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. - ENGINEERING -

FORM No. 604.13.221 Edition - July 2002
EX455 IN-1

INTRODUCTION

TO THE READER

• This manual is written for an experienced technician - If you have any questions or comments, or if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact:

- Be sure to thoroughly read this manual for correct FIAT KOBELCO CONSTRUCTION
information concerning the service procedures. MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALY
PRODUCT SUPPORT
Fax. ++39 011 6877357

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition

to this service manual:

- Operation and Maintenance Instruction

Manual
- Parts Catalog

SERVICE MANUAL COMPOSITION

• The complete service manual consists of three
books:
- Technical Manual - Operational Principle
- Technical Manual - Troubleshooting
- Workshop Manual
- The Workshop Manual includes information needed
for maintenance and repair of the machine, tools and
devices needed for maintenance and repair, mainte-
nance standards, removal/installation and assem-
bly/disassembly procedures.

- The Technical Manual - Operational Principle in- • The Service Manual for EX455 Excavator consists
cludes the technical information concerning the of the following book/print numbers:
operation of main devices and systems.

- The Technical Manual -Troubleshooting includes

the technical information needed for operational
performance tests, and troubleshooting procedures.

BOOK PRINT NUMBER

- Technical Manual - Operational Principle 604.13.221
- Technical Manual - Troubleshooting 604.13.226
- Workshop Manual 604.13.231
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.

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
-1
Force N kgf 0.101 97 min 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
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

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)
SECTION 1
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
EX455
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 (2) 11 870 (2) 3 430 3 330 3 000 3 285 1 190 770
(mm) (3) 11 880 (3) 3 440

With arm: (▲) 7 000 mm Boom

(1) 2 900 mm (*) Rear swing radius
(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

Working weight (kg) 46 000 46 500 47 000 47 500

Spec. Ground Pressure (bar) 0.83 0.72 0.64 0.57

DIGGING DATA

Arm Arm Arm

2 900 mm 3 400 mm 3 900 mm

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

OM0873
T1-1-2 EX455

SPECIFICATIONS

EXCAVATOR DIMENSIONS
(BEH version)

OM0874

VERSION A B C D D'(*) E F G H I L M

EX455BEH (▲) 4 470 5 470 1 380 3 580 3 600 11 470 4 300 3 330 3 000 3 285 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

Working weight (kg) 46 500 47 000 47 500 48 000

Spec. Ground Pressure (bar) 0.83 0.73 0.64 0.58

DIGGING DATA

Arm
2 500 mm

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
OM0875
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
Stroke 1 590 mm 1 940 mm 1 321 mm
Fully retracted length 2 260 mm 2 710 mm 2 041 mm

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

1
3

35 4
5
6
7
8
9
10
11
12
13
34 14

15

33

16
32
17
31
30 18
29 19
28 20
27 21
26 22
25
24
23 SM5701

1 - Bucket Cylinder 19 - 3 Spool Solenoid Valve Unit

2 - Arm 20 - Pump Device
3 - Arm Cylinder 21 - Pilot Filter
4 - Boom 22 - Hydraulic Oil Tank
5 - Boom Cylinder 23 - Travel Device
6 - Front/Swing Pilot Valve 24 - Shockless Valve (Travel)
7 - Swing Bearing 25 - Upper Roller
8 - Center Joint 26 - Swing Shuttle Valve
9 - Swing Device 27 - Shockless Valve (Front)
10 - Fuel Tank 28 - Lower Roller
11 - Control Valve 29 - Travel Shuttle Valve
12 - Engine 30 - Pilot Shut-Off Valve
13 - Radiator 31 - Track Adjuster
14 - Oil Cooler 32 - Front Idler
15 - Counterweight 33 - Air Filter
16 - Fuel Filters 34 - Travel Pilot Valve
17 - Engine Oil Filters 35 - Bucket
18 - Muffler
T1-2-2 EX455
COMPONENT LAYOUT

ELECTRICAL SYSTEM (1)

(Overall system)

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

31

30
29 14
28
27 15
26
25 16
24 17
23 18
22
21
20
19
SM5735

1 - Work Light (On Boom) 17 - Starter

2 - Monitor 18 - EC Motor
3 - Pressure Switch (Travel) 19 - Coolant Level Switch
4 - Horn 20 - DP Sensor (5-Spool Side)
5 - Work Light 21 - 3-Spool Solenoid Valve Unit
6 - Fuel Sensor with Fuel Low Level Switch 22 - Hydraulic Oil Level Switch
7 - Battery 23 - Hydraulic Oil Temperature Switch
8 - DP Sensor (4-Spool Side) 24 - Pressure Switch (Other)
9 - Air Filter Restriction Switch 25 - Pressure Switch (Swing)
10 - Overheat Switch L 26 - Pressure Switch (Arm Roll-In)
11 - Coolant Temperature Sensor (For Monitor) 27 - Pressure Switch (Boom Raise)
12 - Overheat Switch H 28 - Windshield Washer Motor
13 - Alternator 29 - Fuse Box
14 - Engine Oil Level Switch 30 - Wiper Box
15 - Engine Oil Pressure Switch 31 - Wiper Motor
16 - N (Engine Speed) Sensor
EX455 T1-2-3
COMPONENT LAYOUT

ELECTRICAL SYSTEM (2)

(Monitor and Switch panels)

15 16 17

18
1
42 19
20
14
2 41
21
40
22
39 23
24
38

37
3
13 36 25
12
35 26
11 34 27
4 28
10
33
5
9 29
6
30

7
32 31
8

SM6501

1 - Monitor Panel 22 - Preheat Indicator

2 - Switch Panel 23 - Air Filter Restriction Indicator
3 - Cigar Lighter 24 - Fuel Level Indicator
4 - Provision for Hydraulic Breaker Control Switch 25 - Attachment Mode Indicator
5 - Provision for Nordic Kit Control Switch 26 - Precision Mode Indicator
6 - Provision for Rotary Bucket Control Switch 27 - Trenching Mode Indicator
7 - Provision for Load Momentum Alarm Control Switch 28 - General Purpose Mode Indicator
8 - Provision for further option Control Switch 29 - Work Mode Switch
9 - Air Conditioner Control Panel 30 - Buzzer Stop Switch
10 - Engine Control Dial 31 - Travel Mode Switch
11 - E Mode Switch 32 - Auto-Idle Switch
12 - SP Mode Switch 33 - Wiper Switch
13 - Key Switch 34 - Washer Switch
14 - Power Boost Switch 35 - Work Light Switch
15 - Warm Up Complete Indicator 36 - Level Check Switch
16 - Coolant Temperature Gauge 37 - Hydraulic Breaker filter clogging Indicator (opt)
17 - Fuel Gauge 38 - Overheat Indicator
18 - SP Mode Indicator 39 - Engine Oil Pressure Indicator
19 - E Mode Indicator 40 - Alternator Indicator
20 - Auto-Idle Indicator 41 - Engine Oil Level Indicator
21 - Hydraulic Oil Level Indicator 42 - Coolant Level Indicator
T1-2-4 EX455
COMPONENT LAYOUT

ELECTRICAL SYSTEM (3) View C 1

(Relays, Diodes, etc.) F

Cab compartment

2
View E

20
3

View B

19
➮ A
4

➮
View D

➮
18
D
➮
17
16 B
➮

15
C

5
Detail F

View A
6
12
7
13
14 8
9
10
11

SM5702

11 - EC controller 11 - Rear Cab light relay (R6)

12 - PVC controller 12 - EC Motor relay (R7)
13 - Air conditioner relays (if installed) 13 - Diodes 1-2
14 - Q.O.S. Controller 14 - Diodes 3-4-5
15 - Relay box 15 - A-B-C junction connector
16 - Load momentum alarm buzzer provision 16 - D-E-F junction connector
17 - Load momentum alarm relay provision (R1) 17 - G-H-I junction connector
18 - R.H. Rotation bucket relay provision (R3) 18 - J-K-L junction connector
19 - L.H. Rotation bucket relay provision (R4) 19 - Dr. EX connector
10 - Cab light relay (R5) 20 - Fuse box
EX455 T1-2-5
COMPONENT LAYOUT

ELECTRICAL SYSTEM (3)

(Relays, Diodes, etc)

Cab side
1 2

8 7 5

SM5604

1 - Connectors for monitor and switch panels 6 - (1) connector for breaker switch
2 - Cigarette lighter (2) connector for cab light switch
3 - Connectors to cab harness (3) connector for bucket rotation
4 - Connectors not used (4) connector for load momentum alarm switch
5 - Windshield wiper controller (5) connector for rear cab light
7 - Connector not used
8 - Wiper motor connector
T1-2-6 EX455
COMPONENT LAYOUT

ELECTRICAL SYSTEM (4)

(Relays, Batteries, Fuses)

1 3

8
7

5
6

SM5703

1 - Fuse Link 1 (50A) 5 - Battery relay

2 - Fuse Link 2 (40A) 6 - Battery
3 - Fuse Link 3 (80A) 7 - Glow relay
4 - Starter relay 8 - Connection box
EX455 T1-2-7
COMPONENT LAYOUT

ELECTRICAL SYSTEM (5)

(Fuses)

FUSES IN THE BOX

Fuse PROTECTED Rating
No. LABEL CIRCUIT (A)
Back-up
1 SW. BACK UP power 5
Main power
2 ENG. C/U supply for 10
EC Controller

3 E.C. MOTOR Ec Motor 10

OM0231
Auxiliary
4 AUXILIARY power supply 5
REAR CAB Rear Cab light
5 (LIGHT) power supply 10
Lubricator
6 LUBRICATOR power supply 10 20 19 18 17 16 15 14 13 12 11
Rotary bucket
7 ROTARY solenoid valve 10
BUCKET power supply
10 9 8 7 6 5 4 3 2 1
Solenoid valve
8 SOLENOID power supply 5

Switch box OM0232

9 SW. BOX power supply 5 Fuses in the fuse box
HEATING Operator's heating
10 SEAT seat power supply 10

11 WIPER Wiper 10
Heater
12 HEATER power supply 20
Work light
13 LIGHT power supply 15
Cab light
14 CAB LIGHT power supply 10
Radio
15 RADIO power supply 5
16 LIGHTER Lighter
power supply 15
17 HORN Hornes 10
Glow relay
18 GLOW RELAY power supply 5
Power on signal
19 POWER ON from key switch 5

20 AIR COND. Air conditioning 10

FUSES IN THE TOOL KIT AND BATTERIES

COMPARTMENT
Batteries
– FUSE (1) power supply 50

Glow plug
– FUSE (2) power supply 40 Fuse link (1), (2) and (3)
Main power SM5704
– FUSE (3) supply with key 80
Fuses in the tool kit and batteries compartment
T1-2-8 EX455
COMPONENT LAYOUT

OTHER COMPONENTS
Pump Device
5 6

➮
A

View A
9

4 7
SM5706

1 - Main pump 1 (front) 6 - Pump 2 delivery pressure sensor (P sensor)

2 - Pilot pump 7 - Pump Control Proportional Solenoid valve 1
3 - Main pump 2 (rear) 8 - Pump Control Proportional Solenoid valve 2
4 - Pump 1 A sensor (Pump Displacement Sensor) 9 - Pump 2 A Sensor (Pump Displacement Sensor)
5 - Pump 1 delivery pressure sensor (P sensor)
EX455 T1-2-9
COMPONENT LAYOUT

Control valve

Travel (R)
Front Side
Bucket
Travel (L) Boom 1
Auxiliary Arm 2

Boom 2 Arm Regenerative

Valve
Arm 1
DP Sensor
Swing (4-Spool Block Side)

Overload Relief Pump Control Valve

Valve (4-Spool Block Side)

4-Spool
Make-Up Valve
Block

Tank Port
T2
Holding Valve (Arm)

Overload Relief Valve Tank Port

T1

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)

Shuttle Valve Main Relief Valve

Flow Combiner
Valve 4-Spool Block

SM6509
T1-2-10 EX455
COMPONENT LAYOUT

Swing Device Travel Device

SM6506

SM6505

3-Spool Solenoid Valve Unit

4 5 6 7

SM6507

1 - Swing Relief Valve 5 - Travel Mode Shift Solenoid Valve (SB)

2 - Counterbalance Valve 6 - Main Relief Pressure Shift Solenoid Valve (SA)
3 - Travel Relief Valve 7 - Pilot Relief Valve
4 - Swing Parking Brake Release Solenoid Valve (SC)
SECTION 2
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
EX455
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
EX455 T2-1-1
CONTROL SYSTEM

OUTLINE

A microcomputer-built-in pump/valve controller

(PVC) and engine controller (EC) are used for ma-
chine control.
Processing signals from the engine control dial, vari-
ous sensors and switches, the controllers (PVC and
EC) actuate solenoid valves and the EC motor to
control the engine, pumps and valves.

Engine Control
• Engine Speed Control
• Engine Learning Control
• Auto-Idle Control
• Auto Warming Up Control
• SP Mode Control

Pump Control
• Pump Flow Rate Control
• Speed Sensing Control
• E Mode Control
• Horsepower Control
• Relief Flow Rate Reducing Control
• Swing Horsepower Reducing Control
• Pump Maximum Flow Rate Control
• Attachment Mode Control

Valve Control
• Travel Speed Mode Shift Control
• Main Relief Pressure Shift (Power Boost) Control
• Swing Preference Control
• Swing Parking Brake Release Control

Other Control
• Work Mode Control
T2-1-2 EX455
CONTROL SYSTEM

ENGINE CONTROL

Engine Speed Control
Purpose: To control engine speed in proportion to
engine control dial setting.
Operation: An electrical signal in proportion to the
engine control dial setting is input to the controller
EC. Consequently, the EC actuates the EC motor.
The degree of the EC motor rotated is detected by the
EC sensor. The EC sensor then sends a voltage
signal back to the EC.
When the engine is running at slow idle speed, out-
put voltage from the EC sensor is set to be 2.5 V. At
fast idle speed, it is set to be 4.5 V or less.
Engine Learning Control
Purpose: To re-input (learn) the governor lever
positions for the fast idle speed and auto-idle speed.
The EC reinputs the engine speed, of which the
governor lever comes into contact with the stopper,
as the fast idle speed.
Operation: The EC stores the governor lever position
of which the EC sensor output is 2.5 V as the slow idle
position (origin). (The EC sensor has been adjusted so
that it outputs 2.5 V when the governor lever comes
into contact with the slow idle side stopper.)
When the engine control dial is turned to the fast idle
position, the EC motor rotates until the governor lever
comes into contact with the fast idle stopper. After the
governor lever comes to a stop, the EC sensor output
is stabilized (unchanged). Consequently, the EC
stores the incremental pulse number to reach this
point (movable) as the fast idle speed. (This re-input
of the fast idle speed takes place when the engine
control dial output is 4.0 V or larger.)
The maximum speed with SP Mode OFF and the
auto-idle speed, which represents the speeds be-
tween the slow idle and the maximum speed with the
SP Mode ON, are then calculated and stored as
proportional points within the pulse range from the
slow idle (origin) to the maximum speed with the SP
Mode ON (movable point).

Governor Lever 4.5 V or less

3.7±0.2 V

EC Sensor
EC Sensor 2.9V
Output
Voltage
EC Motor
2.5V (With (With
SP SP
0.5V Mode Mode
or more OFF) ON)

Stop Slow Idle Auto-Idle Fast Idle

Position Position Position Position
(Origin) (Movable)

Proportionally
Distributed Range

Controller EC Motor Movement

(EC)

Key Switch SM6511/A

Engine Control Dial

SM6510
EX455 T2-1-3
CONTROL SYSTEM

Auto-Idle Control

Purpose: To save fuel and to lower noise by lowering
the engine speed while all control levers are in neutral.
Operation: When all control levers are in neutral, the
front att. pressure switch located on the shockless
valve and the travel, swing, and other pressure
switches located on the shuttle valves are turned off.
At this moment, if the auto-idle switch is in the ON
position, the controller (PVC) detects that all pressure
switches are off, and sends a signal indicating that all
pressure switches are off, to the EC.
Approximately four seconds later, the EC sends a
signal to the EC motor. The EC motor then moves the
governor lever, lowering the engine speed to
1230±100 min-1 (1230±100 rpm).
When a control lever is operated, the respective
pressure switch is turned on. Then the EC stops
sending the electrical signals to lower the engine
speed to the EC motor. As a result, the engine speed
increases to the speed set by the engine control dial.

Governor Lever

EC Sensor

EC Motor

Pressure Switch (Swing)

Shuttle Valve

Pressure Switch (Bucket,

Pressure Switch Boom Lower, Arm Roll-Out)
(Boom Raise)

Shockless Valve

Pressure Switch (Arm Roll-In)

Shuttle Valve
Controller (EC) Controller (PVC)

Pressure Switch (Travel)

Auto-Idle Switch SM6512

T2-1-4 EX455
CONTROL SYSTEM

Auto Warming Up Control

Purpose: To automatically warm up the hydraulic
system. (Equivalent to the automatic choke for auto-
mobiles)
Operation: When the hydraulic oil temperature is
less than 25 °C (77 °F), the controller (EC), upon
receiving signals from the key switch and the hydrau-
lic oil temperature sensor, actuates the EC motor,
increasing the engine speed to a speed slightly higher
than the slow idle speed until the hydraulic oil tem-
perature rises to 30 °C (86 °F). This system is active
up to 15 minutes after the engine starts.

Governor Lever

EC Motor EC Sensor

Controller
(EC)

Key Switch Hydraulic Oil Temperature Sensor

SM6513
EX455 T2-1-5
CONTROL SYSTEM

SP Mode Control

Purpose: To increase the engine speed approxi-
mately 8% compared to the engine speed with the SP
mode switch turned off. As the pump flow rate in-
creases due to an increase of the engine speed,
actuator speeds increase, increasing the production.
The engine torque also increases (when compared to
the engine torque with the SP mode off). Conse-
quently, the speed sensing (increased horsepower)
control function is activated to increase pump flow
rate, thus increasing the production. (Refer to page
T2-1-7.)
Operation: When the engine control dial is turned to
the maximum speed position and the SP mode switch
is turned on, the controller (EC) actuates the EC
motor, increasing the engine speed approximately
8%, thus increasing horsepower.
As the engine speed increases approximately 8%,
the main pump flow rate also increases. Conse-
quently, actuator's speed and power increase.
NOTE - Since the governor lever stopper position is
set for the maximum speed with the SP mode turned
on, the governor lever does not come into contact
when the engine control dial is turned to the maximum
position with the SP mode switch turned off.

Governor Lever

Q
EC Sensor

EC Motor
SP Mode

Flow
Rate

Normal Mode

Pressure P
Pump P-Q Curve

Controller SM6515
(EC)

Key Switch Engine Control Dial

SP Mode Switch

SM6514
T2-1-6 EX455
CONTROL SYSTEM

PUMP CONTROL

Pump Flow Rate Control

Purpose: To have the main pump deliver the required
oil flow to each actuator in proportion to control lever
stroke.
Operation: When control lever is operated:
Oil quantity flowing through an orifice in the pump
control valve, which is located in the most down-
stream part of the control valve neutral passage,
decreases, resulting in less pressure difference be-
tween the inlet and the outlet of the orifice. Detecting
this pressure difference, the differential pressure
(DP) sensor sends signals to the controller (PVC).
Consequently, the PVC calculates the required oil
flow and, at the same time, compares the pump
displacement angle necessary to have the calculated
oil flow with the one detected by the pump displace-
ment angle (A) sensor.
Then, the PVC actuates the pump control propor-
tional solenoid valve, increasing the main pump dis-
placement angle, thus increasing the main pump flow
rate.
(Refer to the heading Pump Control Valve in the
Control Valve group, the COMPONENT OPERA-
TION section.)
When control lever is in neutral:
As the control valve spool returns to the neutral po-
sition, oil flowing through the orifice in the pump
control valve, which is located in the most down-
stream part of the control valve neutral passage, in-
creases, resulting in a large pressure difference be-
tween the inlet and the outlet of the orifice. Detecting
this pressure difference, the DP sensor sends signals
to the PVC. Consequently, the PVC calculates the
required oil flow and, at the same time, compares the
pump displacement angle necessary to have the
calculated oil flow with the one detected by the A
sensor. Then, the PVC actuates the pump control
proportional solenoid valve, reducing the main pump
displacement angle to the minimum angle, thus de-
creasing the main pump flow rate.

Pump Control Valve

(4-Spool Block Side)

Orifice Neutral
Passage
Differential Pressure (DP) Main Pump
Sensor

Pump Con- Pump Displacement

trol Propor- Angle (A) Sensor
Control Valve tional Sole-
noid Valve

Controller (PVC)
Main
Pump

Pump Control
Neutral Proportional
Orifice
Passage Solenoid
Valve
Differential Pressure (DP)
Sensor

Pump Control Valve

(5-Spool Block Side)
4-Spool Block Side 5-Spool Block Side
SM6516
EX455 T2-1-7
CONTROL SYSTEM

Speed Sensing Control

Purpose: To effectively utilize engine horsepower by
varying the pump delivery rate in proportion to the
moment-to-moment engine speed changes which
occur due to the various loads applied. (This control
functions to prevent the engine from stalling when the
machine is operated in severe environments, such as
when operating at high altitude.)
Operation: As a target engine speed is set by the
engine control dial, the controller (EC) compares the
target engine speed with the actual engine speed
detected by engine speed (N) sensor and calculates
the difference between these two engine speed
values, which is subsequently sent to the controller
(PVC). Then, the PVC calculates a target pump
displacement angle using the engine speed
difference value and a signal from the pump delivery
pressure (P) sensor.
Afterward, comparing the target pump displacement
angle with the actual pump displacement angle de-
tected by the pump displacement angle (A) sensor,
the PVC actuate the pump control proportional so-
lenoid valve to adjust the main pump delivery rate.
If the actual engine speed drops to a speed less than
the target engine speed due to an increased load on
the engine, the EC and PVC actuate the pump control
proportional solenoid valve to reduce the main pump
displacement angle, reducing the main pump delivery
rate. Consequently, the load on the engine is reduced,
preventing the engine speed from dropping and the
engine from stalling. (Horse-power Increase Control).
Contrarily, if the actual engine speed exceeds the
target engine speed, the EC and PVC actuate the
pump control proportional solenoid valve, increasing
the main pump displacement angle, thus utilizing
engine horsepower efficiently. (Horsepower De-
crease Control).
This speed sensing control works for the entire en-
gine speed range: from the slow idle to the fast idle.
However, when the engine speed is less than 1600
min-1, only the horsepower decrease control part of
the speed sensing control is available.

Engine Speed:
more than 1600 min -1

Engine
Control Increase
Dial
Flow
Rate
Controller Controller Decrease
(EC) (PVC) Base Torque

Engine Speed Sensor

(N Sensor)
Pump Delivery Pressure P
Pressure
(P) Sensor Pump P-Q Curve SM6518

Pump Control
Proportional
Solenoid Valves
Q
Engine Speed:
less than 1600 min-1

Pump Displacement
Angle Sensor
(A Sensor) Flow
Rate

SM6517
Decrease
Base Torque

Pressure P
SM6519
T2-1-8 EX455
CONTROL SYSTEM

E Mode Control

Purpose: To increase fuel efficiency by reducing the
load applied to the engine, i.e. lowering the pump
driving torque to 85% of the torque in the SP mode.
This control also functions to prevent the engine from
stalling when the machine is operated in severe en-
vironments, such as when operating at high altitude.
Operation: When the E mode switch is turned on, the
controller (EC) sends a signal to the controller (PVC).
Subsequently, also having a signal from the pump
delivery pressure (P) sensor, the PVC calculates a
target pump displacement angle.
Then, comparing the target pump displacement an-
gle with the actual pump displacement angle de-
tected by the pump displacement angle (A) sensor,
the PVC actuates the pump control proportional so-
lenoid valve to compensate for the difference be-
tween the actual and target pump displacement an-
gles, reducing the pump displacement angle, thus
reducing the main pump flow rate.
NOTE - Engine speed is not controlled (lowered) in
this E mode control. In other words, engine speed
does not change but the E mode function is activated
upon pushing the E mode switch.

Flow Decrease
Rate
Base Torque

E Mode

SM6520
Pressure P

Engine E Mode
Control Switch
Dial

Controller Controller
(EC) (PVC)

Engine Speed Sensor

(N Sensor) Pump Delivery
Pressure
(P) Sensor

Pump Control
Proportional
Solenoid Valves

Pump Displacement
Angle Sensor
(A Sensor)
SM6521
EX455
CONTROL SYSTEM
Horsepower Control
Purpose: To effectively utilize engine horsepower by
controlling the delivery rate of each main pump so that
the sum of the two main pumps torque does not
exceed the engine output torque.
Operation: Delivery pressure of each main pump
usually differs from each other: i.e. the larger the load
applied to a main pump, the higher the delivery
pressure and vice versa. The pump delivery pressure
(P) sensors and the pump displacement angle (A)
sensors detect the actual status (conditions) of two
main pump, sending signals to the controller (PVC).
Controller
(EC)
Pump
Pressure (P) Sensors
Pump Displacement
Angle (A) Sensor
T2-1-9
Then, the PVC calculates a target pump displace-
ment angle using signals from two pump delivery
pressure (P) sensors and compares them with the
actual pump displacement angles detected by the A
sensors. Subsequently, the PVC actuates the pump
control proportional solenoid valve of the larger load
applied main pump, increasing the delivery rate of the
larger load applied main pump to the extent that the
sum of the two main pumps torque does not exceed
the engine output torque. Consequently, the sum of
the two main pumps torque is approximately the same
as the engine output torque.
Controller
(PVC)
Delivery
Pump Control
Proportional
Solenoid Valves
SM6522
T2-1-10 EX455

CONTROL SYSTEM

Relief Flow Rate Reducing Control

Purpose: To reduce hydraulic energy loss and to
prevent the hydraulic oil temperature from rising.
Operation: When an actuator is operated, the pump
delivery pressure varies due to changing load applied
to each actuator. Detecting the pump delivery pres-
sure, the pump delivery pressure (P) sensor sends
signals to the controller (PVC).
When the pump delivery pressure rises to 28.4 MPa
(290 kgf/cm2, 4124 psi), the PVC compares the ac-
tual pump displacement angle detected by the pump
displacement angle (A) sensor with the target pump
displacement angle demanded by the PVC. Conse-
quently, the PVC decreases the pump flow rate to the
minimum (which is demanded by the PVC when the
actuator circuit is relieved).
In addition, when the pressure switch (travel) is turned
on or when the precision mode switch is turned on, the
controller (PVC) deactivates the Relief Flow Rate
Reducing Control.

