This complete service repair workshop manual PDF download for the Fiat Kobelco EX455 (Tier2) Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Fiat Kobelco Heavy Line Crawler Excavator EX455 Tier 2
All EX455 Excavator – Tier 2 – Fiat , Kobelco , Hitachi
MANUAL COMPOSITION :
• The complete service manual consists of three books:
– Technical Manual – Operational Principle
– Technical Manual – Troubleshooting
– Workshop Manual
– The Technical Manual – Operational Principle includes the technical information concerning the operation of main devices and systems.
– The Technical Manual -Troubleshooting includes the technical information needed for operational performance tests, and troubleshooting procedures.
– The Workshop Manual includes information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, removal/installation and assembly/disassembly procedures.
• The Service Manual for EX455 Excavator consists of the following book/print numbers:
– Technical Manual – Operational Principle 604.13.221
– Technical Manual – Troubleshooting 604.13.226
– Workshop Manual 604.13.231
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 878
This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.
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TABLE OF CONTENTS :
INTRODUCTION
OPERATIONAL PRINCIPLE
GENERAL
SYSTEM
COMPONENT OPERATION
TROUBLESHOOTING
WORKSHOP MANUAL
EX455 Tier2
TECHNICAL MANUAL OPERATIONAL PRINCIPLE
INTRODUCTION
OPERATIONAL PRINCIPLE
GENERAL
Group 1 – Specifications
EXCAVATOR DIMENSIONS (LCH version)
EXCAVATOR DIMENSIONS (BEH version)
EXCAVATOR PERFORMANCE
ENGINE
ENGINE ACCESSORY
HYDRAULIC DEVICES
ELECTRICAL EQUIPMENT
Group 2 – Component Layout
MAIN COMPONENTS
ELECTRICAL SYSTEM (1) (Overall system)
ELECTRICAL SYSTEM (2) (Monitor and Switch panels)
ELECTRICAL SYSTEM (3) (Relays, Diodes, etc.)
ELECTRICAL SYSTEM (4) (Relays, Batteries, Fuses)
ELECTRICAL SYSTEM (5) (Fuses)
OTHER COMPONENTS
SYSTEM
Group 1 – Control System
OUTLINE
ENGINE CONTROL
PUMP CONTROL
VALVE CONTROL
OTHER CONTROL
Group 2 – Hydraulic System
OUTLINE
MAIN CIRCUIT
PILOT CIRCUIT
Group 3 – Electrical System
OUTLINE
ELECTRIC POWER CIRCUIT
BULB CHECK CIRCUIT
ACCESSORY CIRCUIT
PREHEAT CIRCUIT
STARTING CIRCUIT
CHARGING CIRCUIT
SURGE VOLTAGE PREVENTION CIRCUIT
ENGINE STOP CIRCUIT
COMPONENT OPERATION
Group 1 – Pump Device
OUTLINE
MAIN PUMP
REGULATORS
PILOT PUMP
N SENSOR (ENGINE SPEED SENSOR)
P SENSOR (PUMP DELIVERY PRESSURE SENSOR)
A SENSOR (PUMP DISPLACEMENT ANGLE SENSOR)
Group 2 – Swing Device
OUTLINE
SWING MOTOR
VALVE UNIT
SWING PARKING BRAKE
SWING REDUCTION GEAR
Group 3 – Control Valve
OUTLINE
HYDRAULIC CIRCUITS
FLOW COMBINER VALVE
PUMP CONTROL VALVE
MAIN RELIEF VALVE
OVERLOAD RELIEF VALVE
MAKE-UP VALVE
HOLDING VALVE
ARM REGENERATIVE VALVE
Group 4 – Pilot Valve
OUTLINE
OPERATION
Group 5 – Travel Device
OUTLINE
TRAVEL REDUCTION GEAR
TRAVEL MOTOR
TRAVEL BRAKE VALVE
TRAVEL MOTOR DISPLACEMENT ANGLE SHIFT
