
• Cylinder Head Top Clearance
• Valve Guide – Checking
• Valve Guide Removal And Installation
• Reconditioning The Valve And Valve Seat
• Valve Spring
• Valve Tappets
• Rocker Arm And Shaft – Checking
• Push Rod Alignment – Checking
• CRANKSHAFT AND PISTONS
• Piston And Connecting Rod Removal And Installation
• Piston And Connecting Rod – Servicing
• Cylinder Bore – Checking
• Connecting Rod Alignment
• Crankshaft Gear Removal And Installation
• Crankshaft And Bearings Removal And Installation
• Crankshaft And Bearings – Servicing
• CAMSHAFT AND TIMING GEARS
• Timing Gearcase Cover Removal And Installation
• Timing Gears Backlash – Checking
• Idle Gear And Camshaft Removal And Installation
• Camshaft – Servicing
• Idle Gear And Shaft – Servicing
• FLYWHEEL AND HOUSING
• Hydraulic Pump Coupler Removal And Installation
• Flywheel Removal And Installation
• Flywheel Ring Gear
• HEATING, VENTILATION & AIR CONDITIONING
• AIR CONDITIONING SYSTEM FLOW
• Description
• Chart
• Components
• Safety Equipment
• REGULAR MAINTENANCE
• Cab Filters
• Air Conditioning Compressor Belt Adjustment
• Air Conditioning Compressor Belt Replacement
• Condenser
• Air Conditioning Lubrication
• Evaporator / Heater Coil
• Air Conditioning Service Chart
• TROUBLESHOOTING
• Blower Motor Does Not Operate
• Blower Motor Operates Normally, But Air Flow Is Insufficient
• Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
• The Compressor Operates Improperly Or Not At All
• Gauge Pressure Related Troubleshooting
• Temperature / Pressure Chart
• Poor A/C Performance
• HVAC Repair And Leaks
• Electrical System
• Engine Coolant Bypassing The Heater Valve
• SYSTEM CHARGING AND RECLAMATION
• Refrigerant Identification
• Reclamation And Charging With Recovery / Charging Unit
• COMPRESSOR
• Removal And Installation
• Oil
• Oil Check
• CONDENSER
• Removal And Installation
• RECEIVER / DRIER
• Receiver / Drier Removal And Installation
• Pressure Relief Valve Removal And Installation
• Pressure Switch Removal And Installation
• EVAPORATOR / HEATER UNIT
• Removal And Installation
• THERMOSTAT
• Description
• Removal And Installation
• EXPANSION VALVE
• Removal And Installation
• EVAPORATOR COIL
• Removal And Installation
• HEATER COIL
• Removal And Installation
• BLOWER FAN
• Removal And Installation
• HEATER VALVE
• Removal And Installation
• HVAC DUCT
• Removal And Installation
• SPECIFICATIONS
• E45 EXCAVATOR SPECIFICATIONS
• Machine Dimensions
• Machine Dimensions – Standard Arm
• Machine Dimensions – Long Arm
• Machine Dimensions – Angle Blade
• Performance
• Controls
• Engine
• Hydraulic System
• Hydraulic Cylinders
• Hydraulic Cycle Times
• Electrical
• Drive System
• Slew System
• Undercarriage
• Capacities
• Tracks
• Ground Pressure
• TORQUE SPECIFICATION FOR BOLTS
• Torque For General SAE Bolts
• Torque For General Metric Bolts
• HYDRAULIC CONNECTION SPECIFICATIONS
• O-ring Face Seal Connection
• Straight Thread O-ring Fitting
• Tubelines And Hoses
• Flare Fitting
• O-ring Flare Fitting
• Port Seal Fitting
• Push To Connect Fittings
• HYDRAULIC FLUID SPECIFICATIONS
• Specifications
• CONVERSIONS
• Decimal And Millimeter Equivalent Chart
• U.S. To Metric Conversion Chart
• ALPHABETICAL INDEX
• SERVICE MANUAL REVISION
• Revision No: E45 – 1