Qm

Flow
Rate
Relief Flow Cut
Qo

Pc Pr
Pressure SM6523

Pilot Pilot Pilot

Valve Valve Valve

Pressure Switches
Control Valve

Work Mode Switch Controller Controller

(Precision Mode) (EC) (PVC)

Main Pump 1
Pump Delivery
Pressure
(P) Sensor
Pump Control
Proportional
Solenoid Valves

Main
Pump 2 4-Spool Block 5-Spool Block

Pump Displacement
Angle (A) Sensor SM6524
EX455 T2-1-11

CONTROL SYSTEM

Swing Horsepower Reducing Control

Purpose: To effectively utilize engine horsepower by
reducing the flow rate of the main pump 1 in which the
swing circuit is located and by increasing the flow rate
of the main pump 2 when the swing pressure switch
is turned on, i.e. when swing function is operated
whether in single or combined operation.
Operation: The swing pressure switch sends a sig-
nal to the controller (PVC) as it is turned on, i.e. when
the swing function is operated. Then, the PVC com-
pares the actual pump displacement angle detected
by the pump displacement angle (A) sensor with the
target pump displacement angle demanded by the
PVC. Consequently, the PVC actuates the main
pump 1 control proportional solenoid valve, decreas-
ing the pump flow rate.
If the "travel" or "other" pressure switch is turned on in
swing combined operations, the PVC actuates the
main pump 2 control proportional solenoid valve upon
receiving a signal from the pressure switch, increas-
ing the pump flow rate.

Q Q

Flow Flow
Rate Rate

P P
Pressure Pressure
Main Pump 1 Main Pump 2
SM6525 SM6526

Pilot Pilot Pilot

Valve Valve Valve

Pressure Switch (Travel) (Other)

(Swing)
Control Valve

Controller Controller
(EC) (PVC)

Main
Pump 1 Pump Delivery
Pressure (P)
Sensor

Pump Control
Proportional
Solenoid

Main 4-Spool Block 5-Spool Block

Pump 2
Pump Displacement
Angle (A) Sensor
SM6527
T2-1-12 EX455

CONTROL SYSTEM

Pump Maximum Flow Rate Control Q

Purpose: To prevent the engine from overheating by

reducing the main pump maximum flow rate setting
and pump torque, thus reducing the load applied to Flow
the engine when the overheat switch (L) is turned on. Rate

Operation: When the overheat switch (L) is turned on

(98 °C, 208 °F), a signal from the switch is sent to the
controller (PVC) via the controller (EC). Then, the
P
PVC compares the actual pump displacement angle Pressure
detected by the pump displacement angle (A) sensor
SM6528
with the target pump displacement angle demanded
by the PVC. Consequently, the PVC actuates the
pump control proportional solenoid valve, re-setting
the maximum pump displacement angle to cut the
maximum flow rate seven percent. In addition, the
pump torque is also lowered.

Overheat Switch (L)

Controller Controller
(EC) (PVC)

Pump Control
Proportional
Solenoid Valves

Pump Displacement
Angle (A) Sensor

SM6529
EX455 T2-1-13

CONTROL SYSTEM

Attachment Mode Control

Then, when the attachment pilot valve is operated,

NOTE - This control system functions only on ma-
chines equipped with the attachment optional kit.
Purpose: When the attachment pilot valve is oper-
ated with the work mode switch in the attachment
mode, the maximum flow rate of main pump 1 is
reduced to 280 L/min (74 US gal), approx. 20 % less
than the normal control maximum flow rate (360 L/min
(95 US gal)) in the general purpose mode, to balance
with the hydraulic breaker operation.
Operation: When the attachment mode is selected
by the work mode switch, the signal from the word
mode switch is sent to the controller (PVC).
the pressure switch is turned ON, delivering the signal
to the PVC via the controller (EC).
The pump displacement angle is always monitored by
the displacement angle (A) sensor. The PVC is kept
instructed by the signal from the A sensor.
Therefore, when the pump displacement angle in-
creases to a point 20 % lower than normal control
maximum flow rate in the general purpose mode, the
PVC operates the pump control proportional solenoid
valve so that the pump displacement angle is held in
that position. The attachment is controlled by the
auxiliary spool in the 5-spool side control valve. Then,
the maximum flow rate of the main pump 1 only is
regulated.

Q
(L/min) 360

280

Pressure P

Attachment Control Pedal

Attachment
Pilot Valve

Work Mode Switch Control Valve

Engine
Control Pressure (Attachment Mode)
Dial Switch

Controller Controller
Pump Delivery (PVC)
(EC)
Pressure (P) Sensor
Auxiliary Spool
(Attachment)
Main Pump 1

Pump Control
Proportional
Solenoid Valve

5 Spool Side
Main
Pump 2 4 Spool Side
Displacement
Angle (A)
Sensor
SM6530
T2-1-14 EX455

CONTROL SYSTEM

VALVE CONTROL

Travel Speed Mode Shift Control

• Slow Travel Mode:
With the travel mode switch turned to the
position, no electrical current flows to the travel
mode shift solenoid valve. As the travel mode shift
solenoid valve is not activated (shifted), the pres-
sure oil from the pilot pump is not supplied to the
travel mode shift valve. For this reason, the travel
mode shift valve is not shifted, and the pressure oil
in the main control valve travel circuit is not supplied
to the tilt pistons. Consequently, the travel motors
rotate in the slow speed mode.
(Refer to the heading Travel Motor in the Travel
Device group, the COMPONENT OPERATION
section for travel motor displacement angle shift.)

From the Main Pump

Travel Mode
Shift Solenoid
Valve

Brake
Pilot Pump
Valve

Hydraulic
Oil Tank

Travel Mode
Travel Motor Shift Valve

Controller
Travel Mode (PVC) Tilt Piston
Switch Parking Brake

SM6531
EX455 T2-1-15

CONTROL SYSTEM

• Fast Travel Mode:
With the travel mode switch turned to the posi-
tion, electrical current flows to the travel mode shift
solenoid valve. As the travel mode shift solenoid
valve is activated (shifted), the pressure oil from the
pilot pump is supplied to the travel mode shift valve.
For this reason, the travel mode shift valve is
shifted, and the pressure oil in the main control
valve travel circuit is supplied to the tilt pistons.
Consequently, the travel motors rotate in the fast
speed mode.
(Refer to the heading Travel Motor in the Travel
Device group, the COMPONENT OPERATION
section for travel motor displacement angle shift.)

From the Main Pump

Travel Mode
Shift Solenoid
Valve

Brake Valve
Pilot Pump

Hydraulic
Oil Tank

Travel Mode
Travel Motor Shift Valve

Controller
Travel Mode (PVC)
Switch
Parking Brake
Tilt Piston
SM6532
T2-1-16 EX455

CONTROL SYSTEM

Main Relief Pressure Shift (Power Boost)

Control

Purpose: To increase the main relief pressure setting
by applying back pressure to the main relief valve.
Operation: Either when travel pressure switch is
turned on, when the precision work mode is selected,
or when the power boost switch is pressed, a signal
enters the controller (PVC). Consequently, the PVC
actuates the main relief pressure shift solenoid valve
(only for 10 seconds in the case the power boost
switch was pressed), routing pressure oil from the pilot
pump to the shuttle valve.
As a result, the main relief valve spring is compressed,
increasing the main relief pressure setting from
29.4 MPa (300 kgf/cm2, 4 266 psi) to 34.3 MPa
(350 kgf/cm2, 4 977 psi).

Control Valve
Pilot Pilot Pilot
Valve Valve Valve

Travel
Pressure
Switch

Work Mode Switch

(Precision Mode) Main Relief
Controller Controller Pressure
(EC) (PVC) Shift Solenoid
Power Boost Switch Valve

Spring
Main Relief Valve

Shuttle Valve

Pilot Pump
SM6533
EX455 T2-1-17

CONTROL SYSTEM

Swing Preference Control

• Swing/Boom Raise Combined Operation (in the

general purpose mode, attachment mode, or preci-
sion mode)
With the work mode set in any of the three work
modes indicated above, the controller (PVC) actu-
ates the swing preference circuit shift solenoid
valve. For this reason, the boom raise operating
pressure 1A flows to 1B, shifting both boom 1 and
2 spools. The swing spool is also shifted at the same
time.

Swing Preference Circuit Shift Solenoid Valve

From the controller (PVC).

P
1A S 1B
F 1A - Boom 1 Raise Section Operating Pressure
D2 1B - Boom 2 Raise Section Operating Pressure
G D2 - To the hydraulic oil tank.

SM6534

• Swing/Boom Raise Combined Operation (in the

trenching mode)
In swing/boom combined operation with the work
mode in the trenching mode, the controller (PVC)
deactivates the swing preference circuit shift sole-
noid valve.
Consequently, boom raise operating pressure 1A
does not flow to 1B and the boom spool (raise)
operating pressure line is connected to the hydrau-
lic oil tank line. For this reason, pressure oil from the
pump 1 flows only to the swing circuit in swing/boom
raise combined operation. (Swing Preference Con-
trol).

Swing Preference Circuit Shift Solenoid Valve

From the controller (PVC).

1A P S F 1B 1A - Boom 1 Raise Section Operating Pressure

1B - Boom 2 Raise Section Operating Pressure
D2 G D2 - To the hydraulic oil tank.

SM6535
T2-1-18 EX455

CONTROL SYSTEM

Swing Parking Brake Release Control

When the swing or front control lever is operated, the noid valve, sending pressure oil from the pilot pump to
swing or front attachment pressure switch is turned the swing motor, thus releasing the swing parking
on, sending a signal to the PVC. Consequently, the brake.
PVC actuates the swing parking brake release sole-

Swing Motor

Swing Parking
Brake

Pilot Pump

Swing Parking Brake

Release
Solenoid Valve

Swing or Front Attachment

Pressure Switch

Controller
PVC

SM6536
EX455
CONTROL SYSTEM
OTHER CONTROL
Work Mode Control
The work modes provide the ideal pressures and
operating speeds for each type of work by controlling
main pump flow rate, main relief pressure shift (power
boost) circuit, etc.
Characteristics of each work mode are as follows:
General Purpose Mode:
Standard work mode. Designed for general dig-
ging and truck loading.
Trenching Mode:
In swing/boom raise operation, the swing prefer-
ence circuit shift valve is actuated so that only one
boom section (out of two) in the control valve is
operated, giving priority to swing movement dur-
ing trenching work. (Refer to page T2-1-17.)
T2-1-19
Precision Mode:
Main pump flow rate is decreased approximately
45% from that in the general purpose mode. At the
same time, the controller (PVC) actuates the main
relief pressure shift solenoid valve, raising the
main relief pressure. This mode is designed for
work in confined work areas that require precision
front attachment movement. (Refer to page
T2-1-16, 17.)
Attachment Mode:
This mode functions when an optional attachment
is installed. When the attachment pilot valve is
operated, the main pump maximum flow rate will be
reduced approximately 20% in this mode. (Applied
when a breaker is used.) (Refer to page T2-1-13.)
T2-1-20 EX455

CONTROL SYSTEM

NOTES
EX455 T2-2-1
HYDRAULIC SYSTEM

OUTLINE

The hydraulic system consists of the main circuit and • Pilot Circuit:
pilot circuit. A hydraulic circuit that shifts the control valve
spools, that controls the pumps, valves, and mo-
• Main Circuit: tors, and that also releases the parking brakes.
A hydraulic circuit that actuates cylinders and mo-
tors using pressure oil delivered from the main
pumps.
T2-2-2 EX455
HYDRAULIC SYSTEM

MAIN CIRCUIT

Main pumps 1 and 2 draw hydraulic oil from the
hydraulic oil tank. Main pump 1 supplies pressure oil
to the 5-spool control valve block while main pump 2
supplies pressure oil to the 4-spool control valve
block.
Main pump discharged oil is routed to cylinders and
motors via the control valve as control valve spool(s)
are shifted.
Return oil from cylinders and motors is routed to the
hydraulic oil tank via the control valve and oil cooler,
cooling hydraulic oil. If oil resistance through the oil
cooler is high, i.e. if oil temperature is low and viscos-
ity is high, the bypass check valve opens to directly
route hydraulic oil to the hydraulic oil tank, bypassing
the oil cooler.

Bucket Arm Boom

Cylinder Cylinder Cylinders

Pilot Valve Pilot

Shut-Off
Valve

Center Joint
Shockless Valve

Travel (L)

Auxiliary Hydraulic Travel (R)

Oil Tank Swing Motors
Boom 2 Bucket

Arm 1 Boom 1

Swing Arm 2

Control Valve
3 Spool Solenoid
Valve Unit By pass
Valve

Main Pump 1

Accumulator
Oil
Cooler

High Pressure Oil

Low Pressure Oil (Return Line)
Main Pump 2
Circuit Line
Pilot Line Drain Line

Center Joint
Left Travel Motor Right Travel Motor OM0682
EX455 T2-2-3
HYDRAULIC SYSTEM

Neutral Circuit Single Operation Circuit

When the control levers are in neutral, pressure oil
from the main pumps returns to the hydraulic oil tank
via the neutral passage in the control valve and the
pump control valve.
Pressure oil from main pump 2 flows into the travel
(R), bucket, boom 1, and arm 2 spool sections in the
4-spool control valve block. Pressure oil from main
pump 1 flows into the swing, arm 1, boom 2, aux., and
travel (L) spool sections in the 5-spool control valve
block. For boom raise and arm roll-out/roll-in single
operations, two main pump flows are combined be-
fore flowing into each cylinder.

Pump Control Valve Hydraulic Oil Tank

Swing
Neutral Swing Motor
Passage

Arm 1
Arm 2

Boom Cylinder

Boom 2
Boom 1

Aux. Oil Flow Combining

Bucket Cylinder Passages
Bucket

Travel (R) Travel (L)

Neutral
Passage

Pump
4-Spool
Control
Block
Valve 5-Spool Block

Right Travel Motor Main Pump 2 Main Pump 1

Left Travel Motor

SM6537
T2-2-4
HYDRAULIC SYSTEM
Combined Operation Circuit
• Boom/Arm Combined Operation (Boom Lower and
Arm Roll-In)
In boom lower / arm roll-in combined operation, the
boom 1, arm 1 and 2 spools are shifted. Also, the
holding valve shift valve is shifted.
Pressure oil from main pump 1 flows into the bottom
side of the arm cylinder via the neutral passage and
arm 1 spool in the 5-spool control valve block. Since
the boom 2 spool is not shifted during boom lower
operation, no pressure oil flows to the boom cylinder
from the 5-spool control valve block. Pressure oil
from main pump 2 flows into the boom 1 spool and
arm 2 spool sections in the 4-spool control valve
block via the parallel passage.
Pressure oil from the boom 1 spool section flows
into the rod side of the boom cylinder while that from
the arm 2 spool section flows into the bottom side of
the arm cylinder after combined with pressure oil
from the arm 1 spool section.
Holding Valve Shift Valve
Arm
Holding Check Valve Regen-
erative
Valve
Arm 2
Boom Cylinder
Orifice
Boom 1
Parallel
Passage
Main Pump 2 Main Pump 1
EX455
An orifice in the parallel passage of the 4-spool
control valve block secures oil flow to the boom
cylinder so that the boom can be operated regard-
less of arm circuit pressure fluctuation.
Return oil from the boom cylinder is routed to the
hydraulic oil tank via the holding check valve and
boom 1 spool section. Return oil from the arm
cylinder is routed to the arm 1 section via the holding
check valve. Return oil from the arm cylinder is
restricted by an orifice in the arm 1 spool and the
arm regenerative valve. If the return oil pressure
becomes higher than that of oil flow to the arm
cylinder bottom, return oil is supplied to the arm
cylinder bottom via the check valve in the arm 1
spool. (For boom and arm holding check valves and
arm regenerative valve, refer to the Control Valve
group, the COMPONENT OPERATION section.)
Hydraulic
Oil Tank Holding Valve Shift Valve
Arm 1
Arm Cylinder
Check Orifice
Valve Boom 2
Holding Check Valve
SM6538
EX455 T2-2-5
HYDRAULIC SYSTEM

• Swing/Boom Combined Operation (in the general pur-
pose mode, attachment mode, and precision mode)
Pressure oil from main pump 2 flows into the boom
cylinder via the boom 1 spool.
Pressure oil from main pump 1 flows into the swing
motor via the swing spool. As the swing circuit
pressure becomes relatively high at the start of
upperstructure rotation, pressure oil from the boom
2 spool section also flows into the boom cylinder
until the upperstructure speed becomes constant.

Swing

Swing Motor
Parallel
Passage

Boom Cylinder
Boom 2
Boom 1

Parallel
Passage

Main Pump 2 Main Pump 1

SM6539
T2-2-6 EX455
HYDRAULIC SYSTEM

• Travel/Swing Combined Operation
In travel/swing combined operation, the travel left
and right spools and swing spool are shifted. The
shifted swing spool blocks the front att. pilot signal
circuit, raising the pilot pressure in that circuit, which
consequently shifts the flow combiner valve.
Although pressure oil from main pump 1 flows into
the swing spool and travel left spool sections via the
5-spool control valve block parallel passage, prior-
ity is given to the swing circuit due to a provided
orifice. The orifice in the parallel passage also
secures the priority to the swing circuit when the
pressure in the travel circuit becomes lower than
that in the swing circuit, i.e. when descending for
instance.
Pressure oil from main pump 2 flows into the right
travel motor via the travel right spool. It also flows to
the left travel motor via the flow combiner valve and
the travel left spool, securing straight travelability.

Front Att. Pilot

Signal Circuit

Swing

Swing Motor
Parallel
Passage

Orifice
Travel (L)

Check
From the Travel (R) Valve
Pilot Pump
Flow
Combiner
Valve

Main Pump 2 Main Pump 1

Right Travel Motor Left Travel Motor

SM6540
EX455 T2-2-7
HYDRAULIC SYSTEM

PILOT CIRCUIT

Pressure oil from the pilot pump is used as operating delivery rate control circuit, main relief pressure shift
pressure for the pilot circuit, travel speed mode shift circuit, and swing preference shift circuit.
circuit, swing parking brake release circuit, pump

Pilot Valve Shuttle Valve

Control Valve

Pilot Valve Shockless

Valve

Pilot Valve Shuttle Valve Shockless Valve

Pilot
Shut-Off
Valve

Pilot Solenoid Valve

Accumulator Check (Swing Preference
Main Relief Valve Circuit Shift)
Pressure Shift
Solenoid Valve

Swing Parking Brake

Release Solenoid Valve

Pilot
3-Spool Solenoid Valve Unit Relief
Valve

Swing Motor

Travel Speed Shift

Solenoid Valve Swing Motor

Left Right
Travel Travel Pilot Filter
Motor Motor

Pilot Pump

Regulator/Pump Regulator/Pump
Control Proportional Control Proportional
Solenoid Valve Solenoid Valve
(on Main Pump 2) (on Main Pump 1)
Hydraulic
Oil Tank
SM6541
T2-2-8 EX455
HYDRAULIC SYSTEM

Pilot Circuit

Pressure oil from the pilot pump is routed to the pilot An accumulator is provided in the pilot circuit so that
valves via a pilot check valve and pilot shut-off valve. pressure oil can be supplied into the pilot circuit for a
When a pilot valve is operated, pressure oil is routed limited period of time in case the engine stalls.
to the control valve via a shockless valve and/or a
shuttle valve, shifting a spool in the control valve.
The machine cannot be moved by operating the
control levers while the pilot shut-off valve is closed
since the pilot oil pressure does not flow to the pilot
valves.

Accumulator

Pilot Shut-Off Valve Pilot Valves

Swing/Arm
Control Lever

Pilot Pump Pilot Check Valve

Travel
Control Levers

Hydraulic Oil Tank

Boom/Bucket
Control Lever

Shuttle Valve Shockless Shuttle Valve

Valve

Shockless
To the control To the control Valve
valve. valve.

To the control valve

SM6542
EX455 T2-2-9
HYDRAULIC SYSTEM

Pump Delivery Rate Control Circuit

• Refer to the heading Pump Control (Pump Flow
Rate Control) in the Control System group.
Travel Speed Mode Shift Circuit
Swing Preference Shift Circuit
• Refer to the headings Valve Control (Swing Prefer-
ence Control) in the Control System group.

• Refer to the heading Travel Motor in the Travel
Device group, COMPONENT OPERATION sec-
tion. Also, refer to the headings Valve Control
(Travel Speed Mode Shift Control) in the Control
System group.
Swing Parking Brake Release Control Circuit
• Refer to the headings Valve Control (Swing Parking
Brake Release Control) in the Control System
group.

Main Relief Pressure Shift Circuit

• Refer to the heading Main Relief Valve in the

Control Valve group, the COMPONENT OPERA-
TION section and to the headings Valve Control
(Main Relief Pressure Shift (Power Boost) Control)
in the Control System group.
T2-2-10 EX455
HYDRAULIC SYSTEM

NOTES
EX455 T2-3-1
ELECTRICAL SYSTEM

OUTLINE

The electrical circuit can be divided into three circuits: • Preheat Circuit
main circuit, control circuit, and monitor circuit. The circuit to aid in engine start in cold weather.

• Main Circuit: • Engine Start Circuit

Engine / accessory circuit. The circuit to rotate the starter to start the engine.

• Control Circuit • Charging Circuit

Engine / pump control circuit, consisting of actua- The circuit supplies electricity to the batteries to
tors (such as solenoid valves), controllers (PVC replenish consumed (discharged) electricity.
and EC), sensors and switches.
• Accessory Circuit
• Monitor Circuit The circuit for accessories which will be activated
Circuit that indicates machine operating conditions, when the key switch is turned to the ACC position.
consisting of sensors and switches.
• Surge Voltage Prevention Circuit
In this section, main constituents and their functions The circuit to protect electronic components, such
of the main circuit are described. as the controller, from surge voltage.

• Power Circuit • Engine Stop Circuit

The power source of all electrical circuits on this The circuit to stop the engine using the EC motor.
machine.

• Bulb Check Circuit

The circuit to check if any indicator bulbs have
blown.
T2-3-2 EX455
ELECTRICAL SYSTEM

ELECTRIC POWER CIRCUIT

(Key switch: OFF)

The battery negative terminal is grounded to the

vehicle.
Current from the positive terminal flows as follows with
the key switch OFF.

→ Fuse
link 2 (40 A) → Glow relay (Power Source)

Terminal 1 - Radio (Backup Power Source)

Monitor (Backup Power Source/clock)

Battery → → Terminal 2 - EC and PVC Power Source

Terminal 3 - EC Motor relay (R7) Power Source

Terminal 4 - Auxiliary source

(relay box)

→ Fuse
link 1 (50 A) → Fuse box
→ Relay box (terminal 14 - Relay R1 -
Anti Load Dump)

→ Terminal B - Key switch

 EX455

Key switch

Glow relay

Glow plugs PVC

Controller
Fuse link
Batteries

Fuse box
Starter
motor

To radio Monitor

Safety
relay
ELECTRICAL SYSTEM

Auxiliary plug

EC Motor relay
(R7)
EC Controller
T2-3-3

SM5707
T2-3-4 EX455
ELECTRICAL SYSTEM

BULB CHECK CIRCUIT

(Key switch: ON)

When the key switch is turned to the ON position, key
switch terminal B connects with key switch terminals
M and ACC.
The current from terminal M flows throught the diode
D2, located inner the relay box, and excites the battery
relay.
Then, the battery power is routed to the monitor
through the battery relay, the fuse box and the wiper
box, turning the warning lights and indicators on (for
bulb check).
 EX455

Key switch

Fuse
link
Batteries
Fuse box
Battery
relay

Monitor
ELECTRICAL SYSTEM

Wiper box

Relay box
T2-3-5

SM5708
T2-3-6 EX455
ELECTRICAL SYSTEM

ACCESSORY CIRCUIT
(Key Switch: ACC)

When the key switch is turned to the ACC position, Then, the battery current flows through the fuse box
terminal ACC is connected to terminal B in the key terminal 15, 16 and 17, to each accessory circuits
switch. (horn, radio, cigar lighter, power outlet, room lamp.
 EX455

Key switch

Fuse
link Cigar
lighter
Batteries Fuse
box
Battery
relay

Power
outlet
ELECTRICAL SYSTEM

Room light

Radio

Relay box

Horn
T2-3-7

SM5709
T2-3-8 EX455
ELECTRICAL SYSTEM

PREHEAT CIRCUIT
(Key switch: ON or START)

When the key switch is turned to the ON or START Terminal #6 of QOS controller grounds to vehicle for 8
position, the key switch terminal B is connected to seconds while preheat, therefore glow signal is ON.
terminal M in the key switch. The current from (When preheat is not done, glow signal is ON for 0.3
terminal M flows to terminal #1 of QOS controller via seconds to check the blown bulb.)
the fuse #18 and supply power to glow relay throught
the relay box.
NOTE - Coolant temperature switch becomes OFF
When the coolant temperature switch is OFF, QOS when coolant temperature is less than 10 °C (50 °F).
controller allows to preheat the engine for approx. 30
seconds. When QOS controller terminal #4 is
grounded, glow plug relay comes ON, so that the glow
plugs are heated.
 EX455

QOS
Controller Key switch

Glow relay Coolant

temperature
switch

Glow plugs
Fuse
link
Batteries
Fuse box
Battery
relay
ELECTRICAL SYSTEM

Monitor panel

Relay box
T2-3-9

SM5710
T2-3-10 EX455
ELECTRICAL SYSTEM

STARTING CIRCUIT
(Key Switch: START)

When the key switch is turned to the START position,
terminal B on the key switch is connected to terminals,
M, and ST. The current from terminal M magnetizes
the battery relay, leading the battery current to termi-
nals B on the starter and starter relay via the battery
relay.
Terminal ST of the key switch is connected to terminal
S on the starter relay so that the battery current flows
through the coil in the starter relay, allowing the relay
to close the circuit. Then, the battery current can flow
to terminal C on the starter, closing the inner starter
relay.
Thereby, the starter begins to rotate.
Electrical current from key switch terminal M also
flows to the controller (EC), which signals that the key
switch has been turned to the ON or START position.
Electrical current from the battery relay is the main
power source of the controller (PVC) and monitor.
Because the EC closes the EC motor relay's coil side
circuit, electrical current from the batteries flows to the
EC motor via the EC motor relay and the EC.
Starter Relay Operation
• When the key switch is turned to the START
position, key switch terminal B and ST have conti-
nuity in the key switch. Then, the current flows to the
base of transistor (Q2) via resistance R4 in the
starter relay, switching transistor (Q2) ON. Thereby,
the current flows through coil (L) of relay, closing the
circuit between starter terminals B and C. Then, the
starter begins to rotate.
• Once the engine is started, the alternator begins
to charge the batteries so that the voltage at
starter relay terminal R rises. When the voltage at
terminal R reaches 21 to 22 V, zener diode (Z) comes
ON. Accordingly, transistor (Q1) is switched ON so
that the base current to transistor (Q2) is cut,
switching transistor (Q2) OFF. At this time, continu-
ity between starter terminal B and C is opened. Then,
the starter is switched OFF.
Capacitor C1 shown in the figure is used to stabilize
the operating voltage. Diode D4 protects the circuit
from damage when the batteries are inversely
connected.

