Putting a short-radius excavator back to work is what these 666 pages are for. The Fiat Kobelco E40SR Evolution, E45SR Evolution shop manual PDF (OEM #604.13.251.00) covers hydraulic circuit operation for travel, slew, and bucket functions, full electric circuit diagrams with harness and cable lists, and teardown procedures for the pump, pilot valve, control valve, slewing motor, travel motor, and swivel joint. Troubleshooting charts walk you from symptom to cause across the hydraulic, electrical, and engine systems. Torque the ATT pilot valve lever lock nut to 4.2 kgf-m (plus or minus 0.3), and check boom foot pin clearance against the 0.020 to 0.111 mm standard, with 1.0 mm the service limit, before you condemn a bushing. Chasing slew drift with a pressure gauge and a hunch gets old fast. Bookmarked by chapter with a live text layer: type the spec, hit enter, get wrenching.
What's Inside This Fiat Kobelco E40SR EVOLUTION, E45SR EVOLUTION Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 1-7 | To the Reader, Additional Reference Manuals, Avoid Accidents, Safety Precautions |
| Preliminary Remarks | 8-14 | General Precautions for Repairs, Escaping Procedure, International Unit Conversion System |
| Specifications | 15-35 | Machine Dimensions, Specifications and Performance, Machine and Components Weight, Engine Specifications |
| Attachment Dimensions | 36-52 | Boom Dimension, Arm Dimension, Bucket Dimension, Dozer Dimension, Swing Bracket Dimension |
| Tools | 53-60 | Torque Specifications, Special Spanners for Tubes, Counterweight Lifting Jig |
| Standard Maintenance Time Table | 61-67 | Standard Working Time Table, Classification of Work Code, Maintenance Time Calculation |
| Maintenance Standards and Tests Procedures | 68-84 | Performance Inspection Standard Table, Hydraulic Oil Pressure, Travel Performances, Slew Performances, Crawler Tension |
| Hydraulic System | 85-111 | Hydraulic Circuit Operation, Travel Operating Circuit, Slew Operating Circuit, Bucket Operating Circuit, Schematic Piping |
| Electrical System | 112-150 | Electric Circuit Diagram, Electrical Equipment List, Harness and Cable List, Components and Harness Arrangement |
| Components System | 151-241 | Hydraulic Pump, Pilot Valve, Control Valve, Slewing Motor, Travel Motor, Swivel Joint, Cylinder |
| Whole Disassembly and Assembly | 242-243 | Explaining Chapter of Whole Disassembly & Assembly, Indication of Tightening Torque |
| Attachments | 244-271 | Removal and Installation of Bucket, Arm, Boom, Swing, Dozer, Cylinder Construction |
| Upper Slewing Structure | 272-415 | Removal and Installation of Canopy/Cab, Counterweight, Fuel Tank, Hydraulic Tank, Engine, Control Valve, Slewing Motor |
| Travel System | 416-506 | Crawler Removal and Installation, Upper Roller, Lower Roller, Front Idler, Travel Motor Disassembly and Assembly |
| Troubleshooting (Hydraulic System) | 507-515 | Trouble Diagnosis, Attachment Operational Failure, Travel Operational Error, Slewing Operational Failure |
| Troubleshooting (Electrical System) | 516-526 | Trouble Diagnosis, Engine Does Not Start, Horn Does Not Sound, Working Light Does Not Light Up |
| Troubleshooting (Engine) | 527-534 | Trouble Diagnosis, Starting Trouble, Rotation Trouble, Output Drops Down, Exhaust Trouble |
| Engine | 535-666 | Engine Specifications, Cooling Water, Lubricating Oil, Fuel Oil, Disassembly and Reassembly, Turbocharger |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Standard clearance for boom foot pin and bushing | 0.020 - 0.111 mm | p. 38 |
| Standard clearance for boom cylinder (head side) pin and bushing | 0.070 - 0.330 mm | p. 38 |
| Pilot valve (ATT) lever lock nut tightening torque | 4.2 ± 0.3 kgf·m | p. 165 |
| Pilot valve (ATT) 6-PF1/4 port fitting torque | 3.0 ± 0.2 kgf·m | p. 165 |
| Swivel joint tightening torque | 4.75 kgf·m (34.4 lbf·ft) | p. 214 |
| E40SR | ||
| Hydraulic pump weight | 35 kg (77 lb) | p. 153 |
| Output torque 1st (E40SR) | 441 kgf·m (3,190 lbf·ft) | p. 199 |
| Output torque 2nd (E40SR) | 242 kgf·m (1,750 lbf·ft) | p. 199 |
| E40SR EVOLUTION | ||
| Hydraulic Pressure (Main Relief P1, P2) | 230 kgf/cm2 | p. 70 |
| E45SR EVOLUTION | ||
| Hydraulic Pressure (Main Relief P1, P2) | 230 kgf/cm2 | p. 72 |
Fiat Kobelco E40SR EVOLUTION, E45SR EVOLUTION Common Problems This Manual Covers
Machine travels weakly, drifts to one side, one track barely pulls
Test P1 and P2 pump pressures against the 230 kgf/cm2 (3270 psi) working pressure spec on page 153, then follow the travel operational error chart starting on page 512. Verify pilot delivery pressure holds 35 kgf/cm2 (500 psi), listed on page 510. If pressures pass, inspect the swivel joint seals and the travel control valve spool for wear or sticking.