PARKING BRAKE
Group 6 – Other Components (Upperstructure)
PILOT SHUT-OFF VALVE
SHOCKLESS VALVES
SOLENOID VALVE
ACCUMULATOR
EC MOTOR
Group 7 – Other Components (Undercarriage)
SWING BEARING
CENTER JOINT
TRACK ADJUSTER
TROUBLESHOOTING
INTRODUCTION
OPERATIONAL PERFORMANCE TEST
Group 1 – Introduction
OPERATIONAL PERFORMANCE TESTS
PREPARATION FOR PERFORMANCE TESTS
Group 2 – Standard
OPERATIONAL PERFORMANCE STANDARD TABLES
MAIN PUMP P-Q CURVE
Group 3 – Engine Test
ENGINE SPEED
ENGINE CHECK AND ADJUSTMENT
Group 4 – Excavator Test
TRAVEL SPEED
TRACK REVOLUTION SPEED
MISTRACK CHECK
TRAVEL PARKING BRAKE FUNCTION CHECK
SWING SPEED
SWING FUNCTION DRIFT CHECK
SWING MOTOR LEAKAGE
SWING BEARING PLAY
MAXIMUM SWINGABLE SLANT ANGLE
HYDRAULIC CYLINDER CYCLE TIME
DIG FUNCTION DRIFT CHECK
CONTROL LEVER OPERATING FORCE
CONTROL LEVER STROKE
COMBINED BOOM RAISE/SWING FUNCTION CHECK
Group 5 – Component Test
PRIMARY PILOT PRESSURE
SECONDARY PILOT PRESSURE
MAIN RELIEF PRESSURE SHIFT CONTROL PRESSURE (SA Pressure)
TRAVEL MODE SHIFT CONTROL PRESSURE (SB Pressure)
SWING PARKING BRAKE RELEASE PRESSURE (SC Pressure)
MAIN RELIEF PRESSURE
OVERLOAD RELIEF VALVE SET PRESSURE (PRESSURE IN POWER BOOST MODE)
MAIN PUMP FLOW TEST
SWING MOTOR DRAINAGE
TRAVEL MOTOR DRAINAGE
TROUBLESHOOTING
Group 1 – Diagnosing Procedure
INTRODUCTION
DIAGNOSING PROCEDURE
Dr.EX
Dr.EX START-UP PROCEDURE
CLEARING THE SELF-DIAGNOSING FUNCTION
RETRIAL “A” (FOR PROBLEMS WITH THE CONTROLLER PVC AND EC)
RETRIAL “B” (FOR PROBLEMS WITH THE SENSORS)
EC-RELATED FAULT CODES
PVC-RELATED FAULT CODES
MONITORING FUNCTION
Group 2 – Component Layout
MAIN COMPONENTS
ELECTRICAL SYSTEM (1)
ELECTRICAL SYSTEM (2)
ELECTRICAL SYSTEM (3)
ELECTRICAL SYSTEM (4)
CONTROL VALVE
OTHER COMPONENTS Pump Device
Group 3 – Troubleshooting A
TROUBLESHOOTING A PROCEDURE
EC-RELATED FAULT CODES
PVC-RELATED FAULT CODES
FAULT CODES 01, 02, 03, 04, 06 (EC Failure)
FAULT CODE 05 (Communication Failure between PVC and EC)
FAULT CODES 09, 10 (EC sensor failure)
FAULT CODES 11, 12 (Engine control dial failure)
FAULT CODE 13 (N sensor failure)
FAULT CODE 14
FAULT CODES 17, 18, 19, 21, 22 (PVC Failure)
FAULT CODE 20
FAULT CODES 23, 24
FAULT CODES 26, 34
FAULT CODES 27, 28, 35, 36
FAULT CODES 29, 30, 37, 38
SENSOR OPERATING RANGE LIST
Group 4 – Troubleshooting B
TROUBLESHOOTING B PROCEDURE
CORRELATION BETWEEN PART FAILURE AND ABNORMALITIES THAT MACHINE MAY SHOW
CORRELATION BETWEEN TROUBLES AND PART FAILURES
ENGINE SYSTEM TROUBLESHOOTING
TOTAL ACTUATOR SYSTEM TROUBLESHOOTING
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING
SWING SYSTEM TROUBLESHOOTING
TRAVEL SYSTEM TROUBLESHOOTING
TROUBLESHOOTING FOR OTHER FUNCTIONS
EC SENSOR INSTALLATION AND VOLTAGE ADJUSTMENT
INSTALLATION AND ADJUSTMENT OF THE A SENSOR (PUMP DISPLACEMENT SENSOR)
Group 5 – Troubleshooting C
TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE
MALFUNCTION OF COOLANT TEMPERATURE GAUGE