Starter Relay

S B
R4 D3
(1) L

C
R3 (2)
(1)
C
R2 Z D2
To Alternator R Q2 M B
Terminal L Q1
(2)
C1 C
Starter
E
D4

12V
B
ST Batteries

Key Switch 12V

SM4015A
 Key switch
EX455

Fuse
Link

Batteries
Fuse box

Battery
relay

Starter motor

Safety relay
ELECTRICAL SYSTEM

SM5711
T2-3-11

Relay box
T2-3-12 EX455
ELECTRICAL SYSTEM

CHARGING CIRCUIT
(Key Switch: ON)

After the engine starts and the key switch is released,
the key switch is returned to the ON position. With the
key switch kept ON, key switch terminal B is con-
nected to terminals ACC and M.
After the engine starts, the alternator begins power
generation. Current from terminal B on the alternator
flows to the batteries through the battery relay recharg-
ing the batteries.
In addition, this current from Alternator terminal L flows
to the monitor to turn off the charge lamp.
 EX455

Key switch

Fuse
Link
Batteries Fuse box
Battery
relay
ELECTRICAL SYSTEM

Monitor panel

Alternator

Relay box

SM5712
T2-3-13
T2-3-14
ELECTRICAL SYSTEM
SURGE VOLTAGE PREVENTION CIRCUIT
When the engine is stopped (key switch is OFF), the
current from key switch terminal M is cut so that
battery relay is turned OFF.
The engine does not stop immediately by the key
switch OFF, due to inertia and the alternator continues
to generate electricity. Because the alternator gener-
ating current dose not flow to the batteries, the surge
voltage (Voltage rise) is developed in the circuit. This
is the cause of failure of electrical parts and compo-
nents.
On account of this, the surge voltage prevention circuit
has been provided.
EX455
While the batteries are being recharged, the generating
current from terminal L on the alternator is led to
terminal #42 on the monitor, turning the output transis-
tor ON for terminal #18 on the monitor.
In the conditions, the batteries current holds the Anti
Load Dump relay R1, located in the relay box, ener-
gised.
Accordingly, even if the key switch is turned OFF while
the engine is running, the battery current can be
supplied through the anti load dump relay (R1) to
magnetize the battery relay, holding the battery relay
ON until the alternator stops generating.
 EX455

Key switch

Batteries Fuse box

Battery
relay
ELECTRICAL SYSTEM

Monitor panel

Relay box

SM5713
T2-3-15
T2-3-16 EX455
ELECTRICAL SYSTEM

ENGINE STOP CIRCUIT

(Key Switch: OFF)

When the key switch is turned from the ON position to Then, the EC Controller moves the EC motor to the
the OFF position, the signal instructing the EC Control- stop position causing the engine to stop.
ler that the key switch is ON is cut.
 EX455

Key switch

Batteries
Fuse box
Battery
relay

Monitor panel
ELECTRICAL SYSTEM

Relay box

SM5714
T2-3-17
T2-3-18 EX455
ELECTRICAL SYSTEM

NOTES
SECTION 3 EX455

COMPONENT OPERATION

CONTENTS

Group 1 - Pump Device Group 4 - Pilot Valve

Outline .................................................. T3-1-1 Outline .................................................... T3-4-1

Main Pump ........................................... T3-1-3 Operation ................................................ T3-4-3
Regulator .............................................. T3-1-6
Pilot Pump ........................................... T3-1-14 Group 5 - Travel Device
N sensor (Engine Speed Sensor) ......... T3-1-14
Outline .................................................. T3-5-1
P Sensor (Pump Delivery
Pressure Sensor) ................................. T3-1-14 Travel Reduction Gear ........................... T3-5-2
A Sensor (Pump Displacement Travel Motor .......................................... T3-5-3
Angle Sensor) ...................................... T3-1-15 Travel Brake Valve ................................ T3-5-5
Travel Motor Displacement Angle Shift .. T3-5-7
Parking Brake ....................................... T3-5-9

Group 2 - Swing Device

Outline ................................................. T3-2-1

Swing Motor ......................................... T3-2-2 Group 6 - Other Components
Valve Unit ............................................ T3-2-4 (Upperstructure)
Swing Parking Brake ............................ T3-2-6
Pilot Shut-off Valve .............................. T3-6-1
Swing Reduction Gear.......................... T3-2-7
Shockless Valves ................................ T3-6-2
Solenoid Valve ..................................... T3-6-3
Accumulator ......................................... T3-6-4
Group 3 - Control Valve EC Motor ............................................. T3-6-5
Outline .................................................. T3-3-1
Hydraulic Circuit .................................... T3-3-6
Flow Combiner Valve ............................ T3-3-8
Pump Control Valve .............................. T3-3-9 Group 7 - Other Components
Main Relief Valve ................................. T3-3-11 (Undercarriage)
Overload Relief Valve ........................... T3-3-12
Swing Bearing ...................................... T3-7-1
Make-up Valve ..................................... T3-3-12
Center Joint ......................................... T3-7-2
Holding Valve ....................................... T3-3-13
Track Adjuster ...................................... T3-7-4
Arm regenerative Valve ........................ T3-3-14
EX455
PUMP DEVICE
OUTLINE
The pump device consists of transmission, main
pump, (pump 1 and pump 2) and pilot pump.
The engine output is transmitted to the transmission
via the coupling. After being distributed by the gears,
the engine power drives the pumps. Reduction gear
ratio of the main pump (pump 1) is 1:1, and of the main
pump (pump 2) and pilot pump are 32:31.
The main pump is a variable displacement swash plate
tander plunger type pump. The two main pumps are
placed in parallel to supply high pressure oil for
operation to the main circuit.
2
1 - Main pump 2 (rear)
2 - Main pump 1 (front)
3 - Pilot pump
T3-1-1
The pilot pump is a gear pump, and it supplies
hydraulic oil to the pilot circuit.
Angle sensor (A Sensor one each pump) detects the
pump displacement angle, and sends signals to the
PVC to control pump flow through proportional pump
control solenoid valve.
Engine speed sensor (N Sensor) is attached on the
engine flywheel housing.
Pressure sensors (P Sensor) are located on the pump
delivery blocks.
1
SM5722
T3-1-2 EX455

PUMP DEVICE

SM5724/A
2

10

9
4
11
5
Regulator SM5723/C

12
12

1 - Joint coupling 17 - Proportional pump 2 control solenoid valve

2 - Pump 2 angle sensor (A Sensor) 18 - Proportional pump 1 control solenoid valve
3 - Main pump 2 (rear) 19 - Pump 1 delivery pressure sensor (P Sensor)
4 - Main pump 1 (front) 10 - Pilot Pump
5 - Pump 1 angle sensor (A Sensor) 11 - Transmission
6 - Pump 2 delivery pressure sensor (P Sensor) 12 - Regulator
EX455 T3-1-3

PUMP DEVICE

MAIN PUMP

The main pump consists of two pumps which are
placed in parallel. The revolution of the engine is
transmitted to driven shaft (1) via shaft (7), drive gear
(6) and driven gear (2), and drives the two pumps.
In addition, driven shaft (1) drives pilot pump (9) which
is located on the rear end.
Plungers (4) slide on shoe plate (5) and the plungers
reciprocate in the bores of cylinder block (3) by means
of the slope of swash plate (8). By the reciprocating
action, hydraulic oil is inhaled and delivered.

1 2

4 3
7 5
6

7 8 5 4 3 SM5715/C

1 - Shaft 4 - Plunger 6 - Drive Gear 8 - Swash Plate

2 - Driven Gear 5 - Shoe Plate 7 - Shaft 9 - Pilot Pump
3 - Cylinder Block
T3-1-4 EX455

PUMP DEVICE

Operation

Engine torque is transferred to nine plungers via shaft, cylinder block to alternatively suck and deliver
causing cylinder block to slide along the surface of hydraulic oil.
valve plate. Plungers move in and out of their bores in

A1 A2

PSV1 G1 G2
6

8 5
T1 T2

4
9

SM5721

1 - Main pump 1 (front) (drive) 6 - Proportional solenoid valve

2 - Pilot pump 7 - Spool
3 - Main pump suction 8 - Servo piston
4 - Main pump 2 (rear) (driven) 9 - Angle sensor (Pump displacement sensor)
5 - Regulator
EX455 T3-1-5

PUMP DEVICE

Delivery Rate Increase/Decrease Operation

The main pump delivery rate is changed by changing

swash plate angle (displacement angle), thus chang-
ing plunger stroke in the cylinder block bores.
Servopiston (2) is moved by pressure oil from the
regulator to control the swash plate angle displace-
ment angle). As swash plate (3) is connected to servo
piston (2), swash plate (3) angle is changes by the
movement of servo piston (2).

SM5719/D

1 - Shaft 4 - Plunger
2 - Servo Piston 5 - Cylinder Block
3 - Swash Plate 6 - Valve Plate
T3-1-6
PUMP DEVICE
REGULATORS
The regulators are provided on the top of the main
pumps to control the pump delivery rate. The pump
delivery (flow) rate is changed as the flow control
pressure from pump control proportional solenoid
valve (11) increases or decreases.
Main pump delivery pressure P1 is routed to spool (3)
via check valve (10), acting on spool (3). Main pump
delivery pressure P1 is also routed into the small
chamber of servo piston (8) via passage (d) all the
time.
Pilot pump
EX455
As pump control proportional solenoid valve (11) is
activated, servo assist pressure Pi (delivery pressure
from the pilot pump) is reduced, becoming pump flow
control pressure, which then acts on pilot piston (1)
via passage (a). Also, servo assist pressure Pi is
combined with main pump delivery pressure P1 via
check valve (2) and passage (b).
Main Pump
SM5716/E
EX455 T3-1-7

PUMP DEVICE

Small
Large Chamber
Chamber

Large ← Displacement Angle → Small

Main Pump

Cross Section A

Main Pump SM5717/F

1. Pilot Piston 4. Sleeve 7. Plug 10. Check Valve

2. Check Valve 5. Pin 8. Servo Piston 11. Pump Control Proportional
3. Spool 6. Spring 9. Feedback Lever Solenoid Valve

a. Passage for Pump Control Proportional Solenoid Valve
Output Pressure.
b. Passage for Servo Assist Pressure to be Combined with
Main Pump Delivery Pressure P1.
c. Servo Piston Large Chamber Side Tank Port.
d. Passage to Servo Piston Small Chamber.
e. Tank Port (Pump Control Proportional Solenoid Valve)
P1 - Main Pump Delivery Pressure
Pi - Servo Assist Pressure (Pilot Pump Delivery Pressure)
T3-1-8
PUMP DEVICE
Regulator Operation with Flow Rate Control Pres-
sure 0 (Minimum Flow Rate)
When the flow rate control pressure from pump control
proportional solenoid valve (11) is 0, spool (3) is
pushed to the left by spring (6). As a result, main pump
delivery pressure P1 is routed into the servo piston (8)
large chamber via check valve (10), sleeve (4) and
spool (3). Although main pump delivery pressure P1 is
also routed into the small chamber, servo piston (8)
moves to the right due to the difference in pressure
receiving areas between tbe servo piston ends.
Pilot Pump
EX455
As servo piston (8) moves, feedback lever (9) rotates
counterclockwise around plug (7). Because the top
end of feedback lever (9) is connected to sleeve (4) by
pin (5), sleeve (4) moves to the left. Servo piston (8)
continues to move until the notch on spool (3) is closed
completely.
With the above operation, the pump displacement
angle becomes the minimum, obtaining the minimum
flow rate.
Main Pump
SM5718/G
EX455 T3-1-9

PUMP DEVICE

Small
Large Chamber
Chamber

Large ← Displacement Angle → Small

Main Pump

Cross Section A

SM5717/H
Main Pump

3. Spool 6. Spring 8. Servo Piston 10. Check Valve

4. Sleeve 7. Plug 9. Feedback Lever 11. Pump Control Proportional
5. Pin Solenoid Valve

d. Passage to Servo Piston Small Chamber P1 - Main Pump Delivery Pressure

e. Tank Port (Pump Control Proportional Solenoid Valve) Pi - Servo Assist Pressure (Pilot Pump Delivery Pressure)
T3-1-10
PUMP DEVICE
Regulator Operation with Flow Rate Control
Pressure increasing (Increasing Flow Rate)
When pump control proportional solenoid valve (11) is
actuated, flow control pressure, proportional to the
movement of pump control proportional solenoid
valve (11), acts on pilot piston (1) via passage (a),
moving spool (3) to the right until spool (3) balances
with spring (6).
When spool (3) moves to the right, the large chamber
of servo piston (8) is connected to the hydraulic oil
tank via passage (c) in spool (3). Since the main pump
delivery pressure P1 is routed into the small chamber
of servo piston (8) via passage (d) all the time, servo
piston (8) moves to the left and oil in the large chamber
is returned to the hydraulic oil tank.
Pilot Pump
EX455
As servo piston (8) is moved to the left, feedback lever
(9) rotates clockwise around plug (7). Because the top
end of feedback lever (9) is connected to sleeve (4) by
pin (5), sleeve (4) moves to the right.
Servo piston (8) continues to move until the motor on
spool (3) is closed completely.
With the above operation, the pump displacement
angle is increased, increasing pump delivery rate.
Note that the rate of the increment is proportional to
the increment of the flow rate control pressure.
Main Pump
SM5717/2
EX455 T3-1-11

PUMP DEVICE

Large B Small
Chamber
Chamber
A

Large ← Displacement Angle → Small

Main Pump

Cross Section A SM5717/Y

Main Pump

1. Pilot Piston 5. Pin 8. Servo Piston 10. Check Valve

3. Spool 6. Spring 9. Feedback Lever 11. Pump Control
4. Sleeve 7. Plug Proportional Solenoid Valve

P1 - Main Pump Delivery Pressure

a. Passage for Pump Control Proportional Solenoid Pi - Servo Assist Pressure (Pilot Pump Delivery Pressure)
Valve Output Pressure.
c. Servo Piston Large Chamber Side Tank Port.
d. Passage to Servo Piston Small Chamber.
T3-1-12
PUMP DEVICE
Regulator Operation with Flow Rate Control Pres-
sure Decreasing (Decreasing Flow Rate)
When the flow control pressure from pump control
proportional solenoid valve (11) decreases, spool (3) is
returned to the left until it balances with spring (6).
The pressure oil exerted on pilot piston (1) is returned
to the hydraulic oil tank via passages (a) and (e).
As spool (3) moves to the left, main pump delivery
pressure P1 is routed into the large chamber of servo
piston (8) via check valve (10), sleeve (4), and spool
(3). Although main pump delivery pressure P1 is also
routed into the small chamber, servo piston (8) moves
to the right due to the difference in pressure receiving
areas between the servo piston ends.
Pilot Pump
EX455
As servo piston (8) moves, feedback lever (9) rotates
counterclockwise around plug (7). Because the top
end of feedback lever (9) is connected to sleeve (4) by
pin (5), sleeve (4) moves to the left. Servo piston (8)
continues to move until the notch on spool (3) is closed
completely.
With the above operation, the pump displacement
angle is reduced, decreasing the pump flow rate.
Note that the rate of the flow rate reduction is propor-
tional to the reduction of the flow rate control pressure.
Main Pump
SM5717/X
EX455 T3-1-13

PUMP DEVICE

Small
Large Chamber
Chamber

Large ← Displacement Angle → Small

Main Pump

Cross Section A

Main Pump
SM5717/U

1. Pilot Piston 5. Pin 8. Servo Piston 10. Check Valve

3. Spool 6. Spring 9. Feedback Lever 11. Pump Control Proportional
4. Sleeve 7. Plug Solenoid Valve

a. Passage for Pump Control Proportional Solenoid Valve P1 - Main Pump Delivery Pressure
Output Pressure. Pi - Servo Assist Pressure (Pilot Pump Delivery Pressure)
d. Passage to Servo Piston Small Chamber
e. Tank Port (Pump Control Proportional Solenoid Valve)
T3-1-14 EX455

PUMP DEVICE

PILOT PUMP Suction port

2 1
Drive gear (1) is driven via the transmission so that
driven gear (2) meshed with drive gear (1) is also ro-
tated.

1 - Drive Gear
2 - Driven Gear

Delivery port

SM0022

N SENSOR (ENGINE SPEED SENSOR)

The N sensor detects the engine speed. This engine

speed data is used for various controls. The N sensor
is located on the top face of the flywheel ring gear and 3
converts the number of gear teeth passing under the 4
N sensor into an electrical signal.
5

3 - Coil
4 - Magnet
5 - Gear
6 - Output
7 - Output 6 7

SM0023
SM0024

P SENSOR (PUMP DELIVERY PRESSURE

SENSOR)

The P sensor (Pump delivery pressure sensor) moni-

tors the pump delivery pressure which is required as
a control signal for regulating various machine opera-
tion systems. The oil pressure acts on diaphragm
(11). The diaphragm deformation is converted into an
electrical signal.

8 - Ground
9 - Output
10 - Electric Power (5 V)
11 - Pressure Receiver (Diaphragm) SM4032
EX455 T3-1-15

PUMP DEVICE

A SENSOR (PUMP DISPLACEMENT ANGLE

SENSOR)

The pump displacement angle is transmitted to A

1
sensor (1) via lever (2).
The A sensor detects displacement angle changes as
changes in electrical resistance. 2

1 - A Sensor (Pump Displacement Angle Sensor)

2 - Lever SM6559
T3-1-16 EX455

PUMP DEVICE

NOTES
EX455 T3-2-1
SWING DEVICE

OUTLINE

The swing device consists of the valve unit, swing
motor and reduction gear.
The swing motor is driven by pressure oil from the
pump and transmits rotational force to the reduction
gear.
The reduction gear functions to reduce the rotation
speed of swing motor and to increase its torque before
transmitting the rotational force from swing motor to
the pinion shaft.
The valve unit functions to protect the swing circuit.

Valve unit

Swing motor

Reduction
Gear

SM6560
T3-2-2 EX455
SWING DEVICE

SWING MOTOR

The swing motor is a swash-plate-type axial plunger
motor.
The swing motor consists of shaft (4), swash plate (3),
shoes (2), plungers (5), rotor (6), valve plate (9),
housing (1), and parking brake.
The spherical end of plunger (5) is installed in shoe (2)
by a ball-and-socket joint. The shaft part of plunger (5)
is inserted into rotor (6). Rotor (6) is installed onto
shaft (4) with a spline coupling.
The parking brake is a wet-type multiple disc brake,
consisting of friction plates (7) and plates (8).

6 2

5
3

4
SM6561

1 - Housing 6 - Rotor
2 - Shoe 7 - Friction Plate
3 - Swash Plate 8 - Plate
4 - Shaft 9 - Valve Plate
5 - Plunger
EX455 T3-2-3
SWING DEVICE

Operational Principle

Swing speed varies depending on the amount of oil
delivered from the pump.
When pressure oil is fed into the rotor bores via port
(A), the plungers are pushed from the top to the
bottom causing the shoes to slide along the swash
plate, developing rotational force.
The rotational force is then transmitted to the swing
reduction gear via the shaft. As the rotor is rotated, the
plungers are moved to port (B) side one by one,
returning oil to the hydraulic oil tank.
When pressure oil is fed via port (B), the motor rotates
in the opposite direction.

Plunger

Shoe

Shaft

SM6562
T3-2-4 EX455
SWING DEVICE

VALVE UNIT

The valve unit consists of the make-up valve and the

relief valve.
Drain Port
Make-Up Valve
Make-Up Valve
Port M
When swing is stopped, the upperstructure tends to (Make-Up Port)
keep rotating due to swing inertia force, causing the
swing motor to continue rotating further, and to begin
Relief Valve
drawing oil from the pump, developing cavitation the
motor.
The make-up valve draws hydraulic oil through the
port M (make-up port) to compensate for the lack of Control Valve
oil, and prevent cavitation.
SM6563

Port M
(Make-Up Port)

Make-Up Valve

Relief Valve

BV

AV

SM6564
EX455 T3-2-5
SWING DEVICE

Relief Valve

When starting or stopping swing operation, oil pres-

sure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the specified pressure. Plunger is pushed to the
left by pressure Pp at port P and pressure-receiving
area A1.
However, plunger is also pushed back to the right by
spring force and pressure Pg at chamber (g) and Relief Valve
pressure-receiving area A2.
Chamber (g) is connected to port P through orifice
(m). When force acting to the left is higher than that to
Control Valve
the right, the relief valve operates.
SM6565

Spring Plunger
g n

Port P

A2 m A1 SM6566
T3-2-6 EX455
SWING DEVICE

SWING PARKING BRAKE Brake is released (OFF).

The swing parking brake is a wet-type multiple disc

brake.
Also, the swing parking brake is a negative type, i.e.
the brake is released when brake release pressure is 1
routed into brake-piston chamber (b). 2
The brake release pressure is supplied from the pilot
b
pump via a solenoid valve when a swing or front
attachment control lever is operated. (Refer to the
SC
Valve Control in the Control System group, the SYS-
TEM section.)
In cases other than above, the brake release pres-
sure is returned to the hydraulic oil tank and the swing
3
parking brake is automatically applied by spring (1).
4
• When the parking brake is released. (When a swing 5
or front attachment control lever is operated.) 6
SM6567
When a swing or front attachment control lever is
operated, the controller (PVC) actuates (shifts) the
solenoid valve. As the solenoid valve is shifted, the
brake release pressure from the pilot pump is
routed to the brake-piston chamber (b), acting on
brake piston (2). As a result, plates (3) and friction
plates (4) break contact, thus releasing the swing
parking brake.
Brake is applied (ON).
• When the parking brake is applied. (When the swing
or front attachment control levers are not operated.)
1
When the swing or front attachment control levers
are not operated, the solenoid valve does not shift. 2
The brake release pressure is released to the
hydraulic oil tank port via the solenoid valve.
From the above, friction plates (4), which are en- b
gaged with the outer circumference of rotor (6), and
plates (3), which in turn are engaged with the inner
wall of motor housing (5), are pushed by spring (1),
3
coming into tight contact with each other. Conse-
quently, rotor (6) is secured immovable.
4
5
6
SM6568

1. Spring 4. Friction Plate

2. Brake Piston 5. Motor Housing
3. Plate 6. Rotor
EX455 T3-2-7
SWING DEVICE

SWING REDUCTION GEAR

The swing reduction gear is a planetary-gear-type
two stage reduction gear.
Both first stage ring gear (2) and second stage ring
gear (4) are immovable as they are fixed to the
housing.
Motor output shaft (10) rotates first stage sun gear (9).
As the first stage reduction takes place between first
stage planetary gears (1) and first stage carrier (8),
second stage sun gear (7) is rotated. Then, the second
stage reduction takes place between second stage
planetary gears (3) and second stage carrier (6), there-
fore the rotational force is transmitted to shaft (5).

10
1

3
8

7 4

SM6569

1 - First Stage Planetary Gear 6 - Second Stage Carrier

2 - First Stage Ring Gear 7 - Second Stage Sun Gear
3 - Second Stage Planetary Gear 8 - First Stage Carrier
4 - Second Stage Ring Gear 9 - First Stage Sun Gear
5 - Shaft 10 - Motor Output Shaft
T3-2-8 EX455
SWING DEVICE

NOTES
EX455 T3-3-1
CONTROL VALVE

OUTLINE

The control valve regulates oil flow rate, oil flow
direction, and oil pressure in the hydraulic circuit. The
main control valve consists of two blocks: the right (4-
spool) block and the left (5-spool) block, connected.
The main control valve is a pilot-pressure operated
type.
The main control valve consists of main relief valve,
pump control valve, flow combiner valve, spools, arm
regenerative valve, and holding valve.
The spool sections of the main control valve are
arranged as follows:
Right (4-spool) block: Travel (R), Bucket, Boom 1,
and Arm 2 sections, in that order viewed from the front
side.
Left (5-spool) block: Travel (L), *Aux., Boom 2, Arm 1,
and Swing sections, in that order viewed from the front
side.
The pump control valve is provided on each main
control valve block downstream of each block's neu-
tral passage. These pump control valves send pres-
sure signals to the DP sensor to control the main
pump delivery rate.

Travel (R)
Front Side Bucket
Travel (L) Boom 1
Auxiliary Arm 2

Boom 2 Arm Regenerative

Valve
Arm 1
DP Sensor
Swing (4-Spool Block Side)

Overload Relief Pump Control Valve

Valve (4-Spool Block Side)

4-Spool
Make-Up Valve
Block

Tank Port
T2
Holding Valve (Arm)

Overload Relief Valve Tank Port

T1

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)
Shuttle Valve Main Relief Valve
Flow Combiner
Valve 4-Spool Block

SM6509
T3-3-2 EX455
CONTROL VALVE

Control Valve Layout

1 2 3 43 4 5 6 7 8 9 10 11 12 13 14 15

42

41
Swing Motors

Boom Cylinder

Arm Cylinder
40

39
16
Bucket Cylinder
17
38 18
19
37
20
36 21
22
35
23
34

33

Right Travel Motor

SM6570
32 31 30 29 28 27 26 25 24

1 - Holding Valve Shift Valve (Boom) 23 - DP Sensor (5-Spool Side)

2 - Load Check Valve (Arm 2 Tandem Circuit) 24 - Pump Control Valve (5-Spool Side)
3 - Pump Control Valve (4- Spool Side) 25 - Load Check Valve (Left Travel Parallel Circuit)
4 - Load Check Valve (Arm 2 Parallel Circuit) 26 - Load Check Valve (Aux. Parallel Circuit)
5 - Check Valve (Arm Flow Combining Circuit) 27 - Check Valve (Bucket Flow Combining Circuit)
6 - Check Valve (Aux. Flow Combining Circuit) 28 - Check Valve (Main Relief Pressure Combining Circuit)
7 - Arm Regenerative Flow Control Valve 29 - Flow Combiner Valve
8 - Check Valve (Arm 1 Parallel Circuit) 30 - Check Valve (Travel Flow Combining Circuit)
9 - Load Check Valve (Arm 1 Parallel Circuit) 31 - Check Valve
10 - Load Check Valve (Swing Tandem Circuit) 32 - Shuttle Valve
11 - Arm Regenerative Valve 33 - Main Relief Valve
12 - Load Check Valve (Arm 1 Tandem Circuit) 34 - Load Check Valve (Bucket Tandem Circuit)
13 - Holding Valve Shift Valve (Arm) 35 - Check Valve (Aux. Parallel Circuit)
14 - Overload Relief Valve (Swing) 36 - Load Check Valve (Boom 1 Parallel Circuit)
15 - Overload Relief Valve (Arm) 37 - Overload Relief Valve (Bucket)
16 - Holding Check Valve (Arm) 38 - Check Valve (Boom Flow Combining Circuit)
17 - Make-Up Valve (Boom 2) 39 - Overload Relief Valve (Boom)
18 - Load Check Valve (Boom 2 Tandem Circuit) 40 - Holding Check Valve (Boom)
19 - Load Check Valve (Boom 2 Parallel Circuit) 41 - Make-Up Valve (Arm 2)
20 - Load Check Valve (Aux. Tandem Circuit) 42 - DP Sensor (4-Spool Side)
21 - Overload Relief Valve (Aux.) 43 - Center Bypass Valve
22 - Load Check Valve (Left Travel Tandem Circuit)
EX455 T3-3-3
CONTROL VALVE

Swing Arm 1 32 33 24 23
Boom 2

Aux.

