Fiat Kobelco EX455 Excavator Service Repair Manual

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.

FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. FORM No. 604.13.221 Edition - July 2002

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ENGINEERING

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IN-2

EX455

INTRODUCTION PAGE NUMBER • Each page has a number, located on the external upper corner of the page. Each page number contains the following information: Example: T 1-2-3 Consecutive page number for each group Group number (if exist) Section number T : Technical Manual W : Workshop Manual

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.

Quantity

To convert from (SI)

Into (Others)

Multiply by

Quantity

To convert from (SI)

Into (Others)

Multiply by

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

kW

CV-PS

1.360

Volume Mass Force Torque

Power

L

US qt

1.057

kW

HP

1.341

m3

yd3

1.308

Temperature

°C

°F

°C x 1.8 + 32

kg

lb

2.205

Velocity

km/h

mph

0.621 4

N

kgf

0.101 97

N

lbf

0.224 8

N.m

kgf.m

0.10197

N.m

lbf.ft

0.737 5

min Flow rate

-1

rpm

1.0

L/min

US gpm

0.264 2

mL/rev

cc/rev

1.0

TECHNICAL MANUAL

EX455

OPERATIONAL PRINCIPLE

SECTION AND GROUP CONTENTS

Section 1 -

GENERAL

Group 1 Group 2

Specifications Component Layout

Section 2 -

SYSTEM

Group 1 Group 2 Group 3

Control System Hydraulic System Electrical System

Section 3 -

COMPONENT OPERATION

Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7

Pump Device Swing Device Control Valve Pilot Valve Travel Device Other Components (Upperstructure) Other Components (Undercarriage)

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

EX455

T1-1-1

SPECIFICATIONS EXCAVATOR DIMENSIONS (LCH version)

OM0872

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 (mm)

(2) 11 870 (2) 3 430

3 330 3 000 3 285 1 190

770

(3) 11 880 (3) 3 440

(▲) 7 000 mm Boom (*) Rear swing radius

With arm: (1) 2 900 mm (2) 3 400 mm (3) 3 900 mm

N-Track shoe width

(mm)

600

700

800

900

O-Maximum width (reduced for transport)

(mm)

2 890

2 990

3 090

3 190

O*-Maximum width (in work condition)

(mm)

3 390

3 490

3 590

3 690

(kg)

46 000

46 500

47 000

47 500

(bar)

0.83

0.72

0.64

0.57

Working weight Spec. Ground Pressure

DIGGING DATA

Arm Arm Arm 2 900 mm 3 400 mm 3 900 mm

OM0873

A

(mm)

11 390

12 050

12 430

A'

(mm)

11 140

11 820

12 200

B

(mm)

7 270

7 730

8 190

B'

(mm)

7 060

7 580

8 050

C

(mm)

10 040

10 990

11 060

D

(mm)

6 890

7 630

7 760

E

(mm)

5 060

4 980

4 920

T1-1-2

EX455

SPECIFICATIONS EXCAVATOR DIMENSIONS (BEH version)

OM0874

VERSION

A

EX455BEH (▲)

B

C

D

D'(*)

E

F

G

H

I

4 470 5 470 1 380 3 580 3 600 11 470 4 300 3 330 3 000 3 285

L

M

1 190

770

(mm) (▲) 6 300 mm Boom (*) Rear swing radius

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

(kg)

46 500

47 000

47 500

48 000

(bar)

0.83

0.73

0.64

0.58

Working weight Spec. Ground Pressure

DIGGING DATA

Arm 2 500 mm

OM0875

A

(mm)

10 700

A'

(mm)

10 360

B

(mm)

6 300

B'

(mm)

6 150

C

(mm)

9 800

D

(mm)

6 900

E

(mm)

4 950

EX455

T1-1-3

SPECIFICATIONS 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

T1-1-4

EX455

SPECIFICATIONS ENGINE ACCESSORY RADIATOR ASSEMBLY - Type ............................................................................................. Radiator/Oil Cooler tandem type assembly - Weight ..................................................................................................................................... 260 kg (573 lb) - Radiator Capacity...................................................................................................................................... 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 CONTROL VALVE - 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)

EX455

T1-1-5

SPECIFICATIONS CYLINDERS Boom

Arm

Bucket

Rod diameter

115 mm

130 mm

120 mm

Cylinder inner diameter

170 mm

190 mm

170 mm

1 590 mm 2 260 mm

1 940 mm 2 710 mm

1 321 mm 2 041 mm

Stroke Fully retracted length

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 - Cracking pressure ....................................................................................... 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

T1-1-6

EX455

SPECIFICATIONS NOTES

EX455

T1-2-1

COMPONENT LAYOUT MAIN COMPONENTS 2 1

3

35

4

5

6

7

8

9

10 11 12 13

34

14 15

33

16 32 31

17 30

18

29 28 27 26

20 22

25

21

24 23

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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Bucket Cylinder Arm Arm Cylinder Boom Boom Cylinder Front/Swing Pilot Valve Swing Bearing Center Joint Swing Device Fuel Tank Control Valve Engine Radiator Oil Cooler Counterweight Fuel Filters Engine Oil Filters Muffler