MALFUNCTION FUEL GAUGE
MALFUNCTION OF FUEL LEVEL INDICATOR (RESERVE)
MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM
MALFUNCTION OF LEVEL CHECK SWITCH
MALFUNCTION OF PREHEAT INDICATOR
MALFUNCTION OF ENGINE OIL LEVEL INDICATOR
MALFUNCTION OF COOLANT LEVEL INDICATOR
MALFUNCTION OF HYDRAULIC OIL LEVEL INDICATOR
MALFUNCTION OF ALTERNATOR INDICATOR
MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR
MALFUNCTION OF OVERHEAT INDICATOR
MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR
MALFUNCTION OF BUZZER
MALFUNCTION OF HOUR METER
Group 6 – Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
INSTRUCTIONS FOR DISCONNECTING CONNECTORS
FUSE CONTINUITY TEST
FUSIBLE MAXI LINK INSPECTION AND REPLACEMENT
BATTERY VOLTAGE CHECK
HOW TO TROUBLESHOOT ALTERNATOR MALFUNCTIONS
CONTINUITY CHECK
VOLTAGE AND CURRENT CHECK
WIPER CONTROLLER
REPLACEMENT OF RELAY
RELAY BOX
REPLACEMENT OF QOS CONTROLLER
REPLACEMENT OF POWER OUTLET
Group 7 – Harness Check
CIRCUIT CHECK
WORKSHOP MANUAL
UPPERSTRUCTURE
Group 1 – Cab
REMOVE AND INSTALL CAB
Group 2 – Counterweight
REMOVE AND INSTALL COUNTERWEIGHT
Group 3 – Main Frame
REMOVE AND INSTALL MAIN FRAME
Group 4 – Upperstructure pump device
REMOVE AND INSTALL PUMP DEVICE
DISASSEMBLE PUMP DEVICE
ASSEMBLE PUMP DEVICE
DISASSEMBLE REGULATOR
ASSEMBLE REGULATOR
DISASSEMBLE PILOT PUMP
ASSEMBLE PILOT PUMP
MAINTENANCE STANDARDS
Group 5 – Control Valve
REMOVE AND INSTALL CONTROL VALVE
DISASSEMBLE CONTROL VALVE 1
ASSEMBLE CONTROL VALVE 1
DISASSEMBLE CONTROL VALVE 2
ASSEMBLE CONTROL VALVE 2
DISASSEMBLE CONTROL VALVE 3
ASSEMBLE CONTROL VALVE 3
DISASSEMBLE CONTROL VALVE 4
ASSEMBLE CONTROL VALVE 4
DISASSEMBLE CONTROL VALVE 5
ASSEMBLE CONTROL VALVE 5
Group 6 – Swing Device
REMOVE AND INSTALL SWING DEVICE
DISASSEMBLE SWING DEVICE
ASSEMBLE SWING DEVICE
DISASSEMBLE SWING MOTOR
ASSEMBLE SWING MOTOR
MAINTENANCE STANDARD
Group 7 – Pilot Valve
REMOVE AND INSTALL RIGHT PILOT VALVE
REMOVE AND INSTALL LEFT PILOT VALVE
REMOVE AND INSTALL TRAVEL PILOT VALVE
DISASSEMBLE RIGHT AND LEFT PILOT VALVE
ASSEMBLE RIGHT AND LEFT PILOT VALVE
DISASSEMBLE TRAVEL PILOT VALVE
ASSEMBLE TRAVEL PILOT VALVE
Group 8 – Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF VALVE
DISASSEMBLE PILOT SHUT-OFF VALVE
ASSEMBLE PILOT SHUT-OFF VALVE
Group 9 – Shockless Valve
REMOVE AND INSTALL FRONT ATTACHMENT SHOCKLESS VALVE
DISASSEMBLE AND ASSEMBLE FRONT ATTACHMENT SHOCKLESS VALVE
REMOVE AND INSTALL TRAVEL SHOCKLESS VALVE
Group 10 – Solenoid Valve Unit
REMOVE AND INSTALL THREE-SPOOL SOLENOID VALVE
GENERAL INFORMATION
Group 1 – Precautions for Disassembly and Assembly
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
MAINTENANCE STANDARD TERMINOLOGY
Group 2 – Tightening Torque
TIGHTENING TORQUE SPECIFICATIONS
TORQUE CHART
PIPING JOINT
UNDERCARRIAGE
Group 1 – Swing Bearing
REMOVE AND INSTALL SWING BEARING
Group 2 – Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