Left Travel
Arm 2
Boom 1

Bucket
31
Right Travel

Front Side
SM6572

SM6571
30 29

44 28 45 37 48 35 49 21

Right Travel Left Travel Bucket Aux.

22 20

34 26

21
25

37 51 6 27 50
47 46
SM6573 SM6574

44 - Right Travel Forward Port 48 - Bucket (Roll-Out) Port

45 - Left Travel Forward Port 49 - Aux. Port
46 - Left Travel Reverse Port 50 - Aux. Port
47 - Right Travel Reverse Port 51 - Bucket (Roll-In) Port
T3-3-4 EX455
CONTROL VALVE

1 2 3 43 4 5 6 7 8 9 10 11 12 13 14 15

42

41
Swing Motors

Boom Cylinder

Arm Cylinder
40

39
16
Bucket Cylinder
17
38 18
19
37
20
36 21
22
35
23
34

33

Right Travel Motor Left Travel Motor

32 31 30 29 28 27 26 25 24 SM6570

1 - Holding Valve Shift Valve (Boom) 23 - DP Sensor (5-Spool Side)

2 - Load Check Valve (Arm 2 Tandem Circuit) 24 - Pump Control Valve (5-Spool Side)
3 - Pump Control Valve (4- Spool Side) 25 - Load Check Valve (Left Travel Parallel Circuit)
4 - Load Check Valve (Arm 2 Parallel Circuit) 26 - Load Check Valve (Aux. Parallel Circuit)
5 - Check Valve (Arm Flow Combining Circuit) 27 - Check Valve (Bucket Flow Combining Circuit)
6 - Check Valve (Aux. Flow Combining Circuit) 28 - Check Valve (Main Relief Pressure Combining Circuit)
7 - Arm Regenerative Flow Control Valve 29 - Flow Combiner Valve
8 - Check Valve (Arm 1 Parallel Circuit) 30 - Check Valve (Travel Flow Combining Circuit)
9 - Load Check Valve (Arm 1 Parallel Circuit) 31 - Check Valve
10 - Load Check Valve (Swing Tandem Circuit) 32 - Shuttle Valve
11 - Arm Regenerative Valve 33 - Main Relief Valve
12 - Load Check Valve (Arm 1 Tandem Circuit) 34 - Load Check Valve (Bucket Tandem Circuit)
13 - Holding Valve Shift Valve (Arm) 35 - Check Valve (Aux. Parallel Circuit)
14 - Overload Relief Valve (Swing) 36 - Load Check Valve (Boom 1 Parallel Circuit)
15 - Overload Relief Valve (Arm) 37 - Overload Relief Valve (Bucket)
16 - Holding Check Valve (Arm) 38 - Check Valve (Boom Flow Combining Circuit)
17 - Make-Up Valve (Boom 2) 39 - Overload Relief Valve (Boom)
18 - Load Check Valve (Boom 2 Tandem Circuit) 40 - Holding Check Valve (Boom)
19 - Load Check Valve (Boom 2 Parallel Circuit) 41 - Make-Up Valve (Arm 2)
20 - Load Check Valve (Aux. Tandem Circuit) 42 - DP Sensor (4-Spool Side)
21 - Overload Relief Valve (Aux.) 43 - Center Bypass Valve
22 - Load Check Valve (Left Travel Tandem Circuit)
EX455 T3-3-5
CONTROL VALVE

56 5 57
52 53
Arm 2 Arm 1
Boom 1 Boom 2 7
17
16 13
41
39
8

36 18 2

1 12

19
4 9

15

40 55 38 54 SM6575 38 59 58 SM6576

42 3 60 14

Swing

15

43
10

14

SM6577 SM6578
40 61

52 - Boom 1 (Lower) Port 57 - Arm 1 (Roll-Out) Port

53 - Boom 2 (Lower) Port 58 - Arm 1 (Roll-In) Port
54 - Boom 2 (Raise) Port 59 - Arm 2 (Roll-In) Port
55 - Boom 1 (Raise) Port 60 - Swing (Left) Port
56 - Arm 2 (Roll-Out) Port 61 - Swing (Right) Port
T3-3-6 EX455
CONTROL VALVE

HYDRAULIC CIRCUITS

Main Circuit Pilot Signal Circuit

Oil flow from the main pumps is routed to the 4-spool
block and 5-spool block of the control valve. A parallel
passage is provided on both control valve blocks,
making combined operations possible.
The main relief valve is provided in the main circuit to
set the main circuit pressure to a certain level. In
addition, an overload relief valve is provided in each
of the boom, arm, bucket, and swing circuits.
A pump control valve is provided downstream of each
control valve block's neutral passage.
Pressure oil from the pilot pump flows through the
control valve blocks, acting as pilot signals.
When the front attachment cylinders or swing motor
are operated, the pilot pressure in the front att. pilot
signal circuit in the main control valve increases,
shifting the flow combiner valve.
EX455 T3-3-7
CONTROL VALVE

Pump Control Valve

(4-Spool Block Side) Front Att. Pilot Signal Circuit

Overload Relief
Valve

Overload Relief
Overload Valve
Relief Valve

From the pilot

pump
Travel Pilot
Signal Circuit
Main Relief
Valve 4-Spool
Block
Side 5-Spool Block
Side
Main Main
Pump 2 Pump 1 Pump Control Valve
From the main (5-Spool Block Side)
relief pressure SM6579
shift solenoid valve.
T3-3-8 EX455
CONTROL VALVE

FLOW COMBINER VALVE

When a control lever, other than the travel levers, is
operated, the front att. pilot signal circuit is restricted
by the movement of the main control valve spool,
increasing the pilot pressure and shifting the flow
combiner valve.
If the travel control levers are operated with the above
mentioned control lever operated, oil flow from main
pump 2 is routed to both Travel (R) and Travel (L)
spools, securing straight travelability in travel com-
bines operations.

Front Att. Pilot Signal

Boom Cylinder

Boom 2
Boom

Travel (L)

Travel (R)

Flow Combiner
Valve
4-Spool
Block 5-Spool Block Side
Side

Main Pump 2 Main Pump 1

Right Travel Motor Left Travel Motor

SM6580
EX455 T3-3-9
CONTROL VALVE

PUMP CONTROL VALVE

A pump control valve is provided on the farthest
downstream part of the neutral passage in each
4-spool and 5-spool control valve block.
The pump control valve routes pressures of neutral
passage before and after the pump control valve's
orifice to the DP sensor as pump flow control signals.
If the pressure difference is large, the pump flow rate
is decreased. If it is small, the pump flow rate is
increased.

Pump Control Valve (4-Spool Block Side)

Neutral
Passage
Pressure Difference
Sensor (DP Sensor)

Neutral
Passage

Pressure Difference
Sensor (DP Sensor)

4-Spool 5-Spool
Block Side Block Side
Pump Control Valve (5-Spool Block Side)

SM6581
T3-3-10 EX455
CONTROL VALVE

Pump control valve operation when control Pump control valve operation when control
valve spools are in neutral. levers are operated.

When the control valve spools are in neutral, all oil
flowing from the main control valve goes through the
orifice before it is returned to the hydraulic oil tank. The
pressure difference between before and after the
orifice becomes large, reducing the main pump flow
rate to the minimum.
When a control lever is operated, a control valve spool
is shifted to route oil flow to an actuator, reducing the
oil flow rate in the neutral passage. As a result, the
pressure difference between before and after the
orifice becomes small, increasing the main pump flow
rate.

DP Sensor

To the controller.

Orifice

(fp)
Neutral Passage

(rp)
Poppet Spring

Return Line SM6582

Pump Control Valve Operation as a Relief Valve

Normally the pump control valve does not act as a

relief valve. However, if oil flow in the neutral passage
becomes excessive, a poppet opens to provide an
extra passage to the return line, in addition to the
orifice passage, to release excessive pressure.

Orifice Poppet

Neutral Passage

Return Line SM6583

EX455 T3-3-11
CONTROL VALVE

MAIN RELIEF VALVE

Main relief valve set pressure can be shifted in two

stages using the pilot pressure from main relief pres-
sure shift solenoid valve (SA).
When traveling or when operating in the precision
mode, the main relief pressure is set in the high stage
(high relief pressure). In other cases, the main relief
pressure is set in the low stage (low relief pressure).

Main Relief Valve Operation in Low Main Relief

Pressure Setting

When the travel pressure switch is OFF or when the
work mode is set in other than the precision mode, the
main relief valve shift solenoid valve is not excited
and, as a result, no pilot pressure exerts on the shuttle
valve port pF2. At the same time, port pF1 is open to
the hydraulic oil tank line. For this reason, the main
relief valve piston is not pushed to the left, keeping the
pilot poppet setting relatively low.
When pressure at port Hp rises to the set pressure,
the pilot poppet opens, routing oil at port Hp to port Lp
via passage A.
The pressure in spring A chamber decreases as the
pilot poppet opens, causing the main poppet to open.
As a result, pressure oil at port Hp is directly routed to
port Lp.

Main Poppet Pilot Poppet Spring Piston

Lp

Hp

Lp

pF1 pF2 Shuttle Valve

Passage A
Spring A Chamber
Main Relief Valve Shift Solenoid Valve

SM6584

Main Relief Valve Operation in High Main Relief

Pressure Setting

When the travel pressure switch is ON or when the work
mode is set in the precision mode, the main relief valve
shift solenoid valve is excited and, as a result, a pilot
pressure is routed to the shuttle valve port pF2. This pilot
pressure acts on the piston, pushing it to the left.
As a result, the spring is compressed, increasing the
pilot poppet setting force. In other words, the main
relief pressure setting is shifted to the high stage.
The valve operation is the same as the one in the low
main relief pressure setting.
T3-3-12 EX455
CONTROL VALVE

OVERLOAD RELIEF VALVE

(With Make-Up Function)
1 2 3 4
An overload relief valve is provided on each of swing,
boom, arm, and bucket actuator port, preventing
excessive pressure from arising in each actuator HP
circuit if each actuator should be forcibly moved by an
external force.
When the pressure at port HP overcomes spring (4),
pilot poppet (3) opens, decreasing the pressure in
chamber (a). As a result, piston (1) is moved to the
LP
right, opening main poppet (2), thus routing pressure
oil at port HP directly to port LP.
SM6585

In addition, the overload relief valve draws oil from the

hydraulic oil tank line to prevent cavitation from occur-
ring if the actuator circuit pressure becomes negative.
2 a

HP

1 - Piston
2 - Main Poppet
3 - Pilot Poppet
4 - Spring

LP

SM6586

MAKE-UP VALVE
5 6
A make-up valve is provided on the cylinder port of d2 d1
boom 2 and arm 2 sections, reinforcing the overload
relief valve's make-up function. HP
Poppet (5) is closed when the pressure at port HP is
higher than the pressure at port LP due to the differ-
ence in pressure receiving areas of poppet ends d1
and d2.
If the pressure at port HP becomes lower than the
pressure at port LP, port LP pressure for the area LP
difference between d1 and d2 is applied to poppet (5), b
opening it.
SM6587

5 - Poppet
6 - Spring

HP

LP

SM6588
EX455 T3-3-13
CONTROL VALVE

HOLDING VALVE

A holding valve is provided on the boom raise side and

arm roll-out side cylinder ports, preventing the boom
and arm cylinders from retracting when the control
levers are in neutral.

Holding valve operation when the control levers

are in neutral.

The cylinder holding pressure at cylinder port c acts receiving areas d1 and d2, check valve (2) is securely
on chamber (a) via orifice (b) in check valve (2). seated on cylinder port C, closing the cylinder port.
Because of the difference in the sizes of pressure

1 External Force

g
2 a
a Holding Pressure
d1
b
g 3
c
b d2
d
c 3

Pi
f

f d e

SM6589

Holding valve operation when the boom lower

or arm roll-in control lever is operated.

Pilot pressure Pi acts on poppet (1), connecting valve (2) opens. At the same time, spool (3) is moved
chamber (a) and the hydraulic oil tank line. to form a circuit ( (c) → (d) → (f) ) so that the actuating
As the pressure in chamber (a) decreases, check cylinder (boom or arm) can move.

1
a
2
a

c 3
d

Pi

f d

1 - Poppet SM6590
2 - Check Valve
3 - Spool
T3-3-14 EX455
CONTROL VALVE

ARM REGENERATIVE VALVE 1

The arm regenerative valve is provided to help PB
smooth arm operation and to prevent arm hesitation PR
from occurring. i
Return oil from cylinder rod side is restricted in two 8
stages at orifice (A) in spool (2) and at orifice (B) in 3
arm regenerative valve (7), increasing cylinder rod 2
side pressure PR.
h
When rod side pressure PR becomes higher than A
bottom side pressure PB, check valve (3) opens,
routing the return oil from the rod side to supplement
the pump oil flow to the bottom side. C
e
7

9 6
b

a d
B

SM6591

PR PB

8 9

A
h

f e a i d
e
7 B

d
c

6 5 4 SM6592

1 - Arm Cylinder 6 - Spring

2 - Spool 7 - Arm Regenerative Valve
3 - Check Valve 8 - Holding Valve
4 - Piston 9 - Load Check Valve
5 - Spool
EX455 T3-3-15
CONTROL VALVE

When bottom side pressure PB is higher than rod side

1
pressure PR, check valve (3) closes. Moreover, bot-
tom side pressure PB acts on piston (4) in arm
PB
regenerative valve (7) via passage (b). As a result, PR
spool (5) is moved to the left, widening orifice (B), thus i
returning rod side oil faster to hydraulic oil tank 8
passage (d). 3
2
h
A

C
e
7

9 6
b

a d
B

SM6591

PR PB

8 9

A
h

f e a i d
e
7 B

d
c

6 5 4 SM6593

1 - Arm Cylinder 6 - Spring

2 - Spool 7 - Arm Regenerative Valve
3 - Check Valve 8 - Holding Valve
4 - Piston 9 - Load Check Valve
5 - Spool
T3-3-16 EX455
CONTROL VALVE

NOTES
EX455 T3-4-1
PILOT VALVE

OUTLINE

The pilot valve controls pilot pressure oil to move the
control valve spools. There are two types of pilot
valves. One is for front/swing operation; the other is for
travel operation. Both have as standard four oil ports.
An optional two-port type is available.
The construction of the reducing valves in both the
front attachment / swing and travel pilot valves are
identical except for the pusher cams.

• Right and left pilot valves (Front attachment/Swing)

Port No. Control

1 Bucket roll-out
Right 2 Boom lower
3 Bucket roll-in
4 Boom raise
1 Swing right
Left 2 Arm roll-out
3 Swing left
4 Arm roll-in T 3 4 P
3 4
T P

P T 2 1

SM0065

1 3 2 4

SM0063
T3-4-2 EX455
PILOT VALVE

• Travel pilot valve

Port No. Control

1 Left travel forward
2 Left travel reverse
3 Right travel reverse
4 Right travel forward

1 P 2

P T

1 2 3 4

4 T 3
SM0064 SM6595
EX455 T3-4-3
PILOT VALVE

OPERATION

• Front and Swing Pilot Valve

The lower face of spool (8) head is suspended by the In neutral

upper face of spacer (4); they are kept in contact by
setting force of balance spring (6). Spacer (4) is
installed between pusher (3) and spring guide (5) and
supported by return spring (7). Piston (9) is located
inside spool (8). The lower end of piston (9) makes
contact with the plate, preventing the piston from
moving further downward.
Above piston (9), a chamber is provided and it is led
to the outside of spool (8) through holes provided in
spool (8).
(Corresponding to A to B in the output diagram):
When control lever (1) is in the neutral position (no
pusher stroke), spool (8) completely blocks pressure
oil from entering port P. Since the delivery port is open
to port T, pressure at the delivery port equals that in
the hydraulic oil tank.
When control lever (1) is slightly moved, cam (2)
moves together, pressing down on pusher (3).
Then, pusher (3), spacer (4), and spring guide (5)
move downward as a unit, compressing return spring
(7).
The lower face of spool (8) is kept in contact with the
upper face of spacer (4) by setting force of balance
spring (6) and moves downward together with spacer
(4). However, even if control lever (1) is moved
further, until clearance (A) at section (a) reaches
zero, the delivery port remains open to port T,
keeping pressure at the delivery port equal to that in
the hydraulic oil tank.

Delivery port
pressure
(pilot pressure)
1

2
A B Pusher stroke

3 OUTPUT DIAGRAM

4
5
6

Section (a)
7
(A)
8
Port T
(A)=0
Delivery port

Port P
9

SM0067

1 - Control Lever 6 - Balance Spring

2 - Cam 7 - Return Spring
3 - Pusher 8 - Spool
4 - Spacer 9 - Piston
5 - Spring Guide
T3-4-4 EX455
PILOT VALVE

Ready to start operation

(Corresponding to B to C section in the output
diagram):

When control lever (1) is tilted slightly further from the
position where clearance (A) in section (a) reaches
zero, and pusher (3) is pushed downward, spool (8)
is moved downward, opening notched section (b) to
allow pressure oil at the port P to flow into the delivery
port.
This oil pressure is also led to the inside of spool (8)
via orifice (10), and acts to push spool (8) upward.
Until this oil pressure force reaches the setting force
of balance spring (6), balance spring (6) will not be
compressed so that spool (8) is not moved upward,
closing the clearance at section (a), keeping the
notch at section (b) opened, and letting the oil
pressure to increase at the delivery port.
If the oil pressure at the delivery port increases, and
the upward-pushing force of spool (8) slightly
exceeds the setting force of balance spring (6), spool
(8) moves upward against setting force of balance
spring (6).
Once spool (8) moves upward, upper clarance at
section (a) is opened and lower notch section at
section (b) is closed, leading oil pressure at the
delivery port to port T, and decreasing oil pressure at
the delivery port.
When oil pressure at the delivery port decreases, the
force to push up spool (8) is reduced so that balance
spring (6) stretches to move spool (8) downward,
closing both the clearance and the notch at sections
(a and b).
Thus, original position of spool (8) is kept resumed.
The oil pressure will continue to increase until it is
equal to setting force of balance spring (6) (shown by
the point C in the output diagram).

Delivery port
pressure
1 (Pilot pressure)

B Pusher stroke

OUTPUT DIAGRAM
3

Section (a) 8

Port T
Clearance (A) reaches zero
Delivery port Section (b)
10
Port P

SM0068

1 - Control Lever 8 - Spool

3 - Pusher 9 - Piston
6 - Balance Spring 10 - Orifice
EX455 T3-4-5
PILOT VALVE

Operation corresponding to the control lever stroke

(Corresponding to C to D in the output diagram):

As control lever (1) is moved further to push pusher
(3) downward, spool (8) is pushed down to open the
notch at section (b), increasing oil pressure at the
delivery port.
As pressure increases, the force to push up spool (8)
increases. Then, when force to push up spool (8)
exceeds the setting force of balance spring (6), spool
(8) starts to move upward, compressing balance
spring (6).
When spool (8) moves upward until the clearance at
section (a) opens, the delivery port is opened to port
T, stopping oil pressure increase at the delivery port
and stopping movement of spool (8).
Accordingly, when compressed by pusher (3), spring
force of balance spring (6) increases in proportion to
the pusher stroke, Then, oil pressure increases to
counteract against this spring force.

Delivery port
pressure
(Pilot pressure)
1
D

Pusher stroke

OUTPUT DIAGRAM

Section (a)
8

Port T

Delivery port
Section (b)

Port P

SM0069

1 - Control Lever 6 - Balance Spring

3 - Pusher 8 - Spool
T3-4-6 EX455
PILOT VALVE

Operation close to pusher stroke end

(Corresponding to D to E in the output diagram):

As pusher (3) is pressed down, balance spring (6) is
compressed, reducing clearance (B) between
pusher (3) and the top of spool (8) (shown at section
(c)), finally to zero.
After that, pusher (3) directly pushes spool (8).
Even if oil pressure at the delivery port increases,
spool (8) cannot move upward, closing the oil
passage from the delivery port to port T, and opening
the oil passage from the delivery port to port P.
Then, oil pressure at the delivery port increases until
it reaches port P pressure.

Delivery port E
pressure
(Pilot pressure)
D

Pusher stroke

3 OUTPUT DIAGRAM

Section (c)

Clearance (B) reaches zero

6

Port T

Delivery port

Port P

SM0070

3 - Pusher 8 - Spool
6 - Balance Spring
EX455 T3-4-7
PILOT VALVE

Full stroke operation

(Corresponding to E to F section in the output
diagram):

Even if control lever (1) is tilted further to push down
pusher (3), spool (8) moves downward along with
pusher (3), only widening the notch at lower section
(b) of spool (8).
Thus, oil pressure at the delivery port is kept same as
at port P. Pusher (3) can be pressed down until spring
guide (5) comes into contact with the shoulder
(section (d)) of the casing.
This position is the stroke end of pusher (3)
(corresponding to F position in the output diagram).
This process corresponds with E to F section in the
output diagram.
The total stroke of the control lever is decided by
dimension C.

Delivery port E F
pressure
1 (Pilot pressure)

Pusher stroke

3 OUTPUT DIAGRAM

Section (d)

C
5

Port T

Delivery port
Section (b)
Port P

SM0071

1 - Control Lever 5 - Spring Guide

3 - Pusher 8 - Spool
T3-4-8 EX455
PILOT VALVE

• Travel Pilot Valve

In neutral Full stroke operation:

(Corresponding to A to B in the output diagram):
Lever - In Neutral (Pusher Stroke: A to B)
In neutral, spool (6) closes port P (the input port) and
tank port T is connected to delivery port through
clearance (A). Thus, the pressure at delivery port is
the same as that at tank port T.
When the control lever is moved slightly from A to B,
pusher (2) and spring guide (3) together move down
against return spring (5) and balance spring (4). At
this time, as both oil pressures above and below
spool (6) are the same as the tank pressure, spool (6)
moves down together with spring guide (3) until
clearance (A) becomes zero.
Lever - Full Stroke (Pusher Stroke)
When the control lever is moved full stroke, pusher
(2) is moved down until spring guide (3) comes into
contact with the shoulder of the valve casing (Lever
Stroke End), opening notch (B) further to port P.
The output pressure (pilot pressure to the control
valve) remains at the pilot system pressure (the port
P pressure).
Dimension (C) in the figure right shows the control
lever full stroke.

Delivery port
Operation corresponding to the control lever stroke pressure
(Corresponding to C to D in the output diagram): (Pilot pressure)
Lever - Operated D
(Pusher Stroke: C to D — Metering)

When the control lever is moved further to push

pusher (2) down, port P is connected to delivery port C
through notch (B) and passage in spool (6), routing
pilot pump pressure. However, when the pressure
applied into spool (6) overcomes the balance spring A B Pusher stroke
force, spool (6) moves up, closing port P. When
pusher (2) is moved further down, compressing
return spring (5) and balance spring (4), the larger the
balance spring force; thus, the output pressure OUTPUT DIAGRAM
increases in proportion to the increase in the balance
spring force.
SM0072
EX455 T3-4-9
PILOT VALVE

Pusher stroke: A to B

4
5
Port T
(A) Clearance A: 0

Port P

Delivery port

SM0073 SM0075

Pusher stroke: C to D Pusher stroke: full stroke

2
2

(C)
4

5
3
Port T Port T
(B)

Port P 6 Port P

Delivery port Delivery port

SM0074 SM0076

1 - Cam 4 - Balance Spring

2 - Pusher 5 - Return Spring
3 - Spring Guide 6 - Spool
T3-4-10 EX455
PILOT VALVE

NOTES
EX455 T3-5-1
TRAVEL DEVICE

OUTLINE

The travel device consists of travel motor (1), the

travel reduction gear (parts (2) to (8), (10) to (14)), and
sprocket (9).

6
7
8

12

11

10

14 13 SM6596

1 - Travel Motor 8 - Third Stage Carrier

2 - Housing 9 - Sprocket
3 - Drum 10 - Third Stage Planetary Gear
4 - First Stage Planetary Gear 11 - Second Stage Planetary Gear
5 - Second Stage Sun Gear 12 - First Stage Carrier
6 - Second Stage Carrier 13 - Ring Gear
7 - Third Stage Sun Gear 14 - Shaft
T3-5-2 EX455
TRAVEL DEVICE

TRAVEL REDUCTION GEAR

The travel reduction gear is a third stage planetary
gear type. When the travel motor rotates, shaft (7)
rotates, transmitting this motor-driving power to ring
gear (1) via first stage planetary gears (8), first stage
carrier (6), second stage sun gear (5), second stage
planetary gears (9), second stage carrier (4), third
stage sun gear (3), third stage planetary gears (10)
and third stage carrier (2).
Third stage carrier (2) does not rotate as it is fixed to
travel motor housing (12). Ring gear (1) and sprocket
(11) are bolted to drum (13) and they rotate together.

