Fiat Kobelco E145W E175W Crawler Excavator Service Manual

02803 60413258 F19072 WORKSHOP MANUAL IMPORTANT: The information contained in this manual are valid at printing time. As the Manufacturer continuously improves his products, some information may not be updated. In case of discrepancies, apply to Sales and Service Department. FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. - ENGINEERING PRINT 604.13.258 Edition April 2003 - Printed in Italy EXCAVATOR

02803 60413258

02803 60413258 INTRODUCTION TO THE READER • This manual has been written for a skilled technician, in order to give him the information necessary to repair this machine. - Read this manual carefully for correct information about repair procedures. - For any question or comment, or in case you notice a mistake in this manual content, please contact: FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. Strada Settimo, 323 San Mauro Torinese (TO) 10099 ITALIA PRODUCT SUPPORT Fax. ++39 011 0077357 ADDITIONAL REFERENCE MANUALS • In addition to this Workshop Manual, refer also to the following: - Operation and maintenance instruction manual - Spare parts catalog DESCRIPTION OF THE COMPLETE WORKSHOP MANUAL • The complete repair manual consists of two volumes: E145W EVOLUTION - E175W EVOLUTION Workshop Manual "Excavator" E145W EVOLUTION - E175W EVOLUTION Workshop Manual "Engine" • "Excavator" and "Engine" Workshop Manuals contain the technical information necessary for machine/engine service and repair, service equipment, information on maintenance standards, remove and install procedures, disassembly and assembly procedures. • The complete Workshop Manual for the excavator models E145W EVOLUTION, E175W EVOLUTION consists of the following volumes identified by print number as shown herebelow: VOLUME - Workshop Manual - "Excavator" - Workshop Manual - "Engine" MACHINE TYPE E145W-E175W E145W-E175W PRINT No. 604.13.258 604.13.263

02803 60413258 INTRODUCTION AVOID ACCIDENTS Most accidents, whether they occur in industry, on the farm, at home or on the highway, are caused by the failure of some individuals to follow simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs. Regardless of the care used in the design and construction of any type of equipment there are conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation. Carefully read indications, cautions and safety warning quoted in the “SAFETY RULES” section. A careful operator is the best insurance against an accident. The complete observance of one simple rule would prevent many thousand serious injuries each year. That rule is: Never attempt to clean, oil or adjust a machine while it is in motion. ATTENTION On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels, loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical device used for controlling the equipment. COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. Product Support - Documentation Centre Strada di Settimo, 323 - S. Mauro T.SE (TO) ITALY All rights reserved. Reproduction of text and illustrations in whole or in part, is strictly prohibited.

02803 60413258 SECTION 1 HOW TO USE INDEX Sections index ................................................................................................................... 1-1 Introduction ....................................................................................................................... 1-3 Introduction ................................................................................................................................................... 1-3 Manual handling ............................................................................................................................................ 1-3 Symbols and indications ............................................................................................................................... 1-4 Features of the manual ..................................................................................................... 1-5 Manual composition ...................................................................................................................................... 1-5 Brief information for manual consultation ...................................................................................................... 1-7

02803 60413258

1-1 SECTIONS INDEX 02803 60413258 SECTION 1 - HOW TO USE Sections index ................................................................................................................ 1-1 Introduction ..................................................................................................................... 1-3 Features of the manual ................................................................................................... 1-5 SECTION 2 - SAFETY RULES Safety rules ...................................................................................................................... S1 Safety signs ................................................................................................................... S35 SECTION 3 - FEATURES Foreword ........................................................................................................................ 3-1 Identification data ........................................................................................................... 3-2 Noise levels (2000/14/EEC) ........................................................................................... 3-3 Summary plate for maintenance operations ................................................................... 3-5 Basic components of the wheeled excavator with monobloc ......................................... 3-6 Basic components of the wheeled excavator with triple articulation ............................... 3-7 Reading key for the liftable load chart located in the cab ............................................ 3-31 Filling chart model E145W EVOLUTION ...................................................................... 3-32 Filling chart model E175W EVOLUTION ...................................................................... 3-33 SECTION 4 - SUPERSTRUCTURE Superstructure ................................................................................................................ 4-1 Main frame and counterweight ....................................................................................... 4-6 Power unit ..................................................................................................................... 4-11 Hydraulic pumps ........................................................................................................... 4-18 Hydraulic oil reservoir ................................................................................................... 4-63 Fuel reservoir ................................................................................................................ 4-65 Covers and protections ................................................................................................. 4-67 Cab ............................................................................................................................... 4-71 Main control valve ......................................................................................................... 4-83 Swing device .............................................................................................................. 4-116 Hand pilot valve .......................................................................................................... 4-147 Travel pilot valve ......................................................................................................... 4-152 Steering valve ............................................................................................................. 4-154 Center joint ................................................................................................................. 4-176 Brake pedal valve ....................................................................................................... 4-179 Accumulators .............................................................................................................. 4-194 Pressure switches ...................................................................................................... 4-197 Solenoid valves .......................................................................................................... 4-200 SECTION 5 - UNDERCARRIAGE Swing bearing ................................................................................................................. 5-3 Lower frame .................................................................................................................... 5-7 Travel unit ....................................................................................................................... 5-8 Wheels and tyres ........................................................................................................ 5-349 Blade assembly .......................................................................................................... 5-362 Lateral stabilizers ........................................................................................................ 5-363 SECTIONS INDEX PAGES

