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Fiat Kobelco EX455 Excavator Service Repair Manual.pdf
1. FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. - ENGINEERING -
FORM No. 604.13.221 Edition - July 2002
EXCAVATOR
TECHNICAL MANUAL
OPERATIONAL PRINCIPLE
(Tier 2)
All information, illustrations and specifications in this manual are based on the latest product information available
at the time of publication.
The right is reserved to make changes at any time without notice.
2. IN-2 EX455
INTRODUCTION
To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.039 37 Pressure MPa kgf/cm2
10.197
mm ft 0.003 281 MPa psi 145.0
L US gal 0.264 2 Power kW CV-PS 1.360
Volume L US qt 1.057 kW HP 1.341
m3
yd3
1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 Velocity km/h mph 0.621 4
Force N kgf 0.101 97 min-1
rpm 1.0
N lbf 0.224 8 Flow rate L/min US gpm 0.264 2
Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0
N.m lbf.ft 0.737 5
PAGE NUMBER
• Each page has a number, located on the external upper corner of the page. Each page number contains the
followinginformation:
Example: T 1-2-3
Consecutive page number for each group
Group number (if exist)
Sectionnumber
T : TechnicalManual
W : WorkshopManual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for
personal injury or machine damage.
This is the safety alert symbol.
When you see this symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed along with the safety alert symbol.
The safety alert symbol is also used to draw attentio in to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy
parts.
UNITS USED
SI Units (International System of Units) are used in this manual.
MKSA system units and English units are also indicated in parentheses just behinds SI units.
Example: 24.5 MPa (250 kgf/cm2
, 3560 psi)
A table for conversion from SI units to other system units is shown below for reference purposes.
3. Section 3 - COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Other Components (Upperstructure)
Group 7 Other Components (Undercarriage)
TECHNICAL MANUAL EX455
OPERATIONAL PRINCIPLE
SECTION AND GROUP CONTENTS
Section 1 - GENERAL
Group 1 Specifications
Group 2 Component Layout
Section 2 - SYSTEM
Group 1 Control System
Group 2 Hydraulic System
Group 3 Electrical System
4. SECTION 1 EX455
GENERAL
CONTENTS
Group 1 - Specifications
Excavator Dimensions
(LCH version) ....................................... T1-1-1
Excavator Dimensions
(BEH version) ...................................... T1-1-2
Excavator Performance ........................ T1-1-3
Engine ................................................. T1-1-3
Engine Accessory................................ T1-1-4
Hydraulic Devices ................................ T1-1-4
Electrical Equipment ............................ T1-1-5
Group 2 - Component Layout
Main Components ................................ T1-2-1
Electrical System (1)
(Overall system) .................................. T1-2-2
Electrical System (2)
(Monitor and Switch panels) ................. T1-2-3
Electrical System (3)
(Relays, Diodes, etc) ........................... T1-2-4
Electrical System (4)
(Relays, Batteries, Fuses) ................... T1-2-6
Electrical System (5) (Fuses)............... T1-2-7
Other Components ............................... T1-2-8
5. SPECIFICATIONS
EX455 T1-1-1
EXCAVATOR DIMENSIONS
(LCH version)
OM0873
DIGGING DATA
OM0872
N-Track shoe width (mm) 600 700 800 900
O-Maximumwidth(reducedfortransport) (mm) 2 890 2 990 3 090 3 190
O*-Maximum width (in work condition) (mm) 3 390 3 490 3 590 3 690
Workingweight (kg) 46000 46500 47000 47500
Spec. Ground Pressure (bar) 0.83 0.72 0.64 0.57
With arm:
(1) 2 900 mm
(2) 3 400 mm
(3) 3 900 mm
(▲
) 7 000 mm Boom
(*) Rear swing radius
VERSION A B C D D'(*) E F G H I L M
(1) 11 980 (1) 3 560
EX455LCH(▲
▲
▲
▲
▲
) 4 470 5 470 1 380 3 580 3 600 (2) 11 870 (2) 3 430 3 330 3 000 3 285 1 190 770
(3) 11 880 (3) 3 440
(mm)
Arm Arm Arm
2 900 mm 3 400 mm 3 900 mm
A 11390 12050 12430
A' 11140 11820 12200
B 7 270 7 730 8 190
B' 7 060 7 580 8 050
C 10040 10990 11060
D 6 890 7 630 7 760
E 5 060 4 980 4 920
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
6. SPECIFICATIONS
T1-1-2 EX455
EXCAVATOR DIMENSIONS
(BEH version)
OM0875
DIGGING DATA
OM0874
(▲
) 6 300 mm Boom
(*) Rear swing radius
VERSION A B C D D'(*) E F G H I L M
EX455BEH(▲
▲
▲
▲
▲
) 4 470 5 470 1 380 3 580 3 600 11470 4 300 3 330 3 000 3 285 1 190 770
(mm)
N-Track shoe width (mm) 600 700 800 900
O-Maximum width (reduced for tranport) (mm) 2 890 2 990 3 090 3 190
O*-Maximum width (in work condition) (mm) 3 390 3 490 3 590 3 690
Workingweight (kg) 46500 47000 47500 48000
Spec. Ground Pressure (bar) 0.83 0.73 0.64 0.58
Arm
2 500 mm
A 10700
A' 10360
B 6 300
B' 6 150
C 9 800
D 6 900
E 4 950
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
7. SPECIFICATIONS
EX455 T1-1-3
EXCAVATOR PERFORMANCE
GRADEABILITY ...........................................................................................................35° (70%) in continuous
TRAVEL SPEED
- Slow .................................................................................................................... 0 to 2.1 mph (0 to 3.4 km/h)
- Fast .....................................................................................................................0 to 3.4 mph (0 to 5.5 km/h)
