Fiat Kobelco EX135 Excavator & Engine Technical & Workshop Manual

Fiat Kobelco EX135 Excavator & Engine Workshop Manual, Technical Operational Principle & Troubleshooting Manual
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This complete service repair workshop manual PDF download for the EX135 Fiat Kobelco 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.


MANUAL COMPOSITION :

• The complete service manual consists of four books:
- Technical Manual - Operational Principle
- Technical Manual - Troubleshooting
- Excavator Workshop Manual
- Engine 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 Excavator and the Engine Workshop Manuals include 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 EX135 Excavator consists of the following book/print numbers:
- Technical Manual - Operational Principle - 604.13.141
- Technical Manual - Troubleshooting - 604.13.146
- Workshop Manual - Excavator - 604.13.151
- Workshop Manual - Engine - 604.13.136


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 763


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 :

OPERATIONAL PRINCIPLE
    OPERATIONAL PRINCIPLE
    INTRODUCTION
    SECTION AND GROUP CONTENTS
    
        Section 1 - GENERAL
            Group 1 - Specification
                Excavator Dimensions
                Excavator performance
                Engine
                Engine accessory
                Hydraulic Device
                Electrical Equipment
            Group 2 - Components layout
            
        Section 2 - SYSTEM
            Group 1 - Control system
                Outline
                Engine control
                Valve control
                Other control function
            Group 2 - Hydraulic system
                Main circuit
                Pilot circuit
                Neutral circuit
                Single actuator operation
                Combined operation
            Group 3 - Electrical system
                Outline
                Electric power circuit
                Bulb check circuit
                Intake air heater circuit
                Starting circuit
                Charging circuit
                Surge voltage prevention circuit
                Accessory circuit
                Engine stop circuit
                Engine emergency stop
                
        Section 3 - COMPONENT OPERATION
            Group 1 - Pump device
                Outline
                Main pump
                Regulator
                Pilot pump
                Pump delivery pressure sensor
            Group 2 - Swing device
                Outline
                Swing motor
                Brake valve
                Swing parking brake
                Swing reduction gear
            Group 3 - Control valve
                Outline
                Hydraulic circuit
                Flow combiner valve
                Pump control valve
                Main relief valve
                Overload relief valve
                Arm regenerative valve
                Boom anti-drift valve, arm anti-drift valve
                Bucket flow control valve
                Travel flow control valve
                Travel/boom lower selector valve
                Boom regenerative valve
            Group 4 - Pilot valve
                Outline
                Operation
            Group 5 - Travel device
                Outline
                Travel reduction gear
                Travel motor
                Travel brake valve
                Parking brake
            Group 6 - Others components (Upperstructure)
                Pilot shut-off valve
                Shockless valve
                Solenoid valve unit
                Pilot relief valve
                EC motor
            Group 7 - Others components (Undercarriage)
                Swing bearing
                Center joint
                Track adjuster
                
TROUBLESHOOTING
    INTRODUCTION
    SECTION AND GROUP CONTENTS
    
        Section 4 - Operational Performance Test
            Group 1 Introduction
                Operational performance test
                Preparation for performance tests
            Group 2 Standard
                Operational Performance standard tables
                Main pump P-Q diagram
            Group 3 Engine test
                Engine speed
            Group 4 Excavator test
                Travel speed
                Track revolution speed
                Mistrack check
                Travel parking 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
                Solenoid valve set pressure
                Main pump delivery pressure
                Main relief valve set pressure
                Overload relief valve set pressure
                Main pump flow test
                Swing motor drainage
                Travel motor drain oil pressure
                