1-2 SECTIONS INDEX 02803 60413258 SECTION 6 - FRONT-END ATTACHMENT Monobloc front-end attachment ...................................................................................... 6-1 Triple articulation front-end attachment .......................................................................... 6-8 Cylinder removal and installation .................................................................................. 6-15 Cylinders ....................................................................................................................... 6-39 Cylinders ....................................................................................................................... 6-67 Antidrop valves ............................................................................................................. 6-96 Pins and bushings ........................................................................................................ 6-98 Pins and bushings ...................................................................................................... 6-100 Nominal dimensions for the connection between the arm and the bucket ................. 6-102 SECTION 7 - HYDRAULIC SYSTEM Hoses and connections .................................................................................................. 7-1 Hydraulic system ............................................................................................................ 7-8 Operation of circuits ...................................................................................................... 7-48 SECTION 8 - ELECTRICAL SYSTEM Safety rules ..................................................................................................................... 8-1 Specifications and data .................................................................................................. 8-2 Location and functions of components ........................................................................... 8-4 Instruments and controls ................................................................................................ 8-9 APC50 electronic unit ................................................................................................... 8-30 Electric components ..................................................................................................... 8-37 Control line and wiring harnesses ................................................................................ 8-42 SECTION 9 - TROUBLESHOOTING Introduction ..................................................................................................................... 9-1 Hydraulic system troubleshooting ................................................................................... 9-3 Electrical system troubleshooting ................................................................................. 9-33 SECTION 10 - PERFORMANCE TEST Introduction ................................................................................................................... 10-1 Standard performances ................................................................................................ 10-2 Preparation for performance test ................................................................................ 10-10 Excavator peformance test ......................................................................................... 10-12 Lift/swing performance ............................................................................................... 10-20 Combined boom raise/swing function check ............................................................. 10-20 Component performance test ..................................................................................... 10-26

1-3 INTRODUCTION 02803 60413258 INTRODUCTION INTRODUCTION This service manual has been prepared in order to increase repair quality, providing to the technicians the elements for a good knowledge of the product and showing the proper procedures to carry out the maintenance operations. We recommend to thoroughly read the content and follow it when necessary. It is a concise guide. It covers construction features, operation principle, troubleshooting, disassembly and assembly of components and repair action. Using this manual in systematic and rational way it is possible to reduce the repairing errors and delay that could cause machine stop with a detriment of cost management. The information quoted in this service manual are supplied also to be used for training aids. Therefore it is advisable to be used in the training of new personnel that will be employed in the machine maintenance. All the information, illustrations and specifications contained in this service manual are based on the latest product information available at the time of publication. The dealer reserves the right to makes changes at any time without notice to this service manual for technical or trading reasons. MANUAL HANDLING CHANGES AND SUPPLEMENTS This service manual is carried out in loose-leaf and therefore can be easily kept up-to-date. The personnel in charge is responsible for updating the manual and will insert the changes or supplements that the Dealer will issue to its service organisation.

1-4 INTRODUCTION 02803 60413258 SYMBOLS AND INDICATIONS In this service manual, symbols and indications are used to draw the attention on important points for safety and quality. SAFETY This safety symbol is used for important safety message. When you see this symbol, be alert to the potential for personal injury. Strictly follow the recommended precautions. INDICATIONS Reading this service manual you can find indications as “IMPORTANT” or “NOTE” that have the following meaning: • IMPORTANT Indicates a situation which, if not avoided, could caused damages to the machine. • Note Indicates supplementary technical information or know-how.

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Fiat Kobelco E145W E175W Crawler Excavator Service Manual

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