The boom settles toward the dirt with a loaded bucket, the crew is standing around, and the dealer cannot get a fitter out until next week. This is the July 2002 Fiat Kobelco workshop manual, print 604.13.237, written for the EX95W wheeled excavator.
It covers the main and swing pumps, main control valve, swing device, center joint, travel motor, transmission and both axles, plus the boom, stick and cylinders. A bound-in Perkins 1000 Series section takes the 1004.42 down to crankshaft, timing and coolant pump. Fold-out hydraulic and wiring diagrams are included.
When it is just you and the machine with nobody to ring, the drift test, start circuit chart and performance test procedures tell you where to look first. Then the EX95W drives back onto the job under its own power.
What's Inside This Fiat Kobelco EX95W Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction and How to Use the Manual | 1-14 | Cover, Publication 604.13.237, Groups Indexes, Features of the Manual |
| Safety Rules | 15-60 | Safety Precautions, Safety Signs |
| Characteristics and Technical Data | 61-88 | Machine Overview, Technical Specifications, Dimensions and Lifting Capacities, Filling Chart |
| Superstructure | 89-156 | Engine Group, Cab, Counterweight, Flexible Hoses and Connections |
| Hydraulic Pumps and Control Valves | 157-248 | Main Pump and Swing Pump, Control Valves, Main Control Valve |
| Swing Device and Hydraulic Valves | 249-358 | Swing Device, Travel Pilot Valve, Center Joint, Steering Valve, Brake Pedal Valve, Accumulators, Solenoid Valves |
| Undercarriage and Travel Hydraulic Motor | 359-418 | Undercarriage, Wheels and Tyres, Travel Hydraulic Motor |
| Transmission and Axles | 419-552 | Transmission, Rear Axle, Front Axle, Braking Unit, Axle Disassembly and Assembly, Special Tools, Axle Troubleshooting, Transmission Shaft |
| Front-End Attachment | 553-628 | Boom and Stick, Hydraulic Cylinders, Pins and Bushings |
| Hydraulic System | 629-689 | Main Hydraulic System, Pilot and Brakes System, Steering System, Brakes System, Operation of Circuits, Travel Circuit |
| Hydraulic System Diagram | 690-692 | Hydraulic System Parts List, Fold-Out Hydraulic System Diagram |
| Electrical System and Circuits | 693-780 | Specifications and Data, Location and Functions of Components, Arrangement and Operation of Electrical Circuits |
| Controller, Electric Components and Wiring Diagram | 781-806 | Electrical System Generalities, Controller, Electric Components, Compartment Wiring Drawings, Fold-Out Wiring Diagram |
| Hydraulic System Troubleshooting | 807-842 | Troubleshooting Introduction |
| Electrical System Troubleshooting | 843-908 | Electrical Circuit Checks, Engine Speed Control, Test Harnesses |
| Operational Performance Test | 909-946 | Performance Standard, Preparation, Excavator Performance Test, Hydraulic Components Performance Test |
| Perkins 1004.42 Engine: Cylinder Head, Pistons and Crankshaft | 947-1060 | General Information, Engine Specifications, Cylinder Head Assembly, Piston and Connecting Rod, Crankshaft, Timing Case Cover and Drive, Cylinder Block |
| Perkins 1004.42 Engine: Timing, Lubrication, Fuel and Cooling | 1061-1128 | Engine Timing, Lubrication System, Fuel System, Cooling System, Flywheel and Housing, Electrical Equipment, Auxiliary Equipment |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine make and model | PERKINS 1004.42 | p. 69 |
| Engine type | diesel, 4 strokes, naturally-aspirated | p. 69 |
| Setting power (ISO/TR14396) | 57 kW | p. 69 |
| Setting power (80/1269 CEE) | 53 kW | p. 69 |
| Rated speed | 2000 rev/min | p. 69 |
| Displacement | 4233 cm³ | p. 69 |
| Bore and stroke | 103x127 mm | p. 69 |
| Equipment/travel pump maximum operating pressure | 350 bar | p. 69 |
| Equipment/travel pump maximum output at 2000 rev/min | 150 l/min | p. 69 |
| Swing control pump maximum operating pressure | 310 bar | p. 69 |
| Swing speed | 9 rev/min | p. 71 |
| Engine cooling system capacity | 18.5 litres | p. 87 |
| Fuel tank capacity | 147 litres | p. 87 |
| Engine oil capacity | 8.5 litres | p. 87 |
| Attachment hydraulic system capacity | 120 litres | p. 87 |
| Front axle differential / rear axle differential oil | 7 litres each | p. 87 |
| Swing reduction unit oil | 3 litres | p. 87 |
Fiat Kobelco EX95W Common Problems This Manual Covers
Front attachment drifts down while holding a loaded bucket
Oil is leaking past the main control valve, the cylinders, or both. Use the drift test in the Operational Performance Test section, then the Hydraulic System Troubleshooting pages, before you strip the boom or arm cylinders.
