Fiat Kobelco EX455 (Tier2) Excavator Technical & Workshop Manual

Fiat Kobelco EX455 (Tier2) Excavator Workshop Manual, Technical Operational Principle & Troubleshooting Manual
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This complete service repair workshop manual PDF download for the EX455 (Tier2) 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.


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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