        Section 5 - Troubleshooting
            Group 1 Diagnosing Procedure
                Introduction
                Diagnosing Procedure
                Dr.EX
                Dr.EX Start-Up Procedure
                Dr.EX Fault Code
                Dr.EX Monitoring Function
                Dr.EX Special Function (Service Mode)
                Adjustable Data List
            Group 2 Component Layout
                Main Components
                Electrical System (Overall System)
                Electrical System (Relays)
                Electrical System (Monitor and Switch Panels)
                Pump and Related Parts
                Control Valve
                Others Components
            Group 3 Troubleshooting A
                Troubleshooting A Procedure
                Fault Codes
                Fault Code 01
                Fault Code 02, 03
                Fault Code 04, 05
                Fault Code 06
                Fault Code 07
                Sensor Operating Range List
            Group 4 Troubleshooting B
                Troubleshooting B Procedure
                Relationship between Machine Trouble Symptoms and Parts in Trouble
                Correlation between Trouble Symptoms and Part Failures
                Engine Troubleshooting
                Actuator Control System Troubleshooting
                Front Attachment Control System Troubleshooting
                Swing System Troubleshooting
                Travel System Troubleshooting
                Troubleshooting for Other Functions
                Engine Speed Adjustment and Engine Learning
                Exchange Inspection Method
            Group 5 Troubleshooting C
                Troubleshooting C Procedure
                Malfunction of Coolant Temperature Gauge
                Malfunction of Fuel Gauge
                Malfunction of Fuel Level Indicator
                Malfunction of Indicator Light Check System
                Malfunction of Level Check Switch
                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
                Inspection and Replacement of Fusible Links
                Battery Voltage Check
                How to Troubleshoot Alternator Malfunctions
                Continuity Check
                Voltage and Current Check
                Replacement of Relay
            Group 7 Harness Check
                Circuit Check
                
WORKSHOP MANUAL
    INTRODUCTION
    SECTION AND GROUP CONTENTS
    
        Section 1 - GENERAL INFORMATION
            Group 1 - Precautions for Disassembling and Assembling
                Precautions for Disassembling and Assembling
            Group 2 - Tightening Torque
                Tightening Torque Specification
                Torque Chart
                Pipe Thread Connection / Union joint Tightening Torque Specifications
                
        Section 2 - 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 - Pump Device
                Remove and Install Pump Device
                Disassemble Pump Device
                Assemble Pump Device
                Disassemble Regulator
                Assemble Regulator
                Disassemble and Assemble Pilot Pump
                Maintenance Standard
            Group 5 - Control Valve
                Remove and Install Control Valve
                Disassemble Control Valve 1
                Assemble Control Valve 1
                Disassemble Control Valve 2
                Assemble Control Valve 2-1
                Assemble Control Valve 2-2
                Disassemble Control Valve 3
                Assemble Control Valve 3
                Disassemble Control Valve 4
                Assemble Control Valve 4-1
                Assemble Control Valve 4-2
            Group 6 - Swing Device
                Remove and Install Swing Device
                Disassemble Swing Device
                Assemble Swing Device
                Disassemble Swing Motor
                Assemble Swing Motor
                Maintenance Standard
                Disassemble Brake Valve
                Assemble Brake Valve
            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 Shockless Valve
                Disassemble and Assemble Shockless Valve
            Group 10 - Solenoid Valve
                Remove and Install Solenoid Valve Unit
                Disassemble Propotional Solenoid Valve
                Assemble Propotional Solenoid Valve
            Group 11- Pilot Relief Valve Unit
                Remove and Install Pilot Relief Valve Unit
                Disassemble Pilot Relief Valve
                Assemble Pilot Relief Valve
                
        Section 3 - 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 Base Plate
                Assemble Base Plate
                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
                Disassemble Track Adjuster
                Assemble Track Adjuster
            Group 5 - Front Idler
                Remove and Install Front Idler
                Disassemble Front Idler
                Assemble Front Idler
                Maintenance Standard
            Group 6 - Upper and Lower Roller
                Remove and Install Upper Roller
                Remove and Install Lower Roller
                Disassemble Upper Roller
                Disassemble Lower Roller
                Assemble Lower Roller
                Maintenance Standard
            Group 07 - Tracks
                Remove and Install Tracks
                Maintenance Standard
                
        Section 4 - FRONT ATTACHMENT
            Group 1 - Front attachment
                Remove and install front attachment
                Maintenance Standard
                Bucket teeth
                Standard dimensions for arm and bucket connection
            Group 2 - Cylinders
                Remove and install cylinders
                Hydraulic circuit pressure release procedure
                Disassemble cylinders
                Assemble cylinders
                Maintenance Standard
                Special Tools
                