11

12 13 2 3 4

5 13 2 3 4 5 9 1 6

7
7

12
8
Third Second First
Stage Stage Stage

11 10
SM6598

10 1 9

SM6597

1 - Ring Gear 8 - First Stage Planetary Gear

2 - Third Stage Carrier 9 - Second Stage Planetary Gear
3 - Third Stage Sun gear 10 - Third Stage Planetary Gear
4 - Second Stage Carrier 11 - Sprocket
5 - Second Stage Sun Gear 12 - Housing (Travel Motor)
6 - First Stage Carrier 13 - Drum
7 - Shaft
EX455 T3-5-3
TRAVEL DEVICE

TRAVEL MOTOR

The travel motor is a swash-plate-type axial plunger
motor, with a built-in hydraulically-released, wet-type
multiple disc parking brake (3).
The travel motor consists of swash plate (6), rotor
(16), plungers (14) with shoes, valve plate (1), output
shaft (10), tilt pistons (12), and casing (7).
Tilt pistons (12) (4 provided) changes the displace-
ment angle of swash plate (6); swash plate (6) is
moved (the angle is changed), having the contact
point with ball (8) as the supporting point.
Rotor (16) is in tight contact with valve plate (1) by
spring (5).

1 2 3 4 5 6 7

8
9

10

17

11
16

15 14 13 12
SM6599

1 - Valve Plate 10 - Output Shaft

2 - Spring 11 - Spring
3 - Parking Brake 12 - Tilt Piston
4 - Retainer Plate 13 - Holder
5 - Spring 14 - Plunger
6 - Swash Plate 15 - Brake Piston
7 - Casing 16 - Rotor
8 - Ball 17 - Valve Cover
9 - Roller Bearing
T3-5-4 EX455
TRAVEL DEVICE

Pressure oil from the pump flows to port A of valve
plate (1), and enters into one-sided bores in rotor (2)
located just behind the right-side crescent-shaped oil
port (port A side) of valve plate (1).
Then, plungers (3) in the right half side of rotor (2) are
pushed out toward swash plate (5), and slide on the
swash plate to rotate rotor (2) and output shaft (6).
As output shaft (6) rotates, rotor (2) also rotates.
Then, when plungers (3) reach port B, oil is routed to
the hydraulic oil tank.
Whether pressure oil from the pump is supplied to port
A or port B determines travel direction.

Port B Port A
Port B
Port A

2 1

4 Valve
Plate
6 5
SM6600

1 - Valve Plate 4 - Shoe

2 - Rotor 5 - Swash Plate
3 - Plunger 6 - Output Shaft
EX455 T3-5-5
TRAVEL DEVICE

TRAVEL BRAKE VALVE

The travel brake valve is located on the travel motor
head and consists of the following valves:
Counterbalance Valve:
ensures smooth starts and stops and prevents
overrunning when traveling down slopes.
Overload Relief Valve:
prevents overloads and surge pressure in the motor
circuit.
Check Valve:
ensures smooth starts and stops, and prevents cavi-
tation from occurring in the motor circuit by function-
ing together with counterbalance valve.
Travel Speed Shift Valve:
controls the tilt pistons when travel mode switch is
operated.

Check Valve

Counterbalance Valve

Overload Relief Valve

Travel Speed Shift Valve

SM6601
T3-5-6
TRAVEL DEVICE
Travel Operation
When supply oil from the control valve is routed to port
BV, supply oil flows around spool CB, opens check
valve BC and is led to motor port BM. However, return
oil from motor port AM is blocked by check valve AC
and spool CB.
As supply oil pressure at port BV increases, supply oil
is routed to chamber G through orifice F in spool CB,
moving spool CB to the left against spring force.
Consequently, return oil from motor port AM starts to
flow into port AV through notch H in spool CB, allowing
the travel motor to rotate.
When the travel levers are returned to the neutral
position, the oil in both ports AV and BV is routed to the
hydraulic oil tank through the control valve. Thus, oil
pressure in chamber G decreases, and spool CB is
moved back to the original position by spring force.
Then, the oil flow circuit is blocked, causing the travel
motors to stop rotating.
Spool CB
Overload Relief Valve
AM
BM
EX455
Descending Operation
When the machine travels down a slope, the travel
motors are forcibly driven by the machine weight so
that the motor sucks oil like a pump. When the motor
sucks oil, oil pressure at port BV and chamber G
decreases, causing spool CB to move to the right.
Then, the return oil flow from the motor is restricted by
the spool, increasing pressure at port AM.
The increased pressure at port AM brakes the motor.
Thus, the restricted return oil flow increases the
pressure at port BV again, moving spool CB back to
the left. This repeat movement of the spool (hydraulic
brake action) prevents the machine from
overrunning.
Circuit Protectors
If pressure in the circuit increases over the setting
pressure of overload relief valve, this valve opens to
relieve peak pressure to the lower pressure side to
protect the motor from overloading. This valve also
functions to release shock pressure caused by inertia
force developing when the motor stops.
When the motor draws oil because of pumping opera-
tion, check valve BC opens to make up vacuum, so
that cavitation will not develop in the circuit.
H Check Valve AC
F
AV
BV
Check Valve BC
SM6602
EX455 T3-5-7
TRAVEL DEVICE

TRAVEL MOTOR DISPLACEMENT ANGLE

SHIFT

Travel speed mode shifts as the displacement angle

of swash plate (4) is changed by tilt pistons (5).

• Slow Speed Travel

(Maximum Displacement Angle)

With the travel mode switch is in the slow speed
position, the controller (PVC) does not shift the
travel speed mode shift solenoid valve SB so that
pilot pressure (3) is not supplied to travel motor
displacement angle shift valve (1) from the travel
speed mode shift solenoid valve SB. Spool (7) in
travel motor displacement angle shift valve (1) is
held in neutral by spring (2), blocking pressure oil
from the control valve. At the same time, the line to
tilt pistons (5) is open to the hydraulic oil tank line.
With the above, the displacement angle of swash
plate (4) is held at the maximum angle, having the
maximum plunger (6) stroke. Accordingly the
amount of oil required to rotate the travel motor (per
turn) becomes the maximum, resulting in slow
speed travel motor operation. (Refer to the Control
System group in the SYSTEM section for the control
circuit.)

2 7 8 9 7 1
To the hydraulic
oil tank

10
4

10

From the control valve

SM6603

1 - Travel Motor Displacement Angle Shift Valve 6 - Plunger

2 - Spring 7 - Spool
3 - Pilot Pressure (From the travel speed mode shift 8 - Chamber A
solenoid valve SB) 9 - Spool
4 - Swash Plate 10 - Ball
5 - Tilt Piston
T3-5-8 EX455
TRAVEL DEVICE

• Fast Speed Travel

(Minimum Displacement Angle)

When the travel mode switch is turned to the fast
speed position, the controller (PVC) shifts the travel
speed mode shift solenoid valve SB so that pilot
pressure (3) is supplied to chamber A (8) of travel
motor displacement angle shift valve (1), shifting
spool (7), thus routing pressure oil from the control
valve to tilt pistons (5).
Consequently, tilt pistons (5) push swash plate (4),
changing the displacement angle to the minimum.
As a result, the travel motor operates at fast speed.
(Refer to the Control System group in the SYSTEM
section for the control circuit.)

5 6

7 8 9 1
From the travel motor
displacement angle
shift valve.

10 4

5
3

10

From the control valve.

SM6604

1 - Travel Motor Displacement Angle Shift Valve 6 - Plunger

2 - Spring 7 - Spool
3 - Pilot Pressure (From the travel speed mode shift 8 - Chamber A
solenoid valve SB) 9 - Spool
4 - Swash Plate 10 - Ball
5 - Tilt Piston
EX455 T3-5-9
TRAVEL DEVICE

PARKING BRAKE

The parking brake is a negative-type brake released
when pressure oil from the control valve is applied to
parking brake chamber M. Whenever the travel con-
trol valve spools are in neutral, the parking brake is
automatically applied.
Friction plates (4) are connected to rotor (6), and
plates (3) to casing (5) via spline coupling respec-
tively. When spring (1) pushes piston (2) to the right,
friction plates (4) come into contact with plates (3),
applying the parking brake.

1 M 2 3 4 5

6
SM6599

1 - Spring 4 - Friction Plate

2 - Piston 5 - Casing
3 - Plate 6 - Rotor
T3-5-10 EX455
TRAVEL DEVICE

Brake ON
1
When the travel levers are in the neutral position,
friction plates (4) and plates (3) are pressed down by
spring (1) force, braking the motor. Pressure oil in
brake chamber M is released to the hydraulic oil tank.

6
SM6605

Brake OFF

When the travel levers are operated, pressure oil from

the control valve is led to brake chamber M and 1
pushes brake piston (2) against spring (1) force.
Consequently, friction plates (4) are separated from
plates (3), releasing the parking brake.

5
SM6606

1 - Spring 4 - Friction Plate

2 - Piston 5 - Casing
3 - Plate 6 - Rotor
EX455 T3-6-1
OTHER COMPONENTS (Upperstructure)

PILOT SHUT-OFF VALVE

The pilot control shut-off valve is a manually operated To Pilot Valve

switch valve. The valve spool is rotated when the pilot
control shut-off lever is operated, switching ON and
OFF the pilot pressure oil to the pilot valve.

From Pilot
Valve

To Hydraulic
Oil Tank

From Pilot
Valve

From Control
Pump

• Operation with Pilot Control Shut-Off Lever in

From Control
LOCK Position
Valve
SM6607
When the pilot control shut-off lever is in the LOCK
position, the pilot shut-off valve is set in neutral
(OFF), blocking the pilot pressure oil from the pilot
pump to the pilot valve. The pilot pressure oil in the From Pilot Valve
pilot valve side is routed to the hydraulic oil tank. As
a result, the pilot valves become inoperable with the
control levers.

• Operation with Pilot Control Shut-Off Lever in

UNLOCK Position From Pilot Pump To Hydraulic Oil Tank

SM6608
When the pilot control shut-off lever is moved to the
UNLOCK position, the pilot shut-off valve is turned
to the ON position, blocking the line to the hydraulic
oil tank and, at the same time, routing the pilot To Pilot Valve
pressure oil from the pilot pump to the pilot valves.
Thus, the pilot valves become operable with the
control levers.

From Pilot Pump

SM6609
T3-6-2 EX455

OTHER COMPONENTS (Upperstructure)

SHOCKLESS VALVES 5

The shockless valves regulate the pilot oil flow be-

tween the pilot valve and control valve spools.

Shockless Valve (for Boom and Arm Functions) 2

The shockless valve consists of orifices (2) and (6), 1
check valve (3), restriction release shift valve (4), heat
circuit check valve (1) (used in the heating circuit), and
shuttle valve (5).
3
• When the boom raise control lever is operated, the
pilot valve is actuated, sending pilot pressure oil to
port A1. At the same time, port A2 is connected to
the hydraulic oil tank line. 4
SM6610
At the start of pilot valve operation, pressure oil from
port A1 goes through orifice (2) only. The pressure 5
oil is regulated as it goes through orifice (2), acting 1
on the control valve spool from port B1 side. As the A1 A2 A3
pressure at port A1 rises, check valve (3) opens.
T1
• Return oil from port B2 also goes through orifice (6)
only before it returns to the hydraulic oil tank in the
beginning of the pilot valve operation. As the pres-
sure at port A1 rises, restriction releasing shift valve
(4) is actuated, regulating the return oil in propor- B1 B2 B3
tional to the pressure value.

2 3 4 6 SM6611

From Port A1 Side 4

B2
A2
Heat Circuit

Hydraulic oil relieved from the pilot relief valve enters

port T1. Then, it flows to the pilot valve from each port 2 3
A via heat circuit check valve (1). SM6612

Shuttle Valve A2 5 A4

The shuttle valve outputs pilot pressures from port A2

(boom lower) and port A3 (arm roll-out) to port P2
(Pressure switch: Others).
To T1

1 - Heat Circuit Check 4 - Restriction Releasing

Valve Shift Valve
2 - Orifice 5 - Shuttle Valve
3 - Check Valve 6 - Orifice
A1 1 A3
SM6613
EX455 T3-6-3
OTHER COMPONENTS (Upperstructure)

SOLENOID VALVE

The 3-spool solenoid valve unit, swing preference 3-Spool Solenoid Valve Unit
circuit shift solenoid valve, pump control proportional Swing Parking Travel Mode Main Relief
solenoid valve are provided on the machine. Brake Release Shift Solenoid Pressure Shift
Solenoid Valve Valve Solenoid Valve

• 3-Spool Solenoid Valve Unit

The solenoid valve unit consists of three solenoid
valves SA, SB, and SC and pilot relief valve.
Solenoid Valve SA: Pilot Relief Valve
Main Relief Pressure Shift Solenoid Valve.
The solenoid valve SA functions to raise the main
relief valve setting upon receiving a signal from the
controller (PVC).
Solenoid Valve SB:
Travel Mode Shift Solenoid Valve
The solenoid valve SB functions to shift the travel
motor displacement angle when the travel mode
switch is operated.
Solenoid Valve SC:
Swing Parking Brake Release Solenoid Valve
The solenoid valve SC functions to release the
swing parking brake when a swing or front attach-
ment function is operated upon receiving signals SM6614
from the cotroller (PVC). (Refer to the heading "Pilot
Circuit" in "Hydraulic System" Group, "SYSTEM"
Section.)

• Swing Preference Circuit Shift Solenoid Valve

The swing preference circuit shift solenoid valve Spring Spool Solenoid
regulates the control valve upon receiving signals
from the controller (PVC). (Refer to the "Hydraulic
System" Group in "SYSTEM" Section.)

• Pump Control Proportional Solenoid Valve

The pump control proportional solenoid valve regu-
lates the pump flow rate upon receiving signals from
the controller (PVC). (Refer to the heading "Regu-
lator" in "Pump Device" Group, "COMPONENT SM6615
OPERATION" Section.) P Output T2
Port Tank Port
Solenoid Valve Operation
• In Neutral:
The spool is pushed to the right by the spring. Pilot
pressure P is blocked.
• When Excited: Spool Spring
The spool is pushed to the left by the excited
solenoid valve. Pilot pressure P is routed to the
output port.

Pilot Relief Valve

The pilot relief valve functions to set the pilot pressure

delivered to port P to a certain level. Relief port T1 is
connected to the heat circuit in the shockless valve. P T1
SM6616
T3-6-4 EX455

OTHER COMPONENTS (Upperstructure)

ACCUMULATOR

The accumulator is provided in the pilot circuit to 6

buffer fluctuations in oil pressure, and to maintain the 1
pilot pressure for a short time period after the engine
is stopped.
The accumulator mainly consists of body (5), holder 5
Nitrogen Gas
(4), bladder (2), which encloses nitrogen gas (N2), (N2) 2
and poppet (1). 4
• Pressure oil from the pilot pump enters into the
accumulator via port A. Pilot pressure com-presses
the nitrogen gas in bladder (2) until they balance Pilot Pressure Oil
against each other. 3

• When pressure supply is stopped due to engine

stall or any other reasons, bladder (2) starts ex-
panding, supplying accumulated oil into the pilot
circuit via port A.

A
SM6617

1 - Poppet 4 - Holder
2 - Bladder 5 - Body
3 - Oil Port 6 - Gas Plug
EX455 T3-6-5
OTHER COMPONENTS (Upperstructure)

EC MOTOR

The EC motor is used to control engine speed. A motor rotation to calculate the governor lever position.
worm gear is incorporated into the EC motor to (Refer to the Control System Group in SYSTEM
prevent a loss of synchronism from occurring. The EC Section).
sensor is provided to detect the degrees of the EC

Output shaft Worm gear

Output gear

Sensor gear
Motor

EC sensor
Worm wheel

SM0097
T3-6-6 EX455

OTHER COMPONENTS (Upperstructure)

NOTES
EX455 T3-7-1
OTHER COMPONENTS (Undercarriage)

SWING BEARING

The swing bearing supports the upperstructure
weight and functions to rotate the upperstructure
smoothly.
This bearing is a single-row shear ball-type bearing,
consisting of outer race (1), inner race (7), balls (4),
supports (5), (6), seals (2)(8).
Outer race (1) is bolted to the upperstructure and
inner race (7) is bolted to the undercarriage. The
internal gear of inner race (7) engages with the output
shaft of the swing reduction gear.

3
2

7 4

6
1 2

SM6618

8 4
7

1 - Outer Race 5 - Support

2 - Seal 6 - Support
3 - Bolt 7 - Inner Race
4 - Ball 8 - Seal
T3-7-2 EX455
OTHER COMPONENTS (Undercarriage)

CENTER JOINT

The center joint is a 360° rotating joint. The center joint Hydraulic oil flows to the right and left travel motors via
functions to allow hydraulic oil to flow smoothly to and the spindle and the oil ports of the body. Seals prevent
from the travel motors without twisting hoses while the oil leaks between the spindle and body into adjacent
upperstructure is rotated. passages.
The spindle is attached to the main frame, and the
body is bolted to the swing center of the undercar-
riage.

Spindle

Body

Seal

SM6619
EX455 T3-7-3
OTHER COMPONENTS (Undercarriage)

1 2
4 3

13 5

1 2
4 3 6
14 5 10

7
13 11
15

12
16
8
9
9 8 6

7
10 6

11 7

10

11

SM6620

1 - Travel Forward (L) 9 - Pilot Line

2 - Travel Reverse (R) 10 - Travel Forward (L)
3 - Travel Forward (R) 11 - Travel Reverse (L)
4 - Travel Reverse (L) 12 - Body
5 - Pilot Port 13 - Drain Port
6 - Travel Forward (R) 14 - Spindle
7 - Travel Reverse (R) 15 - Seal
8 - Drain Line 16 - Ring
T3-7-4 EX455
OTHER COMPONENTS (Undercarriage)

TRACK ADJUSTER

The track adjuster located on the side frame is com-

posed of spring (5) and adjuster cylinder (8). Track
adjuster spring (5) absorbs loads applied to the front
idler. Adjuster cylinder (8) adjusts track sag.
• Grease is applied through grease fitting into cham-
ber A of adjuster cylinder (8) as illustrated below.
The pressure of the grease pushes piston rod (6)
out and decreases track sag.
• To increase track sag, loosen valve (7) 1 to 1.5 turns
counterclockwise to release grease from the track
adjuster cylinder through the grease discharge
hole.
CAUTION
Grease pressure in the adjuster cylinder is very
high. Do not loosen valve (7) quickly or loosen it
too much as valve (7) may fly off or high-pressure
grease may spout out, possibly causing personal
injury.
Loosen carefully, keeping body parts and face
away from valve (7). Never loosen grease fitting.
EX455 T3-7-5
OTHER COMPONENTS (Undercarriage)

13

12

11

10 4

6 a

1 - Front idler wheel

2 - Shaft
3 - Plug 7
4 - Nut
5 - Spring
6 - Piston
7 - Valve assembly
8 - Cylinder b
9 - Plate
10 - Spacer
11 - Yoke
12 - Spring pin
13 - Support c
a - Extension
b - Relief valve
SM6621
c - Grease fitting
T3-7-6 EX455
OTHER COMPONENTS (Undercarriage)

NOTES
COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.
Documentation Centre
Strada di Settimo, 323 - S. MAURO T.SE (TO) ITALY

Reproduction of text or illustrations,

in whole or in part, is strictly prohibited

Print No. 604.13.221 - VII - 2002

Printed by Satiz - Turin (Italy)

Coordinamento Editoriale Satiz - Torino
 EXCAVATOR
TECHNICAL MANUAL
TROUBLESHOOTING
(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. - ENGINEERING -

FORM No. 604.13.226 Edition - July 2002
EX455 IN-1

INTRODUCTION

TO THE READER

• This manual is written for an experienced technician - If you have any questions or comments, or if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact:

- Be sure to thoroughly read this manual for correct FIAT KOBELCO CONSTRUCTION
information concerning the service procedures. MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALY
PRODUCT SUPPORT
Fax. ++39 011 6877357

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition

to this service manual:

- Operation and Maintenance Instruction

Manual
- Parts Catalog

SERVICE MANUAL COMPOSITION

• The complete service manual consists of three
books:
- Technical Manual - Operational Principle
- Technical Manual - Troubleshooting
- Workshop Manual
- The Workshop Manual includes information needed
for maintenance and repair of the machine, tools and
devices needed for maintenance and repair, mainte-
nance standards, removal/installation and assem-
bly/disassembly procedures.

- The Technical Manual - Operational Principle in- • The Service Manual for EX455 Excavator consists
cludes the technical information concerning the of the following book/print numbers:
operation of main devices and systems.

- The Technical Manual -Troubleshooting includes

the technical information needed for operational
performance tests, and troubleshooting procedures.

BOOK PRINT NUMBER

- Technical Manual - Operational Principle 604.13.221
- Technical Manual - Troubleshooting 604.13.226
- Workshop Manual 604.13.231
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.

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
-1
Force N kgf 0.101 97 min 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
EX455 S-1

SAFETY PRECAUTIONS

RECOGNISE SAFETY INFORMATION

• This is your SAFETY ALERT SYMBOL.

- When you see this symbol on your machine or in

this Manual, be alert of the potential for personal
injury.
- Follow recommended precautions and safe
operating practices.

S0021

UNDERSTAND SIGNAL WORDS

• In this Manual you will find the following words:

- DANGER;
- WARNING;
- CAUTION.
referring to different hazard risks. DANGER
These words are always accompanied by the safety
alert symbol.
WARNING
DANGER: indicates an imminent hazardous
situation which, if not avoided, will result in death or
serious injury. CAUTION
WARNING: indicated a potential hazardous
situation which, if not avoided, could result in death or
serious injury. IMPORTANT
CAUTION: indicates a potential hazardous situation
which, if not avoided, may result in minor or moderate NOTE
injury.

IMPORTANT: indicates a situation which, if not

avoided, may cause damage to the machine.

NOTE: indicates an additional explanation for

information purposes.

ENVIRONMENTAL PROTECTION

• This Manual also contains this symbol

accompanying instructions for correct behaviour
as regards environmental protection.

S0024
S-2 EX455

SAFETY PRECAUTIONS

FOLLOW SAFETY PRECAUTIONS

• Carefully read and observe all safety signs on the

machine and read all safety precautions in this
Manual.
• Safety signs should be installed, maintained, and
replaced when necessary.
- If a safety sign or this Manual are damaged or
missing, obtain a replacement from your FIAT
KOBELCO Dealer in the same way you order a
spare part (be sure to detail machine model and
serial number upon ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorised personnel S0022
to operate the machine.
• Keep the machine in proper working conditions.
- Unauthorised changes to the machine may
impair function and/or safety and affect machine
life.
• Safety messages in this Chapter “SAFETY
PRECAUTIONS”, are intended to illustrate basic
safety procedures of the machine. However, it is
impossible for these safety messages to cover
every hazardous situation you may encounter. If
you have any doubts, consult your direct
supervisor prior to operating or servicing the
machine.

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or an accident occurs.

- Keep the first-aid kit and fire extinguisher on
hand.
- Thoroughly read and understand the label
attached to the fire extinguisher to use it properly.
- Establish emergency priority procedures to cope
with fires and accidents.
- Keep emergency numbers for doctors,
ambulance service, hospitals and fire
department posted near the telephone.

S0023
EX455 S-3

SAFETY PRECAUTIONS

WEAR PROTECTIVE CLOTHING

• Wear close-fitting clothing and safety equipment

appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask.
Be sure to correctly wear equipment and clothing
for the job.
- Do not take any chances. S0025

- Avoid wearing loose clothing, jewellery, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
- Wear a suitable hearing protection such as
earmuffs or earplugs to protect objectionable or
uncomfortably loud noise.

S0026

INSPECT THE MACHINE

• Inspect the machine carefully every day or work-

shift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.

- In the walk-around inspection, be sure to cover all

points detailed in the Chapter "MAINTENANCE",
paragraph "EXTERNAL VISUAL INSPECTION"
of the OPERATION AND MAINTENANCE
S0027
INSTRUCTION MANUAL.
S-4 EX455

SAFETY PRECAUTIONS

USE HAND HOLDS AND STEPS

• Falling is one of the major causes of personal injury.

- When you get on and off the machine, always

face the machine and maintain a three-point
contact with the steps and handrails.

- Do not use any control as a handhold.

- Never jump off the machine. Never get on and

off a moving machine.

S0028
- Be careful of slippery conditions of platforms,
steps, and handrails when leaving the machine.

ADJUST THE OPERATOR'S SEAT

• A seat poorly adjusted for operator or work

requirements may quickly fatigue the operator
leading to improper operations.

- The seat should be adjusted whenever machine

operator changes.

- The operator should be able to fully press the

pedals and correctly move the control levers with
his back resting against the seat back.

- If not, move the seat fore and aft, and check

again.

S0029
EX455 S-5

SAFETY PRECAUTIONS

FASTEN SEAT BELT

• Should the machine overturn, the operator may

become injured and/or thrown from the cab. Not
only, the operator may be crushed by the
overturning machine resulting in serious injury or
even death.

- Prior to operating the machine, thoroughly

examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
S0030

- Be sure to remain seated with the seat belt

securely fastened at all times when the machine
is in operation to minimise injury hazard in case
of accident.

- After a significant accident, replace the seat belts

even though they do not look damaged.

MOVE AND OPERATE MACHINE

SAFELY

• Bystanders can be run over.

- Pay the utmost attention not to run over

bystanders.

- Be sure and aware of the location of bystanders

before moving, swinging or operating the
machine.

- If fitted, keep the travel alarm and horn sounding

to warn people that the machine is about to move.
S0031

- When operating, swinging, or moving the

machine in a congested area use a signal man.

- Co-ordinate hand signals before starting the

machine.
S-6 EX455

SAFETY PRECAUTIONS

OPERATE ONLY FROM THE DRIVER'S

SEAT

• Inappropriate engine starting procedures may

cause the machine unexpected movement,
possibly resulting in serious injury and even death.
- Start the engine only from the operator’s seat.

- NEVER start the engine while standing on the

track or on the ground.

- Do not start the engine by shorting across starter

motor terminals.
S0032
- Before starting the engine, ensure that all control
levers are in the neutral position.

KEEP RIDERS OFF THE MACHINE

• Riders on the machine are subject to injuries such

as being struck by foreign objects and being thrown
off the machine.

- Only machine operator is allowed on the

machine. Keep riders off.

- Riders also obstruct the operator’s visibility,

resulting in the machine being operated
unsafely.
S0033

CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN

• Incorrect travel controls operation may result in

serious injury and even death.

- Before driving the machine, be aware of the

undercarriage position relative to the operator’s
position. If travel motors are located at the front
of the cab, the machine will move reverse when
travel controls are moved towards cab front.
S0037
EX455 S-7

SAFETY PRECAUTIONS

AVOID INJURY FROM BACK-OVER AND

SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.

