Gehl Z45 450Z Compact Excavator Service Manual – PDF DOWNLOAD

Gehl Z45 450Z Compact Excavator Service Manual – PDF DOWNLOAD

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Gehl Z45 450Z Compact Excavator Service Manual – PDF DOWNLOAD

Language : English
Pages : 584
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File Type : PDF
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Gehl Z45 450Z Compact Excavator Service Manual – PDF DOWNLOAD

1-2 Safety Precautions
(1) Never attempt servicing while engine is running or immediately after stopping operation.
(2) Wear work cloths, safety shoes and helmet.
(3) Check the equipment and tools before use. Especially, be sure to check the crane, lifting equipment and tools.
(4) When working together with other persons, allocate everyone’s share of job, arrange the signals and act in concert
with the other persons.
(5) The operation of the crane and slinging work must be performed by qualified persons.
(6) Do not enter or pass under the raised load.
(7) Lift and support the massive parts by crane before removing the installation bolts.
(8) Disconnect cables from battery before repairing the electric system.
(9) Remove the battery when welding the machine.
1-3 Preparations
(1) Check the service record of the machine. (That is, check how many months or hours the machine has been
used since the preceding overhaul, what was the trouble then and what parts were replaced.)
(2) Have all servicing tools ready, i.e., tools, measuring devices (which have received periodic maintenance), containers,
oil & grease, etc.
(3) Have the service literature (operation manual, parts catalog, etc.) ready.

TABLE OF CONTENTS:

Gehl Z45 450Z Compact Excavator Service Manual – PDF DOWNLOAD

CHAPTER 1
General Cautions for Maintenance Work
1-1 Correct Work 1-1
1-2 Safety Precautions 1-2
1-3 Preparations 1-1
1-4 Cautions for Disassembly and Reassembly 1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment 1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping 1-2
1-7 Cautions for Handling Seals 1-3
1-8 Correct Installation of Hydraulic Hose 1-3
1-9 Specifications of Hydraulic Hose 1-6
1-10 Air Release of Hydraulic Equipment 1-11
CHAPTER 2
Technical Data
2-1 Specifications 2-1-1
2-2 Outline Drawing and Working Area 2-2-1
2-2-1 Canopy type 2-2-1
2-2-2 Cabin type 2-2-2
2-3 Weight List of Main Parts 2-3-1
2-4 Lifting Capacity List 2-4-1
CHAPTER 3
Service Standards
3-1 Machine Performance 3-1-1
3-2 Engine 3-2-1
3-3 Undercarriage 3-3-1
3-3-1 Rubber Track Specifications 3-3-1
3-3-2 Steel Track Specifications 3-3-2
3-3-3 Common Specifications of Steel & Rubber Tracks 3-3-3
3-4 Controls 3-4-1
3-5 Hydraulic Equipment 3-5-1
3-5-1 Hydraulic Cylinders 3-5-1
3-6 Implement 3-6-1
3-6-1 Front Attachments 3-6-1
3-6-2 Blade Moving Device 3-6-2
3-6-3 Bucket Teeth 3-6-2
3-7 List of Tightening Torque 3-7-1
3-7-1 Machine 3-7-1
3-7-2 Engine 3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts 3-7-4
CHAPTER 4
Engine
4-1 General 4-1-1
4-1-1 How to Read This Manual 4-1-1
4-1-2 Precautions for Service Work 4-1-3
4-1-3 Engine External Views 4-1-4
4-1-4 Structural Description 4-1-4
4-1-5 Exhaust Gas Emission Regulation 4-1-5
4-2 Troubleshooting 4-2-1
4-2-1 Quick Reference Table for Troubleshooting 4-2-1
4-2-2 Troubleshooting by Measuring Compression Pressure 4-2-4
4-3 Inspection and Adjustment 4-3-1
4-3-1 Oil Inspection 4-3-1
4-3-2 Cooling Water Inspection 4-3-1
4-3-3 Inspecting Water Leak from Cooling Water System and Radiator 4-3-1
4-3-4 Fan Belt Tension Inspection and Adjustment 4-3-2
4-3-5 Adjusting the Valve Clearance 4-3-3
4-3-6 Inspecting the Fuel Injection Valve Injection Pressure and Spray Pattern 4-3-5
4-3-7 Fuel Injection Timing Adjustment / Fuel Injection Pump Inspection and Adjustment 4-3-9
4-3-8 Sensor Inspection 4-3-12
4-3-9 Battery Inspection 4-3-13
4-3-10 Adjusting Operation 4-3-15
4-3-11 Long Storage 4-3-16
4-3-12 Periodic Maintenance Schedule 4-3-17
4-4 Engine Body 4-4-1
4-4-1 Introduction 4-4-1
4-4-2 Cylinder Head 4-4-2
4-4-3 Gear Train and Camshaft 4-4-11
4-4-4 Cylinder Block 4-4-16
4-5 Lubrication System 4-5-1
4-5-1 Lubrication System Diagram 4-5-1
4-5-2 Trochoid pump (4TNV88-BXBV) 4-5-2
4-6 Cooling System 4-6-1
4-6-1 Cooling Water System 4-6-1
4-6-2 Cooling Water Pump Components 4-6-1
4-6-3 Disassembly (Reverse the Procedure Below for Assembly) 4-6-2
4-6-4 Servicing Points 4-6-2
4-7 Fuel Injection Pump / Governor 4-7-1
4-7-1 Introduction 4-7-1
4-7-2 Fuel Injection Pump 4-7-1
4-8 Electrical Equipment 4-8-1
4-8-1 Starter Motor 4-8-1
4-8-2 Alternator 4-8-3
4-8-3 Air Heater 4-8-6
CHAPTER 5
Hydraulic System
5-1 Outline 5-1-1
5-1-1 Control Valve Operation 5-1-4
5-1-2 Additional Operation of Control Valve 5-1-6
5-2 Hydraulic Circuit Schematic 5-2-1
5-3 Circuit Operation 5-3-1
5-3-1 Boom 5-3-1
5-3-2 Arm 5-3-3
5-3-3 Bucket 5-3-5
5-3-4 Swing 5-3-7
5-3-5 Boom Swing 5-3-9
5-3-6 Blade 5-3-11
5-3-7 Travel 5-3-13
5-3-8 Non-Deviation Travel (with Boom, Arm or Boom Swing Operation) 5-3-15
5-3-9 Non-Deviation Travel (with Bucket Operation) 5-3-17
5-3-10 Simultaneous Operation of Boom Up and Arm Retract 5-3-19
5-3-11 Simultaneous Operation of Boom Up and Bucket 5-3-21
5-3-12 Simultaneous Operation of Boom Up and Swing 5-3-23
5-3-13 Simultaneous Operation of Arm and Bucket 5-3-25
5-3-14 Hydraulic P T O 5-3-27
5-3-15 Quick Coupler 5-3-29
5-4 Pressure Adjustment 5-4-1
5-4-1 Relief Valves 5-4-1
5-4-2 Swing Brake Valve 5-4-4
5-4-3 Cut-Off Valve 5-4-5
CHAPTER 6
Hydraulic Equipment
6-1 Hydraulic Pump 6-1-1
6-2 Control Valve 6-2-1
6-3 Pilot Valve 6-3-1
6-4 Swing Motor 6-4-1
6-5 Travel Motor 6-5-1
6-6 Blade Control Pilot Valve 6-6-1
6-7 Solenoid Valve for P T O Operation 6-7-1
6-8 Pilot Check Valve (For Quick Coupler Circuit) 6-8-1
CHAPTER 7
Adjustment and Repair
7-1 Electric Equipment of Machine 7-1-1
7-1-1 Parts Layout of Electrical Equipment 7-1-1
7-1-2 Monitor and Alarm Systems 7-1-3
7-1-3 Wiring Diagram 7-1-6
7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging 7-1-7
7-1-5 Removal and Reinstallation of Engine 7-1-9
7-1-6 Removal and Reassembly of Starter Motor 7-1-18
7-1-7 Removal and Reassembly of Drive Belts for Generator and Compressor 7-1-19
7-2 Undercarriage 7-2-1
7-2-1 Outline 7-2-1
7-2-2 Main Parts 7-2-1
7-2-3 Points of Reassembly (Rubber Track) 7-2-2
7-2-4 Points of Reassembly (Steel Track) 7-2-3
7-2-5 Removal and Reinstallation of Track 7-2-4
7-2-6 Removal and Reinstallation of Steel Track 7-2-5
7-2-7 Disassembly and Reassembly of Front Idler 7-2-8
7-2-8 Disassembly and Reassembly of Track Roller 7-2-10
7-2-9 Installation of Floating Seal 7-2-12
7-2-10 Drawings of Jigs 7-2-13
7-2-11 Disassembly and Reassembly of Carrier Roller 7-2-15
7-3 Controls 7-3-1
7-3-1 Control Train 7-3-1
7-3-2 Mechanical Control Linkage 7-3-2
7-3-3 Adjustment of Travel Levers 7-3-4
7-3-4 Adjustment of Boom Swing Pedal 7-3-5
7-3-5 Adjustment of Lock Lever 7-3-6
7-3-6 Adjustment of Accelerator Lever 7-3-7
7-4 Swing Bearing 7-4-1
7-5 Hydraulic Equipment 7-5-1
7-5-1 Removal and Reinstallation of Hydraulic Pump 7-5-1
7-5-2 Removal and Reinstallation of Control Valve 7-5-3
7-5-3 Removal and Reinstallation of Swing Motor 7-5-6
7-5-4 Removal and Reinstallation of Swivel Joint 7-5-9
7-5-5 Disassembly and Reassembly of Swivel Joint 7-5-13
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders 7-5-16
7-5-7 Hydraulic Oil Tank 7-5-20
7-5-8 Piping Layout 7-5-26
7-6 Work Implements 7-6-1
7-6-1 Removal and Reinstallation of Work Implements 7-6-1
7-6-2 Quick Coupler 7-6-10
7-7 Cabin 7-7-1
7-7-1 Cabin 7-7-1
CHAPTER 8
Periodic Inspection and Servicing
8-1 List of Periodic Inspection and Servicing 8-1-1
CHAPTER 9
Fuel, Lube Oil and Grease Recommended
9-1 Fuel, Lube Oil and Grease Recommended 9-1-1
CHAPTER 10
Troubleshooting
10-1 Non-breakdowns 10-1-1
10-1-1 Natural Release of Bucket 10-1-1
10-1-2 Discontinuous Arm Movement 10-1-1
10-1-3 Drifting of Upperstructure on Quick Travel Operation 10-1-2
10-1-4 Thermal Shock of Travel Motor 10-1-3
10-1-5 Elongation of Boom Swing Cylinder on 70 degrees Swing 10-1-4
10-1-6 Telescopic Motion of Boom Swing Cylinder with Lock Lever Set to Lock Position 10-1-5
10-1-7 Time Lag on Travel Speed Switching 10-1-6
10-1-8 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change 10-1-7
10-1-9 Operation of Quick Coupler Cylinder (for Quick Coupler Type) 10-1-8
10-2 Troubleshooting 10-2-1
10-2-1 Machine and Engine 10-2-1
10-2-2 Electrical Equipment on Panel 10-2-23
CHAPTER 11
Reference Data
11-1 Dimensions and Specifications for Attachment 11-1-1