ENGINE
MAIN SPECIFICATIONS
- Manufacturer .........................................................................................................................................ISUZU
- Model....................................................................................................................................AA-6WG1TQA-01
- Type .....................................................Diesel, 4 cycle, vertical, 6-cylinder inline, turbocharged, water-cooled,
direct injection type
- Cyl. No.-bore x stroke .......................................................................... 6-147 mm x 154 mm (5.78 in x 6.06 in)
- Piston displacement ......................................................................................................... 15 681 cm3
(957 in3
)
- Rated output ...................................................................................................................... 235 kW/1 800 min-1
- Compression ratio ......................................................................................................................................16.4
- Dry weight........................................................................................................................... 1 252 kg (2 760 lb)
- Firing order.......................................................................................................................................1-5-3-6-2-4
- Rotation direction ........................................................................................... Clockwise (facing fly wheel end)
COOLING SYSTEM
- Cooling fan............................................................................................... Dia. 850 mm, 6 blades, draw-in type
- Fan pulley ratio .................................................................................................................... Engine rpm x 0.89
- Thermostat (under atmospheric pressure) .......................................................Cracking temp. : 82 °C (180 °F)
Full open temp. : 95 °C (203 °F)
- Water pump ...........................................................................................................Centrifugal type, belt driven
LUBRICATION SYSTEM
- Lubrication pump type ....................................................................................................................Gear pump
- Oil filter ............................................................................... Full-flow paper element type with bypass function
- Oil cooler ........................................................................................................................ Water-cooled, built-in
STARTING SYSTEM
Motor ............................................................................................ Magnetic pinion shift system, reduction type
Voltage-Output ................................................................................................................................... 24 V-7 kW
PRE-HEAT SYSTEM
- Heating method ...........................................................................................Intake heater with magnetic valve
ENGINE STOP SYSTEM
- Stop method ......................................................... Fuel cut (Employs both key switch and engine stop motor)
ALTERNATOR
- Type ........................................................................................................................... AC type (with regulator)
-Voltage-Output ...................................................................................................... 24 V-50 A (Brush-less type)
SUPERCHARGING SYSTEM
- Type ............................................................................................................... Exhaust-gas-turbo type RHC 92
FUEL SYSTEM
- Injection pump model .......................................................................................................Bosch type P-Model
- Governor ............................................................................................... Centrifugal all speed control EP/RSV
- Injection nozzle....................................................................................................................... Multihole nozzle
8. SPECIFICATIONS
T1-1-4 EX455
ENGINE ACCESSORY
RADIATOR ASSEMBLY
- Type .............................................................................................Radiator/Oil Cooler tandem type assembly
- Weight ..................................................................................................................................... 260 kg (573 lb)
- RadiatorCapacity......................................................................................................................................21 L
- Oil Cooler Capacity ...................................................................................................................................16 L
BATTERY
- Capacity ........................................................................................................................................ 180 Ah x 2
- Voltage .............................................................................................................................................. 12 V x 2
HYDRAULIC DEVICES
MAIN PUMP