• To avoid back-over and swing accidents:

- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.

- Keep the travel alarm in working condition (if

equipped).

- ALWAYS BE ALERT FOR BYSTANDERS

S0042
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.

- USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.

- Use hand signals, which conform to your local

regulations, when work conditions require a
signal person.

- No machine motions shall be made unless S0043

signals are clearly understood by both signalman
and operator.

- Learn the meanings of all flags, signs, and

markings used on the job and confirm with the
person in charge of signalling.

- Keep windows, mirrors, and lights clean and in

good condition.

- Dust, heavy rain, fog, etc., can reduce visibility.

As visibility decreases, reduce speed and use
proper lighting.

- Read and understand all operating instructions in

the OPERATION AND MAINTENANCE
INSTRUCTION MANUAL.
S-8 EX455

SAFETY PRECAUTIONS

DRIVE MACHINE SAFELY

• Before starting the machine carefully read the

OPERATION AND MAINTENANCE INSTRUC-
TION MANUAL. (Refer to the OPERATING IN-
STRUCTIONS chapter).

• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.

- Pushing down on the front of the travel pedals or

S0038
pushing the levers forward moves the machine
towards the idlers. (Refer to the OPERATION
AND MAINTENANCE INSTRUCTION
MANUAL).

• Traveling on a grade may cause the machine to slip

or to overturn, possibly resulting in serious injury or
death.

- When traveling up or down a grade, keep the

bucket in the direction of travel, approximately 20
to 30 cm (A) above the ground.

- If machine starts to skid or becomes unstable,

lower the bucket immediately. S0039

- Traveling across the face of a slope may cause

the machine to skid or to overturn. When
travelling (ascending/descending) on a slope, be
sure to point the tracks uphill/downhill.

- Turning on an incline may cause the machine to

tip over.
If turning on an incline is absolutely unavoidable,
do so at a place where the slope is gentle and the
surface is firm.

- When operating on a grade and the fuel reserve

S0004
indicator light lights, immediately refuel.

WRONG
S0005
EX455 S-9

SAFETY PRECAUTIONS

AVOID OVERTURNING

• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death.

• To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the bucket low to the ground and close to
the machine.
- Reduce machine operating speed to avoid
tipping or slipping.
- Avoid changing direction when travelling on
grades. S0002
- NEVER attempt to travel across a grade steeper
than 15 degrees.
- Reduce swing speed as necessary when
swinging loads.

• Be careful when working on frozen ground.

- Temperature increases will cause the ground to
become soft and make ground travel unstable.

S0047

PARK MACHINE SAFELY

• To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Turn auto-idle (A/I) switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Pull the safety lever (pilot-control shut-off lever) to
the LOCK position.
- Close windows, roof window, and cab door.
- Lock all access doors and compartments. S0049
S-10 EX455

SAFETY PRECAUTIONS

AVOID INJURY FROM UNEXPECTED

MACHINE MOVEMENT

• Death or serious injury may result if you attempt to

get on or off a moving machine.

• To avoid roll-aways:
- Select level ground when possible to park
machine.
- Do not park the machine on a grade.
- Lower the bucket and/or other work tools to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
- Turn the auto-idle switch off.
- Run the engine at slow idle speed without load for
S0040
5 minutes to cool down the engine.
- Stop the engine and remove the key from the key
switch.
- Pull the pilot shut-off lever to LOCK position.
- Block both tracks.
- Position the machine to prevent overturning.
- Park a reasonable distance from other machines.

S0041

PROVIDE SIGNALS FOR JOBS

INVOLVING A NUMBER OF MACHINES

• For jobs involving several machines, provide

signals commonly known by all personnel involved.
Also, appoint a signal person to co-ordinate the job
site. Make sure that all personnel obey the signal
person’s directions.

S0036
EX455 S-11

SAFETY PRECAUTIONS

INVESTIGATE JOB SITE BEFORE HAND

• When working at the edge of an excavation or on

a road shoulder, the machine could overturn,
possibly resulting in serious injury or death.
- Investigate the configuration and ground
conditions of the job site beforehand to prevent
the machine from overturning and prevent the
ground, stockpiles, or banks from collapsing.
- Make a work plan. Use machines appropriate to
the work and job site.
- Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
- When working on an incline or road shoulder,
employ a signal person as required.
Confirm that your machine is equipped with a S0034

F.O.P.S. (Falling Object Protective Structure)

cab before working in areas where there is the
possibility of falling stones or landslides.
- When footing is weak, reinforce the ground
before starting the work.
- When working on frozen ground, be extremely
alert. As ambient temperature rises, footing
becomes loose and slipped.

PROTECT AGAINST FALLING STONES

AND LANDSLIDES

• Confirm that your machine is equipped with a

F.O.P.S. (Falling Object Protective Structure) cab
before working in areas where there is the
possibility of falling stones.

S0035
S-12 EX455

SAFETY PRECAUTIONS

DIG WITH CAUTION

• Accidental severing of underground cables or gas

lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
- Before digging, check the location of cables, gas
lines, and water lines.
- Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic
cable should be accidentally severed, do not look
into the end. Doing so may result in serious eye
injury.
- Contact local authorities and/or the utility
companies directly (electric power, gas,
telephone, water, sewers, telecommunications,
etc.) to obtain information about underground S0009

utility lines.

OPERATE WITH CAUTION

• If the front attachment or any other part of the

machine hits against an overhead obstacle, such
as a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury may
results as well.

- Take care to avoid hitting overhead obstacles

with the boom or arm.

S0008

AVOID ELECTRIC LINES

• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines. L
- When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m plus twice the line insulator length (L).
- Check and comply with any local regulations that
may apply.
- Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
- Keep all bystanders or co-workers away from the
site.

S0205
EX455 S-13

SAFETY PRECAUTIONS

KEEP PERSONNEL CLEAR FROM

WORKING AREA

• A person may be hit severely by the swinging front

attachment or counterweight and/or may be
crushed against an other object, resulting in serious
injury or death.

- Keep all persons clear from the area of operation

and machine movement.
- Before operating the machine, set up barriers to
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.

S0044

NEVER MOVE THE BUCKET OVER ANY

ONE

• Never lift, move, or swing bucket above anyone or

a truck cab.
Serious injury or machine damage may result due
to bucket load spill or due to collision with the
bucket.

S0045

AVOID UNDERCUTTING

• In order to retreat from the edge of an excavation if

the footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.

- If the footing starts to collapse and if sufficient

retreat is not possible, do not panic. Often, the
machine can be secured by lowering the front
attachment, in such cases.

S0011
S-14 EX455

SAFETY PRECAUTIONS

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could

occur causing serious injury or death.

S0048

SAFETY LOADS MOVING

• The excavator is no lifting and transportation

means, therefore it should not be used to position
loads accurately. Should it be exceptionally used to
lift and lay building components, special caution
must be taken as follows:

- The machine must be equipped without failure

with the appropriate variant supplied, upon
request, by FIAT KOBELCO. Also, totally comply
with the safety precautions for the operation of the
excavator as a lifting equipment.

- Secure the loads to be raised using cables or

chains fastened with appropriate hooking
mechanisms.

- Never hook cables or chains to the bucket teeth.

- Nobody should be allowed to remain under the

raised load or within the excavator operating
range for any reason whatever.
S0165

- Never exceed specified loading capacity.

Incorrect fastening of slings or chains may cause
boom/arm failure or failure of the lifting means
with consequent bodily injuries and even death.

- Always ensure that slings and chains used for

lifting are adequate to the load and in good
condition.

- All loading capacities are referred to the

machine on a level surface and should be
disregarded when working on a slope.
EX455 S-15

SAFETY PRECAUTIONS

SAFETY TRANSPORTING

• The danger of tipping is present when loading/

unloading the machine onto/from a truck or trailer
bed.
- Be sure to observe local regulations when
transporting the machine on public roads.
- Provide an appropriate truck or trailer for
transporting the machine.

• Take the following precautions when loading/

unloading the machine:
1. Select firm level ground.
2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when loading/ S0052

unloading the machine.

4. Always turn the auto-idle (A/I) switch OFF when
loading or unloading the machine, to avoid
unexpected speed increase due to unintentional
operation of a control lever.
5. Always select the slow speed mode with the
travel speed selector. In the high speed mode,
travel speed may automatically increase.
6. Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify travelling direction, and begin to
drive again.
7. Do not operate any levers besides the travel
levers when driving up or down the ramp.
8. The top end of the ramp where it meets the
flatbed is a sudden jolt. Take care when traveling
over it.
9. Prevent possible injury from machine tipping
while the upperstructure is rotating.
10. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11. Securely fasten machine frame using chains or
cables. Refer to “TRANSPORT” chapter in the
OPERATION AND MAINTENANCE
INSTRUCTION MANUAL for details.
S-16 EX455

SAFETY PRECAUTIONS

SAFE MAINTENANCE
• To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Kepp the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it is
in motion.
- Kepp hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Switch off the Auto-Idle (A/I).
4. Let the engine idle with no load for at least five
minutes until it has cooled down.
5. Move the key-start switch to the OFF position
to stop the engine.
6. Relieve pressure from the hydraulic system by
S0053
cycling control levers several times.
7. Remove the ignition key from the start switch.
8. Apply the "Maintenance in progress" tag .
This tag can be applied o the left-hand control
lever, safety lever or cab door.
9. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
10. Let the engine cool down.
- Do not leave the machine unattended if servicing
requires the engine running .
- If the machine is to be raised, place boom and arm
at an angle 90 to 110°. Lock machine components
which should be raised for maintenance or repair
using suitable supporting means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary. S0054
Refer to the the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL.
- Keep all components in good condition and
properly install. Immediately repair any fault.
- Immediately repair any damage.Replace worn or
failed components. Remove grease, oil, debris
build-ups.
- Disconnect the negative cable (−) from the battery
before carry out any work on the electrical system
or arc-welding on the machine.
EX455 S-17

SAFETY PRECAUTIONS

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause

serious injury.

- Before performing any work on the machine,

attach a maintenance in progress tag. This tag
can be applied o the left-hand control lever,
safety lever or cab door.

S0055

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without

securing the machine first.

- Always lower the attachment or tool to the ground

before working on the machine.
- If you must work on a lifted machine or
attachment, securely support the machine or
attachment.
- Do not support the machine on cinder blocks,
bollow tires, or props that may crumble under
continuous load.
- Do not work under a machine that is supported S0054
solely by a jack.

STAY CLEAR OF MOVING PARTS

• Entanglements in moving parts can cause serious

injury.

• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working near
rotating parts.

S0056
S-18 EX455

SAFETY PRECAUTIONS

DISPOSE OF WASTE IN THE

APPROPRIATE MANNER

• Waste improperly disposed of represents a danger

for the envinronment. Potentially dangerous waste
used on the FIAT KOBELCO excavators includes
lubricants, fuel, coolant, brake fluid, filters and
batteries.

- Used sealed containers when discharging fluids.

Do not use containers for food or beverages
which may induce drinking.

- Do not spill waste over the ground, into drains, or

water beds.
S0064

- Obtain information about the correct methods to

recycle or dispose of waste from local
Authorities, collection centres or your Dealer.

WORK IN A CLEAN AREA

• Before starting an operation, clean the working

area.
Clear the area from all the objects that can be
dangerous for mechanics or people in the working
area.

S0166

PROPERLY LIGHT THE WORKING AREA

• Properly and safely light the working area.

- Use safe portable lamps in order to work inside

and under the machine.

- Make sure that the lamp is shielded by a cage;

the incandescent filament of a lamp, accidentally
broken, can cause fuel or oil fire. F1480

S0167
EX455 S-19

SAFETY PRECAUTIONS

REGULARLY WASH THE MACHINE

• Remove all the traces of grease, oil and deposits,

in order to avoid people accidents or damages to
things.

- Do not spray water or steam in the cab.

F1462 S0153

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

breakers and blades can fall and cause serious
injury or death.

- Securely store attachments and implements to

prevent falling.

- Keep bystanders away from storage areas.

F1463 S0058

PREVENT ACID SCALDS

• The sulphuric acid, contained in the battery, is
poisonous.
It is strong enough to scald the skin, corrode
clothes and cause blindness, if it is sprayed into
the eyes.
To avoid dangers:
- Fill the batteries in airy areas.
- Wear eye protections and rubber gloves.
- Avoid breathing the electrolyte vapours when
topping up.
- Avoid spilling or dripping the electrolyte.
- Use proper emergency starting techniques.
If you are touched with acid sprays:
- Rinse your skin well with water.
- Put on your skin sodium bicarbonate or clay to F1474 S0168

help the acid neutralization.

- Rinse your eyes with water for 10-15 minutes.
- Immediately see a doctor.
If you have swallowed the acid:
- Drink a big quantity of water or milk, swallow
milk of magnesia, scrabbled eggs or vegetal oil.
- Immediately see a doctor.
S-20 EX455

SAFETY PRECAUTIONS

STARTING THE ENGINE WITH

BOOSTER BATTERIES

• Battery gas may explode causing serious damages

and injuries.

- If the engine is to be started using booster

batteries, ensure to comply with all procedures
detailed in the chapter “OPERATING
INSTRUCTIONS” of the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL.

- The operator should be sitting in the driver’s seat

to keep the machine under control when the
engine starts. Starting the engine with booster
S0001
batteries is a two man operation.

- Do not use batteries that have been stored in the

cold for a long time.

- Mistakes in following procedures detailed for

starting the engine with slave batteries may
cause the batteries to explode or machine to
move unexpectedly.

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

- Keep sparks, lighted matches, and flames away

from the top of battery.

- Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.

- Do not charge a frozen battery; it may explode.

Warm battery to 16 °C.

• Battery electrolyte is poisonous. If the battery

should explode, battery electrolyte may be S0001

splashed into eyes, possibly resulting in blindness.

- Be sure to wear eye protection when checking

electrolyte specific gravity.
EX455 S-21

SAFETY PRECAUTIONS

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.

- To prevent possible injury from hot spraying

water. DO NOT remove the radiator cap until the
engine is cool. When opening, turn the cap slowly
to the stop. Allow all pressure to be released
before removing the cap.
- The hydraulic oil tank is pressurized. Again, be S0019

sure to release all pressure before removing the

cap.

Hot fluids and surfaces:

• Engine oil, reduction gear oil and hydraulic oil also

become hot during operation.
The engine, hoses, lines and other parts become
hot as well.

- Wait for the oil and components to cool down

before starting any maintenance or inspection
work.

S0059

KEEP CLEAN THE MACHINE

Keep clean the engine compartment, radiator,

batteries, hydraulic pipes, fuel tank and operator's
position.
The engine compartment temperature can quickly
rise, after stopping the engine.
IN THESE CASES, BE CAREFUL TO POSSIBLE
FIRES.
Open the access doors in order to quicken the engine
cooling process and clean the compartment.

S0177
S-22 EX455

SAFETY PRECAUTIONS

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.

- Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
SA0016

- Relieve the pressure by moving the control levers

several times.

- Tighten all connections before applying pressure.

- Search for leaks with a piece of cardboard; take

care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles for
SA0017
eye protection.

- In an accident occurs, see a doctor familiar with

this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.

SA0018

PREVENT PARTS FROM FLYING OFF

• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result
in serious injury, blindness, or death.

- NEVER attempt to remove GREASE FITTING

or VALVE ASSEMBLY.
- As pieces may fly off, be sure to keep body and
face away from valve.

• Travel reduction gears are under pressure. F3635

S0178
- As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. REDUCTION GEAR OIL is hot. Wait for
gear oil to cool down, then gradually loosen the air
release plug to release pressure.
EX455 S-23

SAFETY PRECAUTIONS

PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body,

serious injury may result.

- Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.

S0046

HANDLE FLUIDS SAFELY - AVOID FIRES

• Handle fuel with care: it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.

- Do not refuel the machine while smoking or when

near open flame or sparks.
- Always stop the engine before refuelling the
machine.
- Fill the tank outdoors.

S0050
• All fuels, most lubrificants, and some antifreeze
fluids are flammable.

- Store flammable fluids well away from fire

hazards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn
spontaneously.

S0051
S-24 EX455

SAFETY PRECAUTIONS

PREVENT FIRES

• Check for Oil Leaks:

- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other,
damage to the oil-cooler, and loose oil-cooler
flange bolts which may cause oil leaks.
- Tighten, repair or replace any missing, loose or S0051
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.

• Check for Shorts circuits which could cause fires:

- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..

• Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.

• Check Key-start Switch:

- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF position
to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.

• Check Heat Shields:

- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
EX455 S-25

SAFETY PRECAUTIONS

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the

following way:

- Stop the engine by turning the key-start switch to

the OFF position if there is time.

- Use a fire extinguisher if there is time.

- Exit the machine.

S0060

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.

- If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.

S0061

USE APPROPRIATE TOOLS

• Use tools appropriate for the job to be performed.

- Inappropriate tools, parts and procedures might

generate dangerous conditions.

- Use tools of correct size to tighten or loosening

securing elements, in order to avoid injuries
caused by a wrench getting out of control.

- Do not use U.S. Standard or British Standard

tools on metric fasteners and vice versa.

• Use only FIAT KOBELCO genuine spare parts

(please refer to the PARTS CATALOG). S0120
S-26 EX455

SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.

Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable ma-
terials.

Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area. Install tem-
porary fire resistant guards to protect hoses or other
materials when welding, soldering, etc.

S0062

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

- Do not weld or flame cut pipes or tubes that contain

flammable fluids.

- Clean them thoroughly with non-flammable solvent

before welding or flame cutting them.

REMOVE PAINT BEFORE WELDING OR

HEATING

• Hazardous fumes can be generated when paints is

heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.

- Avoid breathing potentially toxic fumes and dust.

- Do all such work outside or in a well-ventilated

area.

- Dispose of paint and solvents properly.

- Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the S0063
dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
TECHNICAL MANUAL EX455

TROUBLESHOOTING

SECTION AND GROUP CONTENTS

Section 4 - OPERATIONAL PERFORMANCE TEST

Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test

Section 5 - TROUBLESHOOTING

Group 1 Diagnosing Procedure

Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Electrical System Inspection
Group 7 Harness Check
SECTION 4 EX455

OPERATIONAL PERFORMANCE TEST

CONTENTS

Group 1 - Introduction Swing Speed ........................................ T4-4-5

Operational Performance Tests ............. T4-1-1
Preparation for Performance Tests ........ T4-1-2
Group 2 - Standard
Operational Performance
standard tables .................................... T4-2-1
Main pump P-Q curve .......................... T4-2-5
Swing Function Drift Check .................. T4-4-6
Swing Motor Leakage ........................... T4-4-7
Swing Bearing Play .............................. T4-4-8
Maximum Swingable Slant
Angle ................................................... T4-4-9
Hydraulic Cylinder Cycle Time ............. T4-4-10
Dig Function Drift Check ...................... T4-4-12
Control Lever Operating Force ............. T4-4-13
Control Lever Stroke ............................ T4-4-14
Combined Boom Raise/Swing
Function Check .................................... T4-4-15

Group 3 - Engine Test Group 5 - Component Test

Engine Speed ...................................... T4-3-1 Primary Pilot Pressure ......................... T4-5-1

Engine Check and Adjustment ............. T4-3-3
Group 4 - Excavator Test
Travel Speed ........................................ T4-4-1
Track Revolution Speed ....................... T4-4-2
Mistrack Check .................................... T4-4-3
Travel Parking Brake Function
Check .................................................. T4-4-4
Secondary Pilot Pressure .................... T4-5-3
Main Relief Pressure Shift Control
Pressure .............................................. T4-5-4
Travel Mode Shift Control Pressure ...... T4-5-5
Swing Parking Brake Release Pressure T4-5-6
Main Relief Pressure ............................ T4-5-7
Overload Relief Valve Set
Pressure .............................................. T4-5-11
Main Pump Flow Test ........................... T4-5-14
Swing Motor Drainage .......................... T4-5-18
Travel Motor Drainage .......................... T4-5-20
EX455 T4-1-1
INTRODUCTION

OPERATIONAL PERFORMANCE TESTS

Use operational performance test procedures to quan-

titatively check all system and functions on the ma-
chine.

Purpose of Performance Tests

1. To comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machine’s performance to the desired
standard.
3. To economically operate the machine under opti-
mal conditions.

Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the
operational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.

Performance Standards
“Performance Standard” is shown in tables to evaluate
the performance test data.

Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.

The machine performance does not always deteriorate

as the working hours increase. However, the machine
performance is normally considered to reduce in pro-
portion to the increase of the operation hours. Accord-
ingly, restoring the machine performance by repair,
adjustment, or replacement shall consider the number
of the machine’s working hours.

Definition of “Performance Standard”

1. Operation speed values and dimensions of the new
machine.
2. Operational performance of new components ad-
justed to specifications. Allowable errors will be
indicated as necessary.
T4-1-2 EX455
INTRODUCTION

PREPARATION FOR PERFORMANCE

TESTS

Observe the following rules in order to carry out

performance tests accurately and safely.

THE MACHINE
1. Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on,
before starting to test.

TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make
a full swing with the front attachment extended.
3. If required, rope off the test area and provide
SM0131
signboards to keep unauthorized personnel
away.

PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among
coworkers. Once the test is started, be sure to
communicate with each other using these signals,
and to follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.

MAKE PRECISE MEASUREMENT

SM3026
1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
EX455 T4-2-1
STANDARD

OPERATIONAL PERFORMANCE
STANDARD TABLES

The standard performance values related to excavator tests unless otherwise mentioned in each perform-
test are listed in the table 1 shown below. In table 2 are ance test procedure:
listed the standard performance related to component Engine Control Dial : Fast Idle
test. E Mode Switch : OFF
Refer to the Group T4-3 to T4-5 for performance test SP Mode Switch : ON
procedures. Work Mode Switch : General Purpose Mode
Values indicated in parentheses are reference values. Hydraulic Oil Temperature : 50 ± 5 °C (122 ± 9 °F)
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as NOTE - 1 kgf = 9.807 N, 1 kgf/cm2 = 98.07 kPa
indicated below as the preconditions of performance

Table 1 - Excavator performance

EX455
Ref.
Performance test designation (Performance Remarks
pag.
standard)

ENGINE SPEED (rpm)

Fast idle :
2000 ±50 Dr. EX Value
T4-3-1

(SP MODE SWITCH ON)

Slow idle 900 ±100 Dr. EX Value

Auto-idle (A/I) 1230 ±100 Dr. EX Value

ENGINE COMPRESSION PRESSURE

(at 200 rpm) MPa (kgf/cm2) 2.94 (30) After engine warm up

Valve clearance
(IN, EX) (mm) 0.4 With cold engine
T4-3-3

NOZZLE INJECTION PRESSURE 17.7÷22.1

MPa (kgf/cm2) (180-225) Second step injection

INJECTION TIMING
(Before TDC) (deg.) 10°
T4-2-2 EX455
STANDARD

EX455
Ref.
Performance test designation (Performance Remarks
pag.
standard)

TRAVEL SPEED (s/20 m)

T4-4-1

Fast speed 13.0 ± 2.0

Slow speed 20.0 ± 2.0

TRACK REVOLUTION
T4-4-2

SPEED (s/3 rev)

Fast speed mode 23.0 ± 2.0
T4-4-3

MISTRACK (mm/20 m)
(Both fast and slow travel speed modes) 200 or less

TRAVEL PARKING BRAKE FUNCTION

CHECK
T4-4-4

Track displacement until the parking

brake is applied (rev) 1/6 or less

Travel parking brake slip (mm/5 min) 0

T4-4-9 T4-4-8 T4-4-7 T4-4-6 T4-4-5

SWING SPEED (s/3 rev) 20.0 ± 3.5

SWING FUNCTION DRIFT

CHECK (mm/90°) 835 or less

SWING MOTOR
LEAKAGE (mm/5 min) 0

SWING BEARING PLAY (mm) 1.5 or less Allowable limit: 5 mm

MAXIMUM SWINGABLE SLANT 21 or possibly 3400 mm Arm and 1.8 m3 bucket

ANGLE (deg.) more (SAE heaped)

HYDRAULIC CYLINDER (s) 3400 mm Arm and 1.8 m3 bucket

CYCLE TIME (SAE heaped)

Boom Raise 3.4 ± 0.3

T4-4-10/11

Lower 2.5 ± 0.3

Arm Roll-in 4.4 ± 0.3
Roll-out 3.2 ± 0.3
Bucket Roll-in 4.5 ± 0.3
Roll-out 2.8 ± 0.3
EX455 T4-2-3
STANDARD

EX455
Ref.
Performance test designation (Performance Remarks
pag.
standard)

DIG FUNCTION DRIFT 3400 mm Arm and 1.8 m3 bucket

CHECK (mm/5 min) (SAE heaped)
With the front attachment in the maximum (without hose rupture protection
reach position valves)
T4-4-12

Boom cylinder 10 or less

Arm cylinder 20 or less

Bucket cylinder 20 or less

Bucket bottom 100 or less

CONTROL LEVER OPERATING

FORCE (kgf)

Boom lever 2.0 or less

T4-4-13

Arm lever 2.0 or less

Bucket lever 1.7 or less

Swing lever 1.7 or less

Travel lever 2.5 or less

CONTROL LEVER STROKE (mm)

Boom lever 105 ± 10

Arm lever 105 ± 10

T4-4-14

Bucket lever 83 ± 10

Swing lever 83 ± 10

Travel lever 100 ± 10

BOOM RAISE/SWING COMBINED

OPERATION CHECK
(Bucket empty) (s) 4.2 ± 0.3 3400 mm Arm and 1.8 m3 bucket
T4-4-15

Time to swing 90°

Bucket teeth height:

(mm) 7000 or more
when swinging 90°

NOTE - 1 kgf = 9.807 N.

