What's inside: the factory Fiat Kobelco workshop manual for the EX95W, print 604.13.237, Edition July 2002, 1,128 pages. The EX95W is a WHEELED excavator, so this book carries the running gear a tracked machine never has - travel hydraulic motor, transmission, front and rear axles, brakes and steering - alongside the digging end. You get the Perkins 1004.42 diesel from cylinder head to crankshaft, hydraulic pump and main control valve teardown, the swing device and center joint, technical specifications and filling charts, electrical component locations and the controller, hydraulic and electrical troubleshooting, and a full operational performance test section for measuring whether a repair actually worked. A full hydraulic system diagram sits on page 691 and the machine wiring diagram on page 805.
What's Inside This Fiat Kobelco EX95W Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| How to Use This Manual | 1-14 | Sections and Groups Indexes, Introduction, To the Reader, Manual Layout |
| Safety Rules | 15-60 | Generalities, Safety Precautions, Safety Signs |
| Specifications and Data | 61-88 | Technical Specifications, Filling Chart, Perkins 1004.42 Ratings, Operating Weights, Breakout Forces |
| Superstructure - Layout and Access | 89-144 | Upper Structure Layout, Cab and Canopy Removal, Counterweight, Engine Hood and Access Panels |
| Flexible Hoses and Connections | 145-156 | Hose Routing, Fittings, Connection Torques |
| Superstructure - Pumps, Valves and Swing Device | 157-358 | Hydraulic Pumps, Main Control Valve, Swing Device, Travel Pilot Valve, Center Joint |
| Undercarriage - Travel, Transmission and Axles | 359-552 | Travel Hydraulic Motor, Transmission, Front Axle, Rear Axle |
| Front-End Attachment | 553-628 | Boom, Arm, Bucket, Hydraulic Cylinders, Pins and Bushings |
| Hydraulic System | 629-692 | Main Circuit, Pilot and Brakes Circuit, Steering Circuit, Travel Circuit, Operation of Circuits, Hydraulic System Diagram |
| Electrical System | 693-806 | Location and Functions of Components, Controller, Arrangement and Operation, Wiring Harnesses, Wiring Diagram |
| Troubleshooting | 807-908 | Hydraulic Fault Diagnosis, Electrical Fault Diagnosis, Symptom Charts |
| Operational Performance Test | 909-946 | Performance Standard, Preparation for Performance Test, Excavator Performance Test, Hydraulic Components Performance Test |
| Perkins 1004.42 Engine | 947-1128 | General Information, Cylinder Head Assembly, Piston and Connecting Rod, Crankshaft, Engine Specifications |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | ||
| Engine make and model | PERKINS 1004.42 | p. 69 |
| Rated speed | 2000 rev/min | p. 69 |
| Setting power (ISO/TR14396) | 57 kW | p. 69 |
| Monobloc version | ||
| Operating weight (Rear blade) | 8850 kg | p. 73 |
| Monobloc version, Arm 1850 | ||
| Bucket breakout force | 5400 kg | p. 75 |
| Hydraulic System | ||
| Hydraulic pump (equipment/travel control) maximum output at 2000 rev/min | 150 l/min | p. 69 |
Fiat Kobelco EX95W Common Problems This Manual Covers
Slow cycle times and weak digging force
Run the checks in Section 10 Operational Performance Test (p. 909-946) before pulling anything apart. Measure pump output against the 150 l/min at 2000 rev/min figure and compare cycle times to the performance standard. If the pump is down, Section 4 (p. 157-358) carries the troubleshooting, specifications and disassembly for the pumps and main control valve.
Manual Section: Section 10 Operational Performance Test p. 909Machine creeps in gear or will not reach travel speed
On a wheeled excavator the fault can sit in the travel hydraulic motor, the transmission or the axles, and Section 5 Undercarriage (p. 359-552) covers all three with full disassembly procedures. Read the travel circuit operation in Section 7 first so you separate hydraulic causes from mechanical ones before you open anything up.
Manual Section: Section 5 UndercarriageSoft brakes or heavy steering
Both systems run off the hydraulics on this machine, not a vacuum booster. Section 7 lays out the pilot/brakes system and the steering system with circuit operation diagrams, so you can trace pressure step by step and prove whether the fault is in the valve, the lines or out at the axle end.
Manual Section: Section 7 Hydraulic SystemSlop in the boom pins and cylinders weeping oil
Section 6 Front-End Attachment (p. 553-628) covers the hydraulic cylinders plus the pins and bushings. Worn bushings start as rattle and end as cracked bosses, so catch them early. The section gives the procedures to pull pins, press new bushings and reseal cylinders, with Section 4 group 1A (p. 145-156) backing you up on hose connections.
Manual Section: Section 6 Front-End Attachment p. 553Frequently Asked Questions
Does this cover the axles, transmission and road gear, or just the digging end?
It treats the EX95W as what it is, a wheeled machine. Section 5 Undercarriage (p. 359-552) covers the travel hydraulic motor, the transmission and both axles, front and rear. Section 7 (p. 629-692) covers the brakes system and steering system along with the pilot circuit that feeds them. The 8850 kg operating weight rides on those axles, so the book gives them proper attention. p. 359
Is the Perkins engine rebuild in here, or do I need a separate engine manual?
Section 11 is a dedicated engine section for the Perkins 1004.42, the naturally aspirated four rated 57 kW at 2000 rev/min. It carries general information, specifications, cylinder head assembly, piston and connecting rod, and crankshaft. For a head job or a bottom end refresh you will not need a second book.
My machine digs slow and weak. Can I tell from this manual whether the pump is worn?
Yes, and without guessing. Section 10 Operational Performance Test (p. 909-946) gives the performance standards, the test preparation and the hydraulic component test procedures. The equipment/travel pump should make 150 l/min at 2000 rev/min; measure yours against that. If it fails, Section 4 (p. 157-358) has the pump troubleshooting, specifications and disassembly. p. 909
How do I know this is the right book for my machine?
Match the model and the print number. This is Fiat Kobelco print 604.13.237, Edition July 2002, for the EX95W wheel excavator. Do not confuse Fiat Kobelco with Fiat Allis, they are separate brands with separate manuals. The book does not state serial number breaks, so go by model and print number on your cover plate and paperwork.
Can I reseal my own cylinders and do the pins and bushings with this?
Section 6 Front-End Attachment (p. 553-628) covers the hydraulic cylinders and the pins and bushings. With 5400 kg of bucket breakout force working those joints, bushing wear is a when, not an if. Section 4 group 1A also covers the flexible hoses and connections, which is where you end up when chasing leaks on the boom.
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