DISASSEMBLE TRAVEL DEVICE
ASSEMBLE TRAVEL DEVICE
DISASSEMBLE TRAVEL MOTOR
ASSEMBLE TRAVEL MOTOR
DISASSEMBLE BRAKE VALVE
ASSEMBLE BRAKE VALVE
MAINTENANCE STANDARD
Group 3 – Center Joint
REMOVE AND INSTALL CENTER JOINT
DISASSEMBLE CENTER JOINT
ASSEMBLE CENTER JOINT
MAINTENANCE STANDARD
Group 4 – Track Adjuster
REMOVE AND INSTALL TRACK ADJUSTER AND FRONT IDLER
DISASSEMBLE TRACK ADJUSTER
ASSEMBLE TRACK ADJUSTER
Group 5 – Front Idler
REMOVE AND INSTALL TRACK ADJUSTER AND FRONT IDLER
DISASSEMBLE AND ASSEMBLE FRONT IDLE
MAINTENANCE STANDARD
Group 6 – Upper and Lower Roller
REMOVE AND INSTALL UPPER ROLLER
REMOVE AND INSTALL LOWER ROLLER
DISASSEMBLE UPPER ROLLER
ASSEMBLE UPPER ROLLER
DISASSEMBLE LOWER ROLLER
ASSEMBLE LOWER ROLLER
MAINTENANCE STANDARD
Group 7 – Tracks
REMOVE AND INSTALL TRACKS
MAINTENANCE STANDARD
FRONT ATTACHMENT
Group 1 – Front attachment
HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE
REMOVE AND INSTALL FRONT ATTACHMENT
MAINTENANCE STANDARD
BUCKET TEETH
STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION
Group 2 – Cylinders
REMOVE AND INSTALL CYLINDERS
DISASSEMBLE CYLINDERS
ASSEMBLE CYLINDERS
MAINTENANCE STANDARD
SPECIAL TOOLS
ENGINE AND ACCESSORY
Group 1 – General Information
GENERAL REPAIR INSTRUCTION
ENGINE EXTERNAL VIEW
MAIN DATA AND SPECIFICATIONS
PERFORMANCE CURVE
SERVICE STANDARDS
NUT AND BOLT ANGULAR TIGHTENING METHOD
TORQUE SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS
RECOMMENDED THREAD LOCKING AGENTS
LUBRICANT APPLICATIONS
SEALANT APPLICATIONS
SPECIAL TOOLS
IDENTIFICATION
Group 2 – Maintenance
LUBRICATION SYSTEM
FUEL SYSTEM
INJECTION TIMING ADJUSTMENT
INJECTION NOZZLE
AIR BLEEDING
FEED PUMP STRAINER
FUEL TANK DRAINING
COOLING SYSTEM
VALVE CLEARANCE ADJUSTMENT
COMPRESSION PRESSURE MEASURE
RECOMMENDED LUBRICANTS
ENGINE OIL VISCOSITY CHART
Group 3 – Engine Overhaul
SERVICE PRECAUTION
GENERAL DESCRIPTION
FAN CENTER
TURBOCHARGER
EXHAUST MANIFOLD
INLET MANIFOLD
WATER PUMP
ALTERNATOR
OIL COOLER
INJECTION PUMP
COUPLING ASSEMBLY
CYLINDER HEAD
ROCKER ARM AND SHAFT ASSEMBLY
CAMSHAFT
TIMING GEAR
FLYWHEEL HOUSING
OIL PAN
PISTON
CRANKSHAFT
CRANK PULLEY
FLYWHEEL
CYLINDER BLOCK
Group 4 – Engine Lubrication
SERVICE PRECAUTION
GENERAL DESCRIPTION
OIL PUMP
OIL COOLER
Group 5 – Engine Cooling
SERVICE PRECAUTIONS
GENERAL DESCRIPTION
WATER PUMP
THERMOSTAT
Group 6 – Engine Fuel
SERVICE PRECAUTION
GENERAL DESCRIPTION
FUEL FILTER
INJECTION NOZZLE HOLDER
INJECTION PUMP
Group 7 – Engine Induction
SERVICE PRECAUTIONS
TURBOCHARGER
Group 8 – Starting and Charging
SERVICE PRECAUTION
ALTERNATOR
STARTER MOTOR
Group 9 – Troubleshooting
HARD STARTING
UNSTABLE IDLING
INSUFFICIENT POWER
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ENGINE COOLING TROUBLE
WHITE EXHAUST SMOKE
BLACK EXHAUST SMOKE
LUBRICATION PROBLEMS
ABNORMAL ENGINE NOISE
ALTERNATOR
STARTER MOTOR
TURBOCHARGER
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Source : Sitelux.com