Manual Section: Troubleshooting (Hydraulic System) p. 512Boom and arm movements slow and weak, digging power drops under load
Check pilot pressure first; the pilot pump should deliver 35 kgf/cm2 (500 psi), spec on page 510. Low pilot pressure keeps the main spools from stroking fully. Work through the attachment operational failure chart starting on page 509, then test main relief against 230 kgf/cm2 (3270 psi). If pressures check out, inspect the pump control piston and the control valve spools for sticking.
Manual Section: Troubleshooting (Hydraulic System) p. 509Hydraulic pump makes loud whining or knocking noise, delivery pressure drops, all functions weak
Suspect cavitation first: check hydraulic oil level and inspect the suction line for collapse or air leaks at the fittings. Verify piston pump output against the 230 kgf/cm2 (3270 psi) working pressure on page 153. Then run the pump failure diagnosis on page 509. Steady pressure loss with noise usually means internal wear, so plan on control piston or pump replacement.
Manual Section: Troubleshooting (Hydraulic System) p. 509Engine hard to start, blows black or white smoke, power falls off under load
Drain a fuel sample and check for water or contamination before anything else; bad fuel causes most of these complaints. Follow the starting trouble and exhaust trouble charts beginning on page 527. Measure valve clearance and set intake and exhaust to 0.15-0.25 mm, spec on page 566. If smoke continues, have the injectors pop-tested and check compression.
Manual Section: Troubleshooting (Engine) p. 527Upper structure slews slowly, jerks, or makes grinding noise during rotation
Grease the slewing bearing first; it takes 180 g (6.3 oz), spec on page 450, and a dry bearing grinds and binds. Check bearing play with the attachment raised. Then work the slewing operational failure chart starting on page 515. If pressure and pilot signals test good, pull the slewing motor and inspect it for internal wear.
Manual Section: Troubleshooting (Hydraulic System) p. 515Frequently Asked Questions
What are the torque specifications for the track roller bolts on the Fiat Kobelco E40SR Evolution?
The tightening torque for the lower roller capscrews (2) on the E40SR Evolution is 28.5 kgf·m (206 lbf·ft). p. 430
What is the standard valve clearance for the engine on the E40SR and E45SR Evolution?
The standard intake and exhaust valve clearance for all models is 0.15 to 0.25 mm when the engine is in a cold state. p. 566
What is the standard engine oil capacity for the E40SR Evolution?
The engine oil volume for the E40SR Evolution is 5.8 liters for the maximum capacity and 2.3 liters for the effective capacity. p. 32
What is the standard tightening torque for the cylinder head bolts on the 4TNE84 and 4TNE88 engines?
The tightening torque for the cylinder head bolts on the 4TNE84 and 4TNE88 engines is 8.7 to 9.3 kgf·m (M10 x 1.25), with lubricating oil applied. p. 621
What is the standard fuel tank capacity for the E40SR and E45SR Evolution?
The fuel tank capacity for the E40SR and E45SR Evolution is 50 liters (13.2 gallons). p. 290
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