ENGINE
    ENGINE
    Introduction
    List of Sections
    
        Section1 - Diagnostics
            Diagnostics 
            
        Section2 - Removal & Installation Ex 135 Engine
            Engine/Pumps Assembly Removal
                Air Conditioner
                Electrical Connections
                Hydraulic Pumps
                Engine/Pumps Assembly Lifting
            Engine/Pumps Assembly Installation
                Tightening Torques
            Filling
                Fuel System Air Bleeding
                Filling The Cooling Sistem
                Hydraulic System Oil Refilling
                
        Section3 - Engine Ex 135 Overhaul
            Specifications and data
            Mounting clearances - Data
            Graphic Representation and Symbols
            Tightening torques
            Special tools
            Stripping down the engine in the Workshop
            Repairs - Cylinder block - Checks and measurements
                Replacement of cylinder liners
            Camshaft - Bushes - Valve Lifters
            Cam pitch and bearing journal alignment check
            Driven toothed wheel replacement
            Bush replacement
            Valve lifters
                Replacement of valve lifters
                Mounting of valve lifters - camshaft
            Crankshaft
            Main and connecting rod bearing journals
            Check of main bearing journal alignment
            Replacement of driving toothed wheel steering and oil pump
            Mounting of main bearings
            Checking of main bearing journal mounting clearance
                Crankshaft end play check
            Rear flywheel cover
            Engine flywhee
            Replacement of engine flywheel toothed wheel
            Connecting rod ± piston assembly
            Piston
                Piston diameter measurement
            Piston pins
            Piston rings
            Connecting rods
                Check of rectangularity of connecting rod
            Bushes
            Mounting of connecting rod - piston assembly
                Connecting rod - piston mating
                Connecting rod - piston rectangularity check
                Mounting of piston rings
            Adjustment of the mounting clearance of the connecting rod journals
                Mounting of connecting rod covers
            Steering
            Check and replacement of the transmission gear wheel
            Replacement of bush for transmission gear wheel
                Mounting of the transmission gear wheel and adjustment of the steering
            Cylinder head
                Tightness check
            Dismounting of valves
                Check of cylinder head bearing surface on cylinder block
            Valves
            Removal of incrustration and valve check
                Valve grinding
                Boring of inner surfaces of valve stem guides
                Check of clearance between valve spindle and valve stem guide
            Refinishing of valve seats
                Valve sealing test
                Remounting of valves
                Mounting of cylinder head
            Rods
                Mounting of valve lifter shaft and adjustment of working clearance between valves and valve liftersi
            Lubrication
            Oil pump
            Oil filter
                Oil pump assembly
            Cooling system
            Water pump
            Thermostat
                Carrying out engine assembly at work bench
            Injection pump installation and timing
            Adjustment of the driving belt tension: water pump ± generator and fan
            Turbocharger
                Description
                Necessary checks before dismounting the turbocharger from the engine
            Dismounting
                Checks
                Mounting
            Fuel feed
                Dismounting
            Calibration
            Injection pump
            Marking
            BOSCH stock number
            Mode of operation
                Feed step
                Delivery
                Automatic injection adjustment
                Starting device disconnected
                Load±dependent feed start (L.F.B.)
                Description
                Position of the governor collar in the LFB
                L.D.A. device (load±dependent feed adjustment)
                Mode of operation
                Dismounting of the injection pump
            Checks 
                Check of pressure increasing control valve
                Pre±adjustment of the adjustment screw for the L.D.A. device
                Lift adjustment of the L.D.A. device
                Adjustment of the starting dimension "MS" (only engine 8040.45)
                
                Calibration tables
        Section6 - Recharge and Start - Up 
            Starter Motor
                Quick diagnosis
                Magneti Marelli MT 67CB - 4kW
                Test and checks on the vehicle Current absorption test
                Voltage drop test on the circuit
                Excessive voltage drop test on the circuit
                Starter motor earth test
                Voltage drop test on the solenoid contacts
                Disassembly
                Assembly
                Bench test
            Alternator
                Quick diagnosis
                Bosch   NL1  28V  10/55A
            Test and Checks the Vehicle
                Maximum output test
                Pressure drop test on the circuit
                Voltage drop test on the earth circuit
                Voltage regulator calibration test
                Alternator belt tensioning
                Disassembly and bench test
                Assembly
                
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