T4-2-4 EX455
STANDARD

Table 2 - Component performance standard

Ref. EX455
Performance test designation (Performance Remarks
pag.
standard)

PRIMARY PILOT PRESSURE

T4-5-3 T4-5-1

Engine: Fast idle (kgf/cm2) 40+10

-0
(SP Mode: ON)

SECONDARY PILOT
PRESSURE (kgf/cm2) more than 37

MAIN RELIEF PRESSURE SHIFT

CONTROL PRESSURE
(SA Pressure)
T4-5-4

(Travel/precision mode and with power

boost switch ON) (kgf/cm2) more than 35

(Operations other than the above) 0

TRAVEL MODE SHIFT CONTROL

PRESSURE (SB Pressure)
T4-5-5

(Fast Speed Mode) (kgf/cm2) more than 35

(Slow Speed Mode) 0

SWING PARKING BRAKE RELEASE

T4-5-6

PRESSURE (SC Pressure)

(When a front or swing function
control lever is operated) (kgf/cm2) more than 35

MAIN RELIEF PRESSURE

T4-5-7

(Power Boost OFF)

(Boom, Arm, Bucket)
(kgf/cm2) 300+15
-5

OVERLOAD RELIEF PRESSURE

(Power Boost ON)
(Boom Raise, Arm Roll-In/Out)
(kgf/cm2) 325+15
-10
T4-5-8 to 12

(Boom Lower, Bucket Roll-In/Out) 315+15

-10

TRAVEL/SWING RELIEF
PRESSURE
(Swing Relief Pressure)
(kgf/cm2) 275+10
-0

(Travel Relief Pressure)

355+20
-5

SWING MOTOR DRAINAGE

(With constant maximum speed) (L/min) 2,0 or less
T4-5-18

SWING MOTOR DRAINAGE

(Having the upperstructure
immovable) (L/min) 25 or less
T4-5-20

TRAVEL MOTOR
DRAINAGE
(With track jacked up) (L/min) 5 or less
EX455 T4-2-5
STANDARD

MAIN PUMP P-Q CURVE P-Q Points

(Reference: Measured at Test Stand)
Pressure Flow Rate L/min
kgf/cm2 1 Digging 2 Travel
• Engine rated speed: 1800 min- 1 (rpm)
• Pump rated speed: 1800 min- 1 (rpm) 0 (367) (367)
• Hydraulic oil temperature: 50 ± 5 °C (122 ± 9 °F) 100 360±12 360±12
150 (353) (353)
1 Digging
DP sensor, N sensor: Disconnect 220 238±24 238±24
Other main pump - P sensor: Disconnect 290 (98) (170)
300 (98) (162)
2 Travel
350 – (130)
DP sensor: Disconnect
Other main pump - P sensor, N sensor: Disconnect Reference
Travel pressure switch: ON

NOTE - 1 kgf/cm2 = 0.09807 MPa.

Q 400

367
1 2

300

Flow rate
(L/min)

200

2
1

100
~
~
0 100 200 300 350
Delivery pressure 290
(Kgf/cm2) P

SM6677
T4-2-6 EX455
STANDARD

NOTES
EX455 T4-3-1
ENGINE TEST

ENGINE SPEED 2

Summary: 1
1. Use Dr.EX. If Dr.EX is not available, use an engine
tachometer.
2. Measure the engine speeds in each mode.

NOTE - Measure the engine speed to check that the

engine speed meets specification before performing
other operational performance tests. If the engine
speed is not correctly adjusted, all other performance
test data will be unreliable.

SM6651

Preparation:
1. Connect Dr.EX and select monitor function. When
using an engine tachometer, connect speed pick-
up (1) to injection pipe (2) as illustrated.

2. Warm up the engine until the engine coolant tem- 3

perature reaches 50 °C (122 °F) or more, and
hydraulic oil temperature reaches 50±5 °C
(122±9 °F).

NOTE - Prior to the measurement, confirm that gov-

ernor lever (4) comes into contact with stopper bolts
(3) and (5) at the slow idle and at the fast idle,
respectively.
Be sure to turn on SP mode switch before check 5
governor lever movement.
4
SM5739

SP Mode Switch E Mode Switch

SM6653
Engine Control Dial
T4-3-2 EX455
ENGINE TEST

Measurement:
1. No Load Engine Speeds
1-1. Measure the slow and fast (standard) idle
speed.
1-2. Start the engine. Select the switch positions
as specified.
1-3. Set the engine control dial to the slow idle and
SP Mode Switch E Mode
to the fast idle positions to measure engine
Switch
idle speeds.

Engine E Mode SP Mode Auto- Work

Control Switch Switch Idle Mode
Dial Switch Switch
Slow Idle OFF ON OFF General
Purpose
Mode
Engine Control Dial SM6653
Fast Idle OFF ON OFF General
Purpose
Mode

2. No Load Auto-idle Engine speed

2-1. Start the engine. Select the switch position as
specified.

Engine E Mode SP Mode Auto- Work

Control Switch Switch Idle Mode
Dial Switch Switch
Fast Idle OFF ON ON General
Purpose
Mode

2-2. Operate the bucket control lever.

2-3. Return the bucket control lever to neutral.

Measure the engine speed after it automati-
cally drops approximately 4 seconds later.

Evaluation
Refer to the performance standard table in group
T4-2.

Auto-Idle
Switch Work Mode
Switch

SM6680
EX455 T4-3-3
ENGINE TEST

ENGINE CHECK AND ADJUSTMENT

To perform the compression pressure measurement,

the check and adjustment of valve clearance, the
check of injection nozzle and check and adjustment of
injection timing, make reference to the Workshop
Manual - Section 5.
T4-3-4 EX455
ENGINE TEST

NOTES
EX455 T4-4-1
EXCAVATOR TEST

TRAVEL SPEED

Summary:
Measure the time required for the excavator to travel
a 20 m (65.6 ft) test track to evaluate the travel system
(from the main pump to the travel motors).

Preparation:
1. Adjust the track sag on both side tracks equally. Arm Rolled-In, Bucket Rolled-In
End
2. Prepare a flat and solid test track 20 m (65.6 ft) in Bucket Height: 0.3 to 0.5 m
length with extra length of 3 to 5 m (9.8 to 16 ft) on
both ends for machine acceleration and decelera- Start
20 m
tion. Deceleration
Zone
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the 3 to 5 m
ground with the arm and bucket rolled in. Acceleration
4. Maintain hydraulic oil temperature at 50 ± 5°C Zone
3 to 5 m
(122 ± 9°F).
SM0138

Measurement:
1. Measure both the slow and fast speeds of the
machine.
2. Select the following switch positions:

Travel Engine E Mode SP Mode Work Auto-

Mode Control Switch Switch Mode Idle
Switch Dial Switch Switch
Slow Fast OFF ON General OFF
Mode Idle Purpose
Mode
Fast Fast OFF ON General OFF
Mode Idle Purpose
Mode

3. Start traveling the machine in the acceleration

zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6 ft).
5. After measuring the forward travel speed, turn the
upperstructure 180° and measure the reverse
travel speed.
6. Repeat steps 4. to 5. three times in each direction
and calculate the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-2 EX455
EXCAVATOR TEST

TRACK REVOLUTION SPEED

Summary:
Measure the track revolution cycle time with the track
raised off ground.

Preparation:
1. Adjust the track sag of both side tracks to be equal.
2. On the track to be measured, mark one shoe with
chalk. 90 to 110°
3. Swing the upperstructure 90° and lower the bucket
to raise the track off ground. Keep the boom-arm
angle between 90 to 110° as shown. Place blocks
under the machine frame.
Mark

SM0139
CAUTION
Securely support the raised track using wooden
blocks.

4. Maintain the hydraulic oil temperature at 50 ± 5°C

(122 ± 9°F).

Measurement:
1. Select the following switch positions:

Travel Engine E Mode SP Mode Work Auto-

Mode Control Switch Switch Mode Idle
Switch Dial Switch Switch
Fast Fast OFF ON General OFF
Mode Idle Purpose
Mode

2. Operate the travel control lever of the raised track

to full stroke.
3. Measure the time required for 3 revolutions in both
directions after a constant track revolution speed
is obtained.
4. Raise the other side and repeat the above proce-
dures.
5. Repeat steps 2. to 4. three times and calculate the
average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

NOTE - The measurement data obtained through the

raised track revolution test may have wide variations.
Therefore, the evaluation based on the results ob-
tained from the 20 m (65.6 ft) travel speed check
described before is more recommendable.
EX455 T4-4-3
EXCAVATOR TEST

MISTRACK CHECK

Summary:
1. Allow the machine to travel 20 m (65.5 ft). Measure
the maximum tread deviation from the tread chord
line drawn between the travel start and end points
to check the performance equilibrium between both
sides of the travel device systems (from the main
pump to the travel motor).
2. If measured on a concrete surface, the tread
deviation has a trend to decrease.

Preparation:
1. Adjust the track sag of both tracks to be equal. SM6660
2. Provide a flat, solid test yard 20 m (65.5 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft) on
both ends for machine acceleration and decelera-
tion.
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the
ground with the arm cylinder and the bucket fully
extended, raise the boom.
4. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement: Maximum Distance

1. Measure the amount of mistracking in both fast,

and slow travel speeds.
2. Select the following switch positions: Extra Length
for Acceleration/
Deceleration
Travel Engine E Mode SP Mode Work Auto- 20 m 3 to 5 m
Mode Control Switch Switch Mode Idle
Switch Dial Switch Switch
Slow Fast OFF ON General OFF
Mode Idle Purpose SM6660

Mode
Fast Fast OFF ON General OFF
Mode Idle Purpose
Mode

3. Start traveling the machine in the acceleration

zone with the travel levers at full stroke.
4. Measure the maximum distance between a
straight 20 m (65.5 ft) tread chord line and the tread
made by the machine.
5. After measuring the tracking in forward travel, turn
the upperstructure 180° and measure in reverse
travel.
6. Repeat steps 3. to 5. three times and calculate the
average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-4 EX455
EXCAVATOR TEST

TRAVEL PARKING BRAKE FUNCTION

CHECK

Summary:
To measure the parking brake function on a specified
slope.

Preparation:
1. The surface of the test slope shall be even with a
0.2 to 0.3 m
gradient of 20% (11.31°).
2. Mark a white line on the travel device cover.
3. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above the
ground with the arm and bucket fully rolled in.
4. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).
SM0141

Measurement:
1. Measure in the fast travel mode.
2. Select the following switch positions: Position where the machine
comes to a stop
Travel Engine E Mode SP Mode Work Auto-Idle Position when the travel
levers are in neutral
Mode Control Switch Switch Mode Switch
Displacement
Switch Dial Switch (Revolution Angle)
Mark
Fast Fast OFF ON General OFF
Mode Idle Purpose
Mode

3. Measure the displacement (revolution angle) of

the travel device cover until the parking brake is
applied.
SM0142
3-1. Climb the slope and place the travel levers
in neutral.
3-2. Measure the displacement from the mark
position on the travel device cover when the
levers are placed in neutral to that position
when the machine stops moving.
4. Measure the travel parking brake slip amount
while parked.
4-1. Climb the slope and place the travel levers
in neutral.
Alignment marks on the track
4-2. Stop the engine. side frame and shoe when the
4-3. After the machine stops, put alignment machine comes to a stop
marks on a track link or shoe, and the track Displacement measured
after 5 minutes
side frame.
4-4. After 5 minutes, measure the distance be-
tween the marks on the track link or shoe and SM0143

the track side frame.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
EX455 T4-4-5
EXCAVATOR TEST

SWING SPEED

Summary:
Measure the time required to swing three complete
turns.

Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on
slopes.
3. With the arm rolled out and bucket rolled in, hold the
The same height as the
bucket so that the height of the bucket pin is the boom foot pin height
same as the boom foot pin. The bucket must be
empty.
4. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F). SM0144

CAUTION
Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of the
swing area before starting the measurement.

Measurement:
1. Select the following switch positions:

Engine E Mode SP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF ON General OFF
Idle Purpose
Mode

2. Operate swing control lever fully.

3. Measure the time required to swing 3 turns in one
direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3 turns.
5. Repeat steps 2. to 4. three times and calculate the
average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-6 EX455
EXCAVATOR TEST

SWING FUNCTION DRIFT CHECK

Summary:
Measure the swing drift on the bearing outer
circumference when stopping after a 90° full-speed
swing.

Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on a Two chalk marks
slope. SM0145
3. With the arm rolled out and bucket rolled in, hold the
bucket so that the height of the bucket pin is the
same as the boom foot pin. The bucket must be
empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 90°.
6. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

CAUTION
SM0146
Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of the
swing area before starting the measurement.

Measurement: Measure difference between marks

1. Select the following switch positions:

Engine E Mode SP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF ON General OFF Marking on the Track Frame
Idle Purpose
Mode Marking on the Swing Bearing
SM0147
2. Operate the swing control lever fully and return it to
the neutral position when the mark on the
upperstructure aligns with that on the track frame
after swinging 90°.
3. Measure the distance between the two marks.
4. Align the marks again, swing 180°, then test in the
opposite direction.
5. Repeat steps 3. to 5. three times each and calcu-
late the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
EX455 T4-4-7
EXCAVATOR TEST

SWING MOTOR LEAKAGE

Summary:
Check for upperstructure drift while suspending a
load on a slope.

Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Park the machine on a smooth slope with a gradient
of 26.8 % (15°).
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W = 2400 kg (5290 lb)
4. With the arm rolled out, and bucket rolled in, SM0148
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as illus-
trated.
6. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:
1. Select the following switch position:

E Mode SP Mode Work Auto-

Switch Switch Mode Idle
Switch Switch
Measure difference between marks
OFF ON General OFF
Purpose
Mode

2. Maintain the engine at slow idle. After five minutes,

measure the difference between the marks along
the swing bearing periphery and the track frame. Marking on the Track Frame
3. Perform the measurement in both right and left
swing directions. Marking on the Swing Bearing
4. Perform the measurement three times in each SM0147

direction and calculate the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-8 EX455
EXCAVATOR TEST

SWING BEARING PLAY

Summary:
Measure the swing bearing play using a dial gauge to
check the wear of bearing races and balls.

Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
SM0149
3. Install a dial gauge on the track frame as shown,
using a magnetic base.
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.

Measurement:
1. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to raise
the front idler 0.5 m (20 in). Record the dial gauge
reading (h2).
3. Calculate bearing play (H) from this data (h1 and
h2) as follows:
H=h2-h1
SM0150

Measurement: (h1) Measurement: (h2)

The same height as the

boom foot pin height

SM0144 SM0152

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
EX455 T4-4-9
EXCAVATOR TEST

MAXIMUM SWINGABLE SLANT ANGLE

Summary:
With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.

Preparation:
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W = 2400 kg (5290 lb)
SM0148
3. With the arm cylinder fully retracted and the bucket
cylinder fully extended, hold the arm top pin to the
position flush with the boom foot pin height.
4. Climb a slope and swing the upperstructure 90° to
the slope.
5. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:
1. Select the following switch positions:

Engine E Mode SP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF ON General OFF
Idle Purpose
Mode

2. Operate the swing lever to full stroke to swing the

upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle and repeat steps 2. and 3.
Check both clockwise and counterclockwise.
5. Perform the measurement three times.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-10 EX455
EXCAVATOR TEST

HYDRAULIC CYLINDER CYCLE TIME

Measure the cycle time of the boom, arm, and bucket

cylinders.

Preparation:
1. To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket rolled
in, lower the bucket to the ground, as shown.
2. To measure the cycle time of the arm cylinder:
With the empty bucket rolled in, position the arm so
that it is vertical to the ground. Lower the boom until
the bucket is 0.5 m (20 in) above the ground.
3. To measure the cycle time of the bucket cylinder:
The empty bucket should be positioned at mid-
stroke between roll-in and roll-out, so that the SM0153

sideplate edges are vertical to the ground.

4. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:
1. Select the following switch positions:
0.5 m

Engine E Mode SP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch SM0154

Fast OFF ON General OFF

Idle Purpose
Mode

SM0155
EX455 T4-4-11
EXCAVATOR TEST

2. To measure cylinder cycle times:

(Cylinder full stroke includes cylinder cushioning
zone)
– Boom cylinders:
Measure the time it takes to raise the boom, and
the time it takes to lower the boom. To do so,
position the boom at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
– Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so,
position the arm at one stroke end, then move the
control lever to the other stroke end as quickly as
possible.
– Bucket cylinder:
Measure the time it takes to roll in the bucket, and
the time it takes to roll out the bucket. To do so,
position the bucket at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.

3. Repeat each measurement three times and calcu-

late the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-12 EX455
EXCAVATOR TEST

DIG FUNCTION DRIFT CHECK

• Maximum Reach Position
Extended
Summary: Retracted Distance
Distance
Measure dig function drift, which can be caused by oil Retracted
leakage in the control valve and boom, arm, and Distance
bucket cylinders, with the loaded bucket.
Same Height
NOTE - When testing the dig function drift just after
cylinder replacement, slowly operate each cylinder to
Bucket Bottom
its stroke end to purge air.

SM0156

Preparation:
1. Load bucket fully. In lieu of loading the bucket, Arm Cylinder Extension
weight (W) of the following specification can be
used.
W = 2400 kg (5290 lb)
2. Position the arm cylinder with the rod 50 mm (2 in)
extended from the fully retracted position.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position. Mark
4. With the arm rolled out and the bucket rolled in, hold
the bucket so that the height of the bucket pin is the
same as the boom foot pin.
5. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:
SM0157
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and bucket
Boom and Bucket Cylinder Retraction
cylinders.
3. Repeat step 2. three times and calculate the Mark Mark
average values.

Evalution:
Refer to the Performance Standard Table in Group
T4-2.

SM0158
EX455 T4-4-13
EXCAVATOR TEST

CONTROL LEVER OPERATING FORCE

Summary:
Use a spring scale to measure the maximum
resistance of each control lever as illustrated.

Preparation:
Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:
1. Start the engine.
2. Select the following switch positions:
SM0159
Engine E Mode SP Mode Work Auto-
Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF ON General OFF
Idle Purpose
Mode

CAUTION
Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of the
swing area before starting the measurement.

3. Operate each boom, arm, bucket and swing lever

to at full stroke and measure the maximum oper-
ating force for each.
4. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating force SM0160

required. When finished, lower the track and then

jack-up the other track.
5. Repeat steps 3. to 4. three times and calculate the
average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-14 EX455
EXCAVATOR TEST

CONTROL LEVER STROKE

Summary:
Measure each lever stroke at the lever top using a
ruler.

NOTE - When the lever has play, take a half of this

value and add it to the measured stroke.

Preparation:
Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).
SM0161
Measurement:
1. Stop the engine.

2. Measure each lever stroke at the lever top from

neutral to the stroke end using a ruler.

3. Repeat step 2. three times and calculate the

average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
EX455 T4-4-15
EXCAVATOR TEST

COMBINED BOOM RAISE/SWING

FUNCTION CHECK

Summary:
Check boom raise and swing movement and speeds
while operating both functions simultaneously.

Preparation:
1. Start the engine and run it at fast idle. Operate the
boom raise function and check to be sure that the
cylinder movement is smooth, with out sticking. SM0162
2. With the arm fully rolled out and bucket fully rolled
in, lower the bucket to the ground. The bucket
must be empty.
3. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

CAUTION
Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of the
swing area before starting the measurement.

Measurement:
1. Select the following switch positions:

Engine E Mode SP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch SM0163

Fast OFF ON General OFF

Idle Purpose
Mode
Fast OFF ON Trenching OFF
Idle Mode

2. Raise the boom and swing simultaneously, both at

full stroke.
3. When the upperstructure rotates 90°, release the
control levers to stop both functions. Measure the
time required to swing 90° and the height (H) of the
bucket teeth.
4. Repeat steps 2. to 3. three times and calculate the
average values.

Evaluation:
Refer to the Performance Standard Table in Group SM0164

T4-2.
T4-4-16 EX455
EXCAVATOR TEST

NOTES
EX455 T4-5-1
COMPONENT TEST

PRIMARY PILOT PRESSURE

Preparation:
1. Properly shut down the engine.

CAUTION
The hydraulic oil tank cap may pop off if turned
quickly. Slowly turn it to release internal pressure
before removing it.

2. Move all control levers to release pressure remain-

ing in the system. Slowly turn the hydraulic oil tank SM6661

cap approximately 30 degrees counter-clockwise

to release remaining pressure from the hydraulic oil
tank.

: 4 mm

3. Disconnect the hose end from the pilot filter outlet

port. Install adapter (75301304), fitting (75301519),
pressure gauge and coupling.

: 24 mm, 27 mm

4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:
1. Select the following switch positions:

Engine E Mode SP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF ON General OFF
Idle Purpose
Mode

2. Measure the pilot pressure in specified setting

above.
3. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-2 EX455
COMPONENT TEST

Primary Pilot Pressure Adjustment Procedure

Adjustment:
Adjust the setting pressure of pilot relief valve (the
primary pilot pressure) as necessary.

: 22 mm

Pilot Relief SM6662

Valve

1. Remove plug (1).

2. Install the estimated necessary number of shims
(2).
3. Tighten plug (1).
1
: 29.5 Nm (3 kgf•m, 21.5 lbf•ft) 2

4. Check the relief pressure of relief valve.

Reference: Standard Change in Pressure

Change in Relief Pressure

Shim Thickness (mm)
kPa kgf/cm2 psi

0.25 78 0.8 11
SM6663
0.5 147 1.5 21

1.0 294 3.0 42

EX455 T4-5-3
COMPONENT TEST

SECONDARY PILOT PRESSURE

Connecting Port
Preparation:
1. Properly shut down the engine.

CAUTION
The hydraulic oil tank cap may pop off if turned
quickly. Slowly turn it to release internal pressure
before removing it.

2. Move all control levers to release pressure remaining

in the system. Slowly turn the hydraulic oil tank cap
approximately 30 degrees counterclockwise to re-
lease remaining pressure from the hydraulic oil tank.
: 4 mm
3. Install adapter (75301520), fitting (75301519),
pressure gauge and coupling onto the pilot hose
end of the measuring circuit.
SM6664
: 19 mm, 22 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:

CAUTION
Before starting measurement, check that there
are no bystanders and/or obstructions within the
swing radius.
When measuring the boom lower secondary pilot
pressure operate the machine carefully as the
base machine front will be raised off the ground.
This will cause the base machine to become
imbalanced and possibly allow the rear of the
machine to come in contact with the ground.

1. Select the following switch positions:

Engine E Mode SP Mode Work Auto-
Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF ON General OFF
Idle Purpose
Mode
Slow OFF ON General OFF
Idle Purpose
Mode

2. Measure the pilot pressure in each specified set-

ting above with the corresponding control lever
operated full stroke.
3. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-4 EX455
COMPONENT TEST

MAIN RELIEF PRESSURE SHIFT CONTROL

PRESSURE (SA Pressure) SA

Preparation:
1. Properly shut down the engine.

CAUTION
The hydraulic oil tank cap may pop off if turned
quickly. Slowly turn it to release internal pressure
before removing it.

2. Move all control levers to release pressure remain-

ing in the system. Slowly turn the hydraulic oil tank
cap approximately 30 degrees counter-clockwise
to release remaining pressure from the hydraulic oil
tank.

: 4 mm

3. Disconnect the hose end from the solenoid valve

SM6662
SA output port. Install adapter (75301521), fitting
(75301519), pressure gauge and coupling.

: 19 mm, 22 mm

4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Select the following switch positions:

Engine Control SP Mode E Mode Auto- Work Power

Control Levers Switch Switch Idle Mode Boost
Dial Switch Switch Switch
Fast Idle Travel ON OFF OFF General OFF
lever Purpose
operation
Fast Idle All in ON OFF OFF Precison OFF
neutral
Fast Idle All in ON OFF OFF General *ON
neutral Purpose
Fast Idle All in ON OFF OFF General OFF
neutral Purpose

NOTE - * The Power Boost functions only for 10

seconds.

2. Read the pressure gauge in each setting above.

3. Repeat the measurement three times and calcu-

late the average values.

Evaluation:
Refer to the performance standard table in group
T4-2.
EX455 T4-5-5
COMPONENT TEST

TRAVEL MODE SHIFT CONTROL PRES- SB

SURE (SB Pressure)

Preparation:
1. Properly shut down the engine

CAUTION
The hydraulic oil tank cap may pop off if turned
quickly. Slowly turn it to release internal pressure
before removing it.

2. Move all control levers to release pressure remain-

ing in the system. Slowly turn the hydraulic oil tank
cap approximately 30 degrees counter-clockwise
to release remaining pressure from the hydraulic oil
tank.

: 4 mm

3. Disconnect the hose end from the solenoid valve

SM6662
SB output port. Install adapter (75301521), fitting
(75301519), pressure gauge and coupling.

: 19 mm, 22 mm

4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Select the following switch positions:

Engine Travel SP Mode E Mode Auto- Work

Control Mode Switch Switch Idle Mode
Dial Switch Switch Switch
Fast Idle Fast ON OFF OFF General
Speed Purpose
Mode
Fast Idle Slow ON OFF OFF General
Speed Purpose
Mode

2. Read the pressure gauge in each setting above.

3. Repeat the measurement three times and calcu-

late the average values.

Evaluation:
Refer to the performance standard table in group
T4-2.
T4-5-6 EX455
COMPONENT TEST

SWING PARKING BRAKE RELEASE PRES- SC

SURE (SC Pressure)

Preparation:
1. Properly shut down the engine

CAUTION
The hydraulic oil tank cap may pop off if turned
quickly. Slowly turn it to release internal pressure
before removing it.

2. Move all control levers to release pressure remain-

ing in the system. Slowly turn the hydraulic oil tank
cap approximately 30 degrees counter-clockwise
to release remaining pressure from the hydraulic oil
tank.

: 4 mm

3. Disconnect the hose end from the solenoid valve

SM6662
SC output port. Install adapter (75301521), fitting
(75301519), pressure gauge and coupling.

: 19 mm, 22 mm

4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Select the following switch positions:

Engine SP E Mode Auto- Work

Control Mode Switch Idle Mode
Dial Switch Switch Switch
Fast Idle ON OFF OFF General
Purpose
Mode

2. Read the pressure gauge while operating a front

attachment (boom, arm, or bucket) or swing lever.
Also, read the pressure gauge with all control
levers in neutral.

3. Repeat the measurement three times and calcu-

late the average values.

Evaluation:
Refer to the performance standard table in group
T4-2.
EX455 T4-5-7
COMPONENT TEST

MAIN RELIEF PRESSURE

Summary:
Measure the main relief valve setting pressure at the
main pump delivery port. The main relief pressure can
also be measured with Dr. EX.
Preparation:
1. Properly shut down the engine.

CAUTION
The hydraulic oil tank cap may pop off if turned
quickly. Slowly turn it to release internal pressure
before removing it.

2. Move all control levers to release pressure remaining Pressure

in the system. Slowly turn the hydraulic oil tank cap Check Port Pressure
approximately 30 degrees counter-clockwise to re- Check Port
lease remaining pressure from the hydraulic oil tank.
: 4 mm SM5732

3. Remove the plug from the test port located on

the main pump delivery port. Install fitting and
pressure gauge.
: 19 mm
Or, connect Dr. EX. to monitor main pump delivery
pressure.
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).