- Model ...........................................................................................................................................K5V200DPH
- Type ................................................................. Variable displacement plunger pump: regulator attached type
- Max. flow (Theoretical value) ..................................................................................................... 360 L/min x 2
PILOT PUMP
- Model .................................................................................................................................... HY/ZFS 11/16.8
- Type ....................................................................................................... Fixed displacement type gear pump
- Max. flow (Theoretical value) .......................................................................................................... 33.6 L/min
CONTROLVALVE
- Model ............................................................................................................................................... UH36-52
- Type ................................................................................................................... Pilot pressure operated type
(4-spool + 5-spool)
- Main relief pressure ................................................................... Normal: 29.4 MPa (300 kgf/cm2
) at 80 L/min
Power Boost (Travel): 34.3 MPa (350 kgf/cm2
) at 200 L/min
- Overload relief pressure ..................................... (Boom, Arm, Bucket): 30.9 MPa (315 kgf/cm2
) at 110 L/min
Swing: 26.5 MPa (270 kgf/cm2
) at 160 L/min
SWING DEVICE
- Type ........................................................................................................ Two-stage planetary reduction type
- Reduction ratio ........................................................................................................................................ 16.2
- Weight .....................................................................................................................................278 kg (617 lb)
SWING MOTOR
- Model ..................................................................................................................... M2X150CAB-10A-06/250
- Type ..............................................................................Swash-plate type, fixed-displacement plunger motor
- Displacement.............................................................................................................................148.5 cm3
/rev
SWING BRAKE VALVE
- Type ...............................................................................................................Non counterbalance valve type
- Relief pressure ........................................................................................ 24.5 MPa (250 kgf/cm2
) at 90 L/min
SWING PARKING BRAKE
- Type ..............................................................................................................Multiple-wet-plate negative type
- Cracking pressure for release .......................................................................................... 2 MPa (20 kgf/cm2
)
TRAVEL DEVICE
- Type ..................................................................................................... Three-stage planetary reduction gear
- Reduction gear ratio ............................................................................................................................ 55.318
- Weight ..................................................................................................................................................560 kg
TRAVEL MOTOR
- Model ..................................................................................................................................... MSF340VP-CB
- Type ......................................................................... Swash-plate type, variable displacement plunger motor
- Displacement (Theoretical value) ......................................................... Fast speed: 175.7 cm3
(10.7 in3
) /rev.
Slow speed: 271.5 cm3
(16.6 in3
) /rev.
TRAVEL BRAKE VALVE
- Type .................................................................................................................... Counter balance valve type
- Relief pressure .......................................................................................................... 36.8 MPa (375 kgf/cm2
)
TRAVEL PARKING BRAKE
- Type ..............................................................................................................Multiple-wet-plate negative type
- Brake release cracking pressure ................................................................................. 1.67 MPa (17 kgf/cm2
)
9. SPECIFICATIONS
EX455 T1-1-5
Boom Arm Bucket
Roddiameter 115 mm 130 mm 120 mm
Cylinderinnerdiameter 170 mm 190 mm 170 mm
Stroke 1 590 mm 1 940 mm 1 321 mm
Fully retracted length 2 260 mm 2 710 mm 2 041 mm
CYLINDERS
ACCUMULATOR
- Model .............................................................................................................................................MU70-300
- Type ........................................................................................................... Nitrogen gas sealed bladder type