Manual Section: Operational Performance Test / Hydraulic System Troubleshooting p. 929Diesel engine will not start and the starter does not turn
The Electrical System Troubleshooting chart walks the start circuit in order. It checks start-up relay R20, cables 505, 523 and 525, the start-up key, then monitor pin C14. Use the fold-out wiring diagram to find each point on the machine.
Manual Section: Electrical System Troubleshooting p. 886Coolant leaking from the hole in the coolant pump body
Coolant there means it has got past the seal and into the bearings. Topping up will not fix it. The Perkins cooling system section covers removing and overhauling the pump.
Manual Section: Perkins 1004.42 Engine: Timing, Lubrication, Fuel and Cooling - Cooling system p. 1099Low brake pressure warning comes on
The brake low pressure switch monitors accumulator charge, so the warning points at the charging side. Work through the accumulator charge circuit and charge valve using the pilot and brakes system pages. Check the accumulators themselves in the hydraulic valves section.
Manual Section: Hydraulic System - Pilot and Brakes System / Swing Device and Hydraulic Valves - Accumulators p. 660Frequently Asked Questions
My boom and stick creep down with a full bucket. Can this book tell me if it is the valve or the cylinders?
Yes. The Operational Performance Test section gives a drift test that separates control valve leakage from cylinder leakage. Run it before you pull a cylinder. Swapping boom cylinder seals when the spool is passing oil wastes a day and a seal kit. p. 929
What pressures and flows should the pumps make on a healthy machine?
The equipment/travel pump is rated at 350 bar maximum operating pressure and 150 l/min at 2000 rev/min. The swing control pump is rated at 310 bar, and swing speed is 9 rev/min. The Operational Performance Test section covers preparation and the component tests to check your gauge readings against. p. 69
Does it cover the Perkins engine, or only the excavator?
The engine is a PERKINS 1004.42: diesel, 4 strokes, naturally-aspirated, 4233 cm³, bore and stroke 103x127 mm. Setting power is 57 kW (ISO/TR14396) at 2000 rev/min. A bound-in Perkins section covers the cylinder head, pistons, connecting rods, crankshaft, timing, lubrication, fuel and cooling systems. p. 69
Are the hydraulic and wiring diagrams actually in there, or just referenced?
Both are bound in as fold-outs. The hydraulic diagram has its own parts list, and the wiring diagram comes with compartment wiring drawings. Tracing a pilot line or a dead circuit on paper instead of by guesswork is the reason to own the book. p. 691
What are the fluid capacities for a full service on the EX95W?
The filling chart lists engine oil at 8.5 litres and the cooling system at 18.5 litres. The fuel tank holds 147 litres and the attachment hydraulic system 120 litres. Front and rear axle differentials take 7 litres each, and the swing reduction unit takes 3 litres. p. 87
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