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

-

19

SM5701

3 Spool Solenoid Valve Unit Pump Device Pilot Filter Hydraulic Oil Tank Travel Device Shockless Valve (Travel) Upper Roller Swing Shuttle Valve Shockless Valve (Front) Lower Roller Travel Shuttle Valve Pilot Shut-Off Valve Track Adjuster Front Idler Air Filter Travel Pilot Valve Bucket

T1-2-2

EX455

COMPONENT LAYOUT ELECTRICAL SYSTEM (1) (Overall system) 2 3

4 5

1

12 6 7

13 8

9

10 11

31

30 29

14

28 15

27 26 16

25 24 23

18

17

22 21

20

19 SM5735

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

-

Work Light (On Boom) Monitor Pressure Switch (Travel) Horn Work Light Fuel Sensor with Fuel Low Level Switch Battery DP Sensor (4-Spool Side) Air Filter Restriction Switch Overheat Switch L Coolant Temperature Sensor (For Monitor) Overheat Switch H Alternator Engine Oil Level Switch Engine Oil Pressure Switch N (Engine Speed) Sensor

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

-

Starter EC Motor Coolant Level Switch DP Sensor (5-Spool Side) 3-Spool Solenoid Valve Unit Hydraulic Oil Level Switch Hydraulic Oil Temperature Switch Pressure Switch (Other) Pressure Switch (Swing) Pressure Switch (Arm Roll-In) Pressure Switch (Boom Raise) Windshield Washer Motor Fuse Box Wiper Box Wiper Motor

EX455

T1-2-3

COMPONENT LAYOUT ELECTRICAL SYSTEM (2) (Monitor and Switch panels)

15

16

17

18 1

19

42 14

20 2

41 21

40

22 23

39

24

38 3 13

37 36

25

35

26

34

27

12 11 10

4

28 33

5 29

9 6

30

7 32

31

8 SM6501

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

-

Monitor Panel Switch Panel Cigar Lighter Provision for Hydraulic Breaker Control Switch Provision for Nordic Kit Control Switch Provision for Rotary Bucket Control Switch Provision for Load Momentum Alarm Control Switch Provision for further option Control Switch Air Conditioner Control Panel Engine Control Dial E Mode Switch SP Mode Switch Key Switch Power Boost Switch Warm Up Complete Indicator Coolant Temperature Gauge Fuel Gauge SP Mode Indicator E Mode Indicator Auto-Idle Indicator Hydraulic Oil Level Indicator

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

-

Preheat Indicator Air Filter Restriction Indicator Fuel Level Indicator Attachment Mode Indicator Precision Mode Indicator Trenching Mode Indicator General Purpose Mode Indicator Work Mode Switch Buzzer Stop Switch Travel Mode Switch Auto-Idle Switch Wiper Switch Washer Switch Work Light Switch Level Check Switch Hydraulic Breaker filter clogging Indicator (opt) Overheat Indicator Engine Oil Pressure Indicator Alternator Indicator Engine Oil Level Indicator Coolant Level Indicator

T1-2-4

EX455

COMPONENT LAYOUT 1

View C

ELECTRICAL SYSTEM (3) (Relays, Diodes, etc.)

F

Cab compartment

2 View E

20 3

View B

➮

19

4

A

➮

View D

D

17 16 15

➮

B

➮

18

➮

E

C

5 Detail F

12 13 14

View A

6 7 8 9 10 11

SM5702

11 12 13 14 15 16 17 18 19 10

-

EC controller PVC controller Air conditioner relays (if installed) Q.O.S. Controller Relay box Load momentum alarm buzzer provision Load momentum alarm relay provision (R1) R.H. Rotation bucket relay provision (R3) L.H. Rotation bucket relay provision (R4) Cab light relay (R5)

11 12 13 14 15 16 17 18 19 20

-

Rear Cab light relay (R6) EC Motor relay (R7) Diodes 1-2 Diodes 3-4-5 A-B-C junction connector D-E-F junction connector G-H-I junction connector J-K-L junction connector Dr. EX connector Fuse box

EX455

T1-2-5

COMPONENT LAYOUT ELECTRICAL SYSTEM (3) (Relays, Diodes, etc) Cab side

1

2

3

4

8

5

7

6

SM5604

1 2 3 4 5

-

Connectors for monitor and switch panels Cigarette lighter Connectors to cab harness Connectors not used Windshield wiper controller

6

7 8

- (1) connector for breaker switch (2) connector for cab light switch (3) connector for bucket rotation (4) connector for load momentum alarm switch (5) connector for rear cab light - Connector not used - Wiper motor connector

T1-2-6

EX455

COMPONENT LAYOUT ELECTRICAL SYSTEM (4) (Relays, Batteries, Fuses)

1

8

3

7 2

4

5

5 6

SM5703

1 2 3 4

-

Fuse Link 1 (50A) Fuse Link 2 (40A) Fuse Link 3 (80A) Starter relay

5 6 7 8

-

Battery relay Battery Glow relay Connection box

EX455

T1-2-7

COMPONENT LAYOUT ELECTRICAL SYSTEM (5) (Fuses) FUSES IN THE BOX Fuse No.