- Capacity ............................................................................................................................ 300 cm3
(18.3 in 3
)
- Gas charging pressure ..................................................................................... 2.4 MPa (24 kgf/cm2
, 341 psi)
PILOT SHUT-OFF VALVE
- Model .................................................................................................................................................... RC50
- Type ............................................................................................................................................. Rotary type
SHOCKLESS VALVE (Front functions)
- Model ........................................................................................................................................... VUP149J/0
- Type ............................................................................................................. 4 valve block flow regulator type
SHOCKLESS VALVE (Travel function)
- Type ............................................................................................................. 4 valve block flow regulator type
3-SPOOL SOLENOID VALVE UNIT
- Application ....................................................................................................SA: Main relief pressure shift
SB: Travel speed mode shift
SC: Swing parking brake release
- Pilot relief pressure ........................................................................................... 3.9 MPa (40 kgf/cm2
, 569 psi)
at 13 Liters (3.4 US gal)/min
FRONT ATTACHMENT PILOT VALVE
- Model ................................................................................................................................. HVP04D-040-101
TRAVEL PILOT VALVE ..........................................................................................................HVP04A-040-101
OIL COOLER BYPASS CHECK VALVE
- Crackingpressure ....................................................................................... 340 kPa (3.5 kgf/cm2
) at 40 L/min
ELECTRICAL EQUIPMENT
BATTERY RELAY
- Voltage-Current .......................................................................................................................... 24 V - 100 A
STARTER RELAY
- Voltage .................................................................................................................................................... 24 V
HORN
- Specifications ................................................................................................................. 24 V - 1.5 A, 113 dB
LIGHT
- Specifications ............................................................................................Work lights: Halogen 24 V - 70 W
Dome light: 24 V - 10 W
AIR CONDITIONER
- Refrigerant............................................................................................................................................. 134 a
- Temperature control ............................................................................................................ Electronic control
17. COMPONENT LAYOUT
EX455 T1-2-7
Fuses in the tool kit and batteries compartment
ELECTRICAL SYSTEM (5)
(Fuses)
Fuses in the fuse box
8 6 4 3
5 2 1
7
9
19 18
20 16
17 14 13
15 12 11
10
OM0231
OM0232
SM5704
Fuse link (1), (2) and (3)
FUSES IN THE BOX
Fuse
LABEL
PROTECTED Rating
No. CIRCUIT (A)
1 SW. BACK UP
Back-up
5
power
Mainpower
2 ENG. C/U supply for 10
ECController
3 E.C. MOTOR Ec Motor 10
4 AUXILIARY
Auxiliary
5
powersupply
5
REAR CAB Rear Cab light
10
(LIGHT) powersupply
6 LUBRICATOR
Lubricator
10
powersupply
ROTARY
Rotary bucket
7
BUCKET
solenoid valve 10
powersupply
8 SOLENOID
Solenoid valve
5
powersupply
Switch box
5
9 SW. BOX powersupply
10
HEATING Operator'sheating
10
SEAT seat power supply
11 WIPER Wiper 10
12 HEATER
Heater
20
powersupply
13 LIGHT
Work light
15
powersupply
14 CAB LIGHT
Cab light
10
powersupply
15 RADIO
Radio
5
powersupply
16 LIGHTER Lighter
15
powersupply
17 HORN Hornes 10
18 GLOWRELAY
Glowrelay
5
powersupply
19 POWERON
Power on signal
5
from key switch
20 AIRCOND. Airconditioning 10
FUSES IN THE TOOL KIT AND BATTERIES
COMPARTMENT
– FUSE (1)
Batteries
50
powersupply
– FUSE (2)
Glowplug
40
powersupply
– FUSE (3)
Mainpower
80
supply with key
18. COMPONENT LAYOUT
T1-2-8 EX455
OTHER COMPONENTS
Pump Device
1 - Main pump 1 (front)
2 - Pilot pump
3 - Main pump 2 (rear)
4 - Pump 1 A sensor (Pump Displacement Sensor)
5 - Pump 1 delivery pressure sensor (P sensor)
6 - Pump 2 delivery pressure sensor (P sensor)
7 - Pump Control Proportional Solenoid valve 1
8 - Pump Control Proportional Solenoid valve 2
9 - Pump 2 A Sensor (Pump Displacement Sensor)
3
2
4
1
6
5
➮
A
SM5706
View A
9
6
8
5
7
4
19. COMPONENT LAYOUT
EX455 T1-2-9
Control valve
SM6509
Make-Up Valve
Holding Valve (Boom)
Overload Relief Valve
5-Spool Block
Pump Control Valve
(5-Spool Block Side)
DP Sensor
(5-Spool Block Side)
Shuttle Valve
Flow Combiner
Valve 4-Spool Block
Main Relief Valve
Front Side
SM6508
Travel (L)
Auxiliary
Boom 2
Arm 1
Swing
Overload Relief
Valve
Make-Up Valve
Holding Valve (Arm)
Overload Relief Valve
5-Spool
Block
Tank Port
T1
Tank Port
T2
4-Spool
Block
Pump Control Valve
(4-Spool Block Side)
Arm Regenerative
Valve
DP Sensor
(4-Spool Block Side)
Arm 2
Boom 1
Bucket
Front Side
Travel (R)
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