LABEL

PROTECTED CIRCUIT

1

SW. BACK UP

2

ENG. C/U

3

E.C. MOTOR

Ec Motor

4

AUXILIARY

Auxiliary power supply

5

5

REAR CAB (LIGHT)

Rear Cab light power supply

10

6

LUBRICATOR

Lubricator power supply

10

7

ROTARY BUCKET

Rotary bucket solenoid valve power supply

10

8

SOLENOID

Solenoid valve power supply

5

9

SW. BOX

Switch box power supply

5

10

HEATING SEAT

Operator's heating seat power supply

10

11

WIPER

Wiper

10

12

HEATER

Heater power supply

20

13

LIGHT

Work light power supply

15

14

CAB LIGHT

Cab light power supply

10

15

RADIO

Radio power supply

5

16

LIGHTER

Lighter power supply

15

17

HORN

Hornes

10

18

GLOW RELAY

Glow relay power supply

5

19

POWER ON

Power on signal from key switch

5

20

AIR COND.

Air conditioning

10

Back-up power Main power supply for EC Controller

Rating (A) 5 10 10 OM0231

20 19 18 17 16 15 14 13 12 11

10 9

8

7

6

5

4

3

Fuses in the fuse box

2

1

OM0232

FUSES IN THE TOOL KIT AND BATTERIES COMPARTMENT –

FUSE (1)

Batteries power supply

50

–

FUSE (2)

Glow plug power supply

40

–

FUSE (3)

Main power supply with key

80

Fuse link (1), (2) and (3) SM5704

Fuses in the tool kit and batteries compartment

T1-2-8

EX455

COMPONENT LAYOUT OTHER COMPONENTS Pump Device 5

6

➎ A

2

1

4

3

View A

9

8

6

5

4

7 SM5706

1 2 3 4 5

-

Main pump 1 (front) Pilot pump Main pump 2 (rear) Pump 1 A sensor (Pump Displacement Sensor) Pump 1 delivery pressure sensor (P sensor)

6 7 8 9

-

Pump Pump Pump Pump

2 delivery pressure sensor (P sensor) Control Proportional Solenoid valve 1 Control Proportional Solenoid valve 2 2 A Sensor (Pump Displacement Sensor)

EX455

T1-2-9

COMPONENT LAYOUT Control valve

Travel (R) Bucket

Front Side Travel (L)

Boom 1 Arm 2

Auxiliary

Arm Regenerative Valve

Boom 2 Arm 1

DP Sensor (4-Spool Block Side)

Swing

Pump Control Valve (4-Spool Block Side)

Overload Relief Valve

4-Spool Block

Make-Up Valve

Tank Port T2 Holding Valve (Arm) Tank Port T1

Overload Relief Valve 5-Spool Block

SM6508

DP Sensor (5-Spool Block Side) Pump Control Valve (5-Spool Block Side) 5-Spool Block Make-Up Valve

Overload Relief Valve Front Side

Holding Valve (Boom)

Main Relief Valve

Shuttle Valve Flow Combiner Valve

4-Spool Block SM6509

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T1-2-10

EX455

COMPONENT LAYOUT

Travel Device

Swing Device 1

3

2

SM6506

SM6505

3-Spool Solenoid Valve Unit 4

5

6

7

SM6507

1 2 3 4

-

Swing Relief Valve Counterbalance Valve Travel Relief Valve Swing Parking Brake Release Solenoid Valve (SC)

5 6 7

- Travel Mode Shift Solenoid Valve (SB) - Main Relief Pressure Shift Solenoid Valve (SA) - Pilot Relief Valve

SECTION 2

EX455

SYSTEM

CONTENTS Group 1 -

Control System

Outline .................................................... T2-1-1 Engine Control ........................................ T2-1-2 Pump Control .......................................... T2-1-6 Valve Control ........................................ T2-1-14 Other Control ........................................ T2-1-19

Group 2 -

Hydraulic System

Outline ................................................. T2-2-1 Main Circuit .......................................... T2-2-2 Pilot Circuit .......................................... T2-2-7

Group 3 -

Electrical System

Outline ................................................... T2-3-1 Power Circuit .......................................... T2-3-2 Bulb Check Circuit ................................. T2-3-4 Accessory Circuit .................................. T2-3-6 Preheat Circuit ....................................... T2-3-8 Engine Start Circuit............................. T2-3-10 Charging Circuit .................................. T2-3-12 Surge Voltage Prevention Circuit ......... T2-3-14 Engine Stop Circuit ............................. T2-3-16