Measurement:
1. Select the following switch positions:
Engine E SP Mode Work Auto-
Control Mode Switch Mode Idle
Dial Switch Switch Switch
Fast Idle OFF ON General OFF
Purpose
Mode

2. Relieve each actuator to measure main relief pres-

sure. First, slowly operate bucket, arm, and boom
control levers to the stroke end to relieve each
function one at a time.
3. As for the swing function, secure the upperstruc-
ture immovable. Slowly operate the swing lever to
relieve the swing function.
4. As for the travel function, secure the tracks against
an immovable object. Slowly operate the travel
levers to relieve the travel function.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

NOTE - If the measured pressures for all functions are

lower than the specified range, the probable cause is
a decrease in the setting pressure main relief valve. In
cases where the relief pressure of a particular function
is low, the probable cause may be something other
than the main relief valve.
T4-5-8 EX455
COMPONENT TEST

Main Relief Pressure Setting Adjustment Proce-

dure

Adjustment:
Adjust the main relief valve pressure settings using
plug (3) (for the low-side main relief pressure) and
sleeve (1) (for high-side main relief pressure) after
loosening lock nut (4).

• High-Side Main Relief Pressure Setting Adjust-

ment Procedure
1. Loosen lock nut (4). Tighten plug (3) until the
bottom of piston (5) comes into contact with sleeve
(1). Retighten lock nut (4).

: 22 mm, 30 mm
: Lock nut (4): 59 N⋅m (6 kgf⋅m, 13 lbf⋅ft)
Main Relief Valve
SM6666
2. Loosen lock nut (2). Turn sleeve (1) to adjust the
relief pressure setting, referring to the table below.
3
: 22 mm, 41 mm
: Lock nut (2): 98 N⋅m (10 kgf⋅m, 22 lbf⋅ft) 4
1
• Low-Side Main Relief Pressure Setting Adjust-
ment Procedure 2

3. Loosen lock nut (4). Turn plug (3) counterclockwise

until the specified value is obtained. Retighten lock
nut (4). 5

: 22 mm, 30 mm
: Lock nut (4): 59 N⋅m (6 kgf⋅m, 13 lbf⋅ft)

4. Recheck the set pressures.

Reference : Change in Pressure Setting

Sleeve (1) and

plug (3) turns 1/4 1/2 3/4 1

MPa 4.4 8.8 13.2 17.7

SM6667
kgf/cm2 45 90 135 180
psi 640 1280 1920 2560

Sleeve (1), Plug (3)

Pressure Increase Pressure Decrease

SM6668
EX455 T4-5-9
COMPONENT TEST

Swing Relief Pressure Setting Adjustment Proce- Swing Relief Valve

dure

Adjustment:
Adjust the pressure setting of the swing relief valve
using adjusting screw (1) after loosening lock nut (2).

1. Loosen lock nut (2).

: 19 mm

2. Turn adjusting screw (1) adjust the pressure setting

referring to the table below.

: 10 mm

3. Retighten lock nut (2).

: 19 mm SM6669
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

4. Recheck the set pressure.

1 2

SM6670

Reference: Standard Change in Pressure

Adjusting Screw (1)
Screw Turns 1/4 1/2 3/4 1
MPa 0.76 1.52 2.28 3.04
kgf/cm2 7.75 15.5 23.3 31
psi 110 220 331 440 Pressure Pressure
Increase Decrease

SM0174A
T4-5-10 EX455
COMPONENT TEST

Travel Relief Pressure Setting Adjustment Proce- Travel Relief Valve

dure

Adjustment:
Adjust the pressure setting of the travel relief valve
using the adjusting screw after loosening the lock nut.

1. Loosen the lock nut.

: 17 mm
SM6671

2. Turn the adjusting screw to adjust the pressure

setting, referring to the table below.

: 6 mm
Lock Nut
3. Retighten the lock nut.

: 17 mm
: 49 N•m (5 kgf•m, 36 lbf•ft)

4. Recheck the set pressure.

Adjusting Screw

SM6672

Reference: Standard Change in Pressure

Adjusting Screw
Screw
1/4 1/2 3/4 1
Turns
MPa 1.96 3.92 5.88 7.85
Pressure Pressure
kgf/cm2 20 40 60 80 Increase Decrease
psi 280 570 850 1140

SM0174
EX455 T4-5-11
COMPONENT TEST

OVERLOAD RELIEF VALVE SET PRESSURE

(PRESSURE IN POWER BOOST MODE)

Summary:
1. The circuit pressure must be increased by applying
an external force while blocking the return circuit
from the control valve. This measuring method is
hazardous and the results obtained with this
method are unreliable.
2. Pressure setting of the overload relief valve must
be made at a specified oil flow rate normally far
smaller than the main pump delivery flow rate.
Accordingly, even if the main relief valve set
pressure can be reset higher than the overload
relief valve set pressure, the main pump supplies
too much oil to correctly measure the setting
pressure of the overload relief valve.
For this reason, in order to correctly measure the Pressure Pressure
Check Port Check Port
set pressure of the overload relief valve, the over-
load relief valve unit must be removed from the
SM5732
machine and tested on a test stand.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload
relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main relief pressure of the front
functions as follows:
The main relief pressure can also be measured with
Dr. EX.

Preparation:
1. Properly shut down the engine.

CAUTION
The hydraulic oil tank cap may pop off if turned
quickly. Slowly turn it to release internal pressure
before removing it.

2. Move all control levers to release pressure remain-

ing in the system. Slowly turn the hydraulic oil tank
cap approximately 30 degrees counterclockwise to
release remaining pressure from the hydraulic oil
tank.
: 4 mm
3. Remove the plug from the test port located on the
main pump delivery port. Install fitting and pressure
gauge.
: 19 mm
Or, connect Dr. EX. Select the monitor function to
monitor main pump delivery pressure.
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 ± 5°C
(122 ± 9°F).
T4-5-12 EX455
COMPONENT TEST

Measurement:
1. Select the following switch positions:

Engine SP E Mode Auto- Work

Control Mode Switch Idle Mode
Dial Switch Switch Switch
Fast Idle ON OFF OFF General
Purpose
Mode

2. Press the power boost switch while relieving each

actuator to measure main relief pressure.
First, slowly operate bucket, arm, and boom con-
trol levers to the stroke end to relieve each function
one at a time.
3. Read the pressures on the pressure gauge while
releasing the front functions.
4. Perform the measurement for the bucket, arm,
and boom, in that order.
5. Repeat the measurement three times and calcu-
late the average value for each front function.

Evaluation:
1. Performance of each overload relief valve is nor-
mal if the measured main relief pressure of the
concerned function is within the specified value
range.

Refer to the Performance Standard Table in Group

T4-2.
EX455 T4-5-13
COMPONENT TEST

Overload Relief Valve Set Pressure Adjusting Pro-

cedure

NOTE - In principle, adjust the overload relief valve set

pressure on a test stand.

Adjustment:
Adjust the pressure setting of the overload relief valve
using adjusting screw (2) after loosening lock nut (1).

1. Loosen lock nut (1).

Overload Relief Valve
: 19 mm SM6673

2. Turn adjusting screw (2) to adjust the pressure

setting referring to the table below.

: 6 mm
2
3. Retighten lock nut (1).

: 19 mm

: 98 N•m (10 kgf•m, 72 lbf•ft)

4. Recheck the set pressures.

1
SM6674

Reference: Standard Change in Pressure

Adjusting Screw (2)
Screw
1/4 1/2 3/4 1
Turns
MPa 4.9 9.8 14.7 19.6
2 Pressure Pressure
kgf/cm 50 100 150 200 Increase Decrease
psi 710 1420 2130 2840

SM0174
T4-5-14 EX455
COMPONENT TEST

MAIN PUMP FLOW TEST

Summary:
To check the main performance, measure the pump
flow rate by connecting a flowmeter portable tester at
the main pump delivery port.

Preparation:
1. Properly shut down the engine.

CAUTION
The hydraulic oil tank cap may pop off if turned
quickly. Slowly turn it to release internal pressure
before removing it. SM6675

2. Move all control levers to release pressure remain-

ing in the system. Slowly turn the hydraulic oil tank
cap approximately 30 degrees counterclockwise to
release remaining pressure from the hydraulic oil
tank. Connect a vacuum pump to the filter.

: 4 mm

NOTE - Be sure to keep the vacuum pump 75298347

operated while connecting the portable flowmeter to
the main pump.

3. Disconnect the pump delivery hoses (A) and install

the flowmeter kit with two pressure gauges, as
illustrated.

1 - Instrument
2 - Turbine 1
3 - Turbine 2
Flowmeter 4 - Hose
Kit No. 5 - Hose
75298406 6 - Hose
7 - Hose
8 - Flange (Q2)
9 - Flange (Q2)
10 - Flange (Q4)

SM5733/A
EX455 T4-5-15
COMPONENT TEST

4. Disconnect the DP sensor and engine speed (N)

sensor connectors. (The pump displacement angle
will be the maximum.)
Air Bleed
Plug
5. Remove the P (delivery pressure) sensor from the
other main pump.

6. Disconnect the vacuum pump. Loosen the bleed

plug of the main pump to bleed air from the casing
(until oil comes out).

7. Connect an engine tachometer to the injection

pipe. Fully open the loading valve of the portable
tester.

8. Start the engine. Check line connections for any oil SM5706/L

leaks.

Measurement:
1. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

2. Select the following switch positions:

Travel SP E Mode Auto- Work

Mode Mode Switch Idle Mode
Switch Switch Switch Switch
Fast ON OFF OFF General
Speed Purpose
Mode Mode

3. Adjust the engine speed to approx. 1800 min-1 with

the engine control dial.

4. Slowly close the loading valve of the portable

flowmeter to increase the delivery oil pressure.

5. Measure oil flow rates and engine speeds at the

following delivery pressures:
9.81 MPa (100 kgf/cm2)
21.6 MPa (220 kgf/cm2)

NOTE - Repeat step (5) three times and calculate the

mean values.
T4-5-16 EX455
COMPONENT TEST

Evaluation:
1. Convert the measured pump flow rate obtained in
step 5. above into the rated pump speed using the
following formula:

Converted Pump Flow Rate (Qc) = (Np x Q) / (Ne)

Where:
Qc: Converted Pump Flow Rate
Q: Measured Pump Flow Rate
Np: Rated Pump Speed
Ne: Measure Engine Speed

2. Check that the converted flow rates (Qc) are within

the ranges shown below:
360 ± 12 (L/min) at 9.81 MPa (100 kgf/cm2)
238 ± 24 (L/min) at 21.6 MPa (220 kgf/cm2)
EX455 T4-5-17
COMPONENT TEST

NOTES
T4-5-18 EX455
COMPONENT TEST

SWING MOTOR DRAINAGE

Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.

NOTE - The amount of drain oil from the swing motor 2 A

will change depending on hydraulic oil temperature.
Maintain hydraulic oil temperature at 50 ± 5°C (122 ± 1
9°F).

Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor to warm the
inside of the motor. B

CAUTION
The hydraulic oil tank cap may pop off if turned
quickly. Slowly turn it to release internal pressure
before removing it.

2. Move all control levers to release pressure re-

maining in the system. Slowly turn the hydraulic
oil tank cap approximately 30 degrees
counterclockwise to release remaining pressure
from the hydraulic oil tank. SM6679

: 4 mm

3. To measure the left swing motor drainage, dis-

connect left swing motor drain hose (1) at part A.
Install plug (75301524) on the tee side.

: 27 mm
: 93 N•m (9.5 kgf•m, 70 lbf•ft)

4. To measure the right swing motor drainage, dis- Preconditions for Measurement:
connect drain hose (2) at part B. Connect the test 1. Select the following switch positions:
drain hose (3/4-UN) to the motor side and plug
(75301525) to drain hose (2). Engine E Mode SP Mode Work Auto-
Control Switch Switch Mode Idle
: 27 mm Dial Switch Switch
: 93 N•m (9.5 kgf•m, 70 lbf•ft)
Fast Idle OFF ON General OFF
Purpose
Mode
CAUTION
Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of the
swing area before starting machine operation.
Also, take care not to fall off the machine while the
measurement is performed.
EX455 T4-5-19
COMPONENT TEST

Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the
arm tip pin height is the same as the boom foot
pin height. Be sure that the bucket is empty.
(2) Start the engine. Operate and hold the swing The same height as
boom foot pin height
lever full stroke. Start draining oil measure-
ment after the swing speed reaches a con-
stant maximum speed. The measuring time SM0144
should be more than 20 seconds.
(3) Repeat the measurement three times in both
clockwise and counterclockwise directions,
and calculate the average values.

2. Amount of Oil Drained While Relieving Swing

Motor Circuit
(1) Thrust the bucket teeth into the ground as
illustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
hose end. The measuring time should be more
than 20 seconds.
SM0190
(3) Repeat the measurement three times in both
clockwise and counterclockwise directions,
and calculate the average values.

NOTE - Because the left swing motor drain hose is

connected to the right swing motor drain port, the total
of the left and right swing motor drainage will be
measured when measuring the right swing motor
drainage according to step 4 in Preparation. For this
reason, be sure to deduct the amount of left swing
motor oil drainage (step 3 in Preparation) from that
total amount.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

* Conversion of the amount of drain oil measured into

the per-minute value
SM0191
First measure the amount of drain oil using a cali-
brated container. Then, convert the measured drain
oil into the per-minute value using the formula below:

∆Q = 60 x q / t

Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-20 EX455
COMPONENT TEST

TRAVEL MOTOR DRAINAGE

Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor while
rotating the travel motor with the measuring side track
jacked up.

NOTE - The amount of drain oil from the travel motor

and the drain oil pressure will change depending on
hydraulic oil temperature. Maintain hydraulic oil
temperature at 50 ± 5°C (122 ± 9°F).

Preparation:
1. Maintain hydraulic oil temperature at 50 ± 5°C 2
(122 ± 9°F). Rotate the travel motor to warm the
inside of the motor.

CAUTION
The hydraulic oil tank cap may pop off if turned
quickly. Slowly turn it to release internal pressure
before removing it.

2. Properly shut down the engine.

3. Move all control levers to release pressure re-

maining in the system. Slowly turn the hydraulic oil 1
tank cap approximately 30 degrees counter-
clockwise to release remaining pressure from the
hydraulic oil tank.

: 4 mm

4. Disconnect the travel motor drain hose (1) at the

center joint end. Install plug (75301525) to the SM6679

disconnected end. Connect hose (2) (3/4-16UN)

to the center joint.

: 27 mm

: 93 N•m (9.5 kgf•m, 70 lbf•ft)

Preconditions for Measurement:

1. Select the following switch positions:

Engine SP Mode E Mode Travel Work Auto-

Control Switch Switch Mode Mode Idle
Dial Switch Switch Switch
Fast Idle ON OFF Fast General OFF
Mode Purpose
Mode
EX455 T4-5-21
COMPONENT TEST

Measurement:

CAUTION
Prevent personal injury. Always make sure that
90° to 110°
the area is clear and that coworkers are out of the
area before starting the measurement.
When working around moving parts is unavoid-
able, pay special attention to ensure that hands,
feet, and clothing do not become entangled.
Securely support the raised track using wooden SM0139

blocks.

(1) Start the engine. Jack up the measuring side

track using the front attachment, as illustrated.

(2) Rotate the raised track with the travel lever

operated full stroke. Start drain oil measure-
ment after the track rotation speed reaches a
constant speed. The measuring time should
be more than 20 seconds.

(3) Repeat the measurement three times in both

forward and reverse directions, and calculate
the average value.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

The total performance of the travel motor should be

evaluated by referring to the test results of travel
speed and mistrack.

* Conversion of the amount of drain oil measured into

the per-minute value

First measure the amount of drain oil using a cali- SM6679

brated container. Then, convert the measured drain

oil into the per-minute value using the formula below:

∆Q = 60 x q / t

Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-22 EX455
COMPONENT TEST

NOTES
SECTION 5 EX455

TROUBLESHOOTING

INDEX

Group 1 - Diagnosing Procedure Fault Codes 09, 10

(EC Sensor Failure) ............................. T5-3-6
Introduction ............................................ T5-1-1
Fault Codes 11, 12
Diagnosing Procedure ............................ T5-1-2
(Engine Control Dial Failure) ................ T5-3-7
Dr. EX ..................................................... T5-1-4
Fault Code 13 (N Sensor Failure) ........... T5-3-8
Dr. EX Start-Up Procedure .................... T5-1-4
Fault Code 14 (Overheat Switch L
Clearing the Self-Diagnosing ................. T5-1-5
Failure, Hydraulic Oil Temperature
EC Related Fault Codes ........................ T5-1-7
Sensor Failure)..................................... T5-3-9
PVC Related Fault Codes ...................... T5-1-8
Fault Codes 17, 18, 19, 21, 22
Monitoring Function ............................... T5-1-9
(PVC Failure) ..................................... T5-3-10
Fault Code 20 (Communication
Failure between PVC and EC) ............. T5-3-11
Group 2 - Component Layout
Fault Codes 23, 24

Main Components ................................. T5-2-1 (Pump Control Failure) ...................... T5-3-12

Electrical System (1) ............................. T5-2-2 Fault Codes 26, 34

Electrical System (2) ................................ T5-2-3 (DP Sensor Failure) ........................... T5-3-14

Electrical System (3) ............................. T5-2-4 Fault Codes 27, 28, 35, 36

Electrical System (4) ............................. T5-2-5 (P Sensor Failure) .............................. T5-3-15

Control Valve ........................................... T5-2-6 Fault Codes 29, 30, 37, 38

Other Components ................................ T5-2-10 (A Sensor Failure) .............................. T5-3-16

Sensor Operating Range List ............ T5-3-17

Group 3 - Troubleshooting A

Troubleshooting A Procedure ................. T5-3-1

EC Related Fault Codes ........................ T5-3-2
PVC Related Fault Codes ...................... T5-3-3
Fault Codes 01, 02, 03, 04, 06
(EC Failure) .......................................... T5-3-4
Fault Code 05 (Communication
Failure between PVC and EC) ............... T5-3-5

INDEX
Group 4 - Troubleshooting B
Troubleshooting B Procedure ................. T5-4-1
Correlation between Part Failure
and Abnormalities that Machine
may Show ........................................... T5-4-2
Correlation between Troubles and
Part Failures ...................................... T5-4-6
Engine System Troubleshooting .......... T5-4-10
Total Actuator System
Troubleshooting ................................ T5-4-20
Front Attachment System
Troubleshooting ................................. T5-4-25
Swing System Troubleshooting ............ T5-4-30
Travel System Troubleshooting ............ T5-4-33
Troubleshooting for Other Functions ... T5-4-36
EC Sensor Installation and
Voltage Adjustment .......................... T5-4-40
Installation and Adjustment
of the A Sensor
(Pump Displacement Sensor) ........... T5-4-41
Group 5 - Troubleshooting C
Troubleshooting C Procedure ................. T5-5-1
Malfunction of Coolant
Temperature Gauge ............................. T5-5-2
Malfunction of Fuel Gauge .................... T5-5-4
Malfunction of Fuel Level Indicator ......... T5-5-6
Malfunction of Indicator Light
Check System .................................... T5-5-8
Malfunction of Level Check Switch ....... T5-5-8
Malfunction of Preheat Indicator ............ T5-5-9
Malfunction of Engine Oil Level
Indicator ............................................ T5-5-10
Malfunction of Coolant
Level Indicator .................................. T5-5-12
EX455
Malfunction of Hydraulic Oil
Level Indicator .................................. T5-5-14
Malfunction of Alternator Indicator ...... T5-5-16
Malfunction of Engine Oil Pressure
Indicator ............................................ T5-5-18
Malfunction of Overheat Indicator ....... T5-5-20
Malfunction of Air Filter
Restriction Indicator ........................... T5-5-21
Malfunction of Buzzer ........................... T5-5-22
Malfunction of Hour Meter ..................... T5-5-24
Group 6 - Electrical System
Inspection
Precautions for Inspection and
Maintenance ........................................ T5-6-1
Instructions for Disconnecting
Connectors .......................................... T5-6-3
Fuse Continuity Test ............................... T5-6-4
Fusible Link Inspection and
Replacement ....................................... T5-6-5
Battery Voltage Check............................. T5-6-6
How to Troubleshoot Alternator
Malfunctions ........................................ T5-6-7
Continuity Check ..................................... T5-6-8
Voltage and Current Check .................... T5-6-10
Wiper Box ............................................. T5-6-14
Replacement of Relay ........................... T5-6-16
Relay Box ............................................. T5-6-18
Preheat Controller (QOS)
Replacement ..................................... T5-6-20
Replacement of Power outlet ................. T5-6-21
Group 7 - Harness Check
Circuit Check ......................................... T5-7-1
EX455 T5-1-1
DIAGNOSING PROCEDURE

INTRODUCTION

Each troubleshooting section group is presented in an

orderly fashion so as to make the inspecting and
troubleshooting procedures easy to follow. Use the
troubleshooting section to guide you in locating the
source of any problems that may arise.

The troubleshooting section consists of 7 groups: the

diagnosing procedure, the component layout, the trou-
bleshooting A (using fault codes), troubleshooting B
(starting with symptoms), troubleshooting C (gauges
and indicators), the electrical system inspection pro-
cedures, and harness check groups.

• Diagnosing Procedure

• Component Layout Drawing

• Troubleshooting A (using fault codes)

Use these charts when the self-diagnosing function
of Dr.EX shows any fault codes.
(The controller automatically diagnoses and memo-
rizes malfunctions that have occurred in the signal
sending system.)

Example: Fault Code 01 EC Failure (1)

• Troubleshooting B (starting with symptoms)

Use these charts when the machine is exhibiting
trouble and when Dr.EX does not indicate any fault
codes.

Example: Even if engine control dial is operated,

engine speed does not change.

• Troubleshooting C (Gauges and indicators)

Use these charts when any gauges or indicators
malfunction.

Example: The fuel gauge does not operate.

• Electrical System Inspection Procedure

Refer to this group for precautions and inspection
procedures of the electrical system when or before
performing inspections on the electrical system.

Example: Fuse Inspection

• Harness Check
Refer to this group for information about the test
harnesses.

Example: 75301706 D
T5-1-2 EX455
DIAGNOSING PROCEDURE

DIAGNOSING PROCEDURE

These six basic steps are essential for efficient

troubleshooting:

1. Study the System

Study the machine’s technical manuals. Know the
system and how it works, and what the construc-
tion, functions and specifications of the system
components are.

2. Ask the operator

Before inspecting, get the full story of malfunctions SM0600

from your star witness ···· the operator.

(a) How is the machine being used? (Find out if the

machine is being operated correctly)

(b) When was the trouble noticed, and what types

of work the machine doing at that time?

(c) What are the details of the trouble? Is the

trouble getting worse, or did it appear suddenly
for the first time?

(d) Did the machine have any other troubles previ-

ously? If so, which parts were repaired before?

SM0601
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator’s manual.

Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the control-
lers, causing total operational failure of the ma-
chine.
Fuse failure is often caused by a fine crack in the
fuse, and such fine cracks are very hard to detect
by visual inspection.

SM0602
EX455 T5-1-3
DIAGNOSING PROCEDURE

4. Operate the machine yourself.

Try to identify the trouble by operating the machine
yourself.
If the trouble cannot be confirmed, stop the engine
and obtain further details of the malfunction from the
operator.
Also, check for any incomplete connections of the
wire harnesses.

5. Perform troubleshooting SM0603

CAUTION:
Never attempt to disconnect harnesses or hydrau-
lic lines while the engine is running. The machine
may malfunction or pressurized oil may spout,
possibly resulting in personal injury. Be sure to
stop the engine before disconnecting harnesses
or hydraulic lines.

Connect the diagnostic analyzer, Dr.EX, to the PVC

(Controller) to obtain malfunction records. SM0604

If any fault codes are displayed on the monitor,

check sensing signal circuits, referring to Trouble-
shooting A.

If no fault code is indicated on the monitor, go to the

troubleshooting B group.
Note that Dr.EX will be necessary in the trouble-
shooting B procedures for monitoring real time
component performance.

∗Note that the fault codes displayed do not neces-

sarily indicate machine trouble. The controller
stores even temporary electrical malfunctions,
such as a drop in battery output voltage or discon-
nections of the switches, sensors, etc., for inspec-
tions. SM0605

For this reason, the “RETRIAL” is required to erase

the accumulated fault codes from the controller
memory and to confirm if any fault codes are
indicated after the “RETRIAL”.

6. Trace possible causes

Before reaching a conclusion, check the most likely
causes again. Try to identify the actual cause of the
trouble.

Based on your conclusion, make a plan for appro-

SM0606
priate repairs to avoid consequent malfunctions.
T5-1-4 EX455
DIAGNOSING PROCEDURE

Dr.EX

The Dr.EX (75301336) is a handy microcomputer used
for diagnosing malfunctions of the machine electronic
control system, including the controllers.
When Dr.EX is connected to the controller, malfunc-
tions recorded in the controller memory are indicated
as fault codes on the Dr.EX display.
(Self-Diagnosing Function)
Input signals from the sensors and switches that are
connected to the controller, and output signals from
the controller to the solenoid valves can be monitored
in real-time while the machine is operated. (Real-Time
Monitoring Function)
Dr.EX can also function to increase the pump dis-
placement angle to the maximum angle.
(Special Function)

Dr.EX START-UP PROCEDURE

1. Connect the Dr.EX harness end to the diagnosing

connector in the cab. Start

NOTE - Be sure to use the harness supplied with Model Selec-

Dr.EX for connecting the Dr.EX to the machine. Once tion Screen
Dr.EX is connected properly and switched on, the self- (Select
diagnosing function will automatically start up. "40t~kg2")

Initial Pattern Communica-

2. Turn the key switch to the ON position, or start the (Dr. EX) tion Failure
engine.
• Check the
harness.
3. Turn the Dr.EX power switch on. The model select- • Check the
ing screen will appear on the Dr.EX display. On Model Code fuse.
each step (screen), select an appropriate item and/ Confirmation
Screen
or follow the instructions at the bottom of the
screen to proceed to the next step. The other NOT OK
Install the
new-version
screens shown below will appear, in the order
OK software.
shown.
1. Model Selection Screen (Select "40t~kg2.") Function Se-
lection Screen
2. Initial Pattern (Dr.EX)
3. Model Code Confirmation Screen Real-Time Special Function
Example: Controller Model :EX400-5 Monitoring (A sensor
Self-Diagnosing Function Function adjustment)
4. Function Selection Screen
F1: Self-Diagnosing Function Accumulated Monitor Item Fixing Pump
F2: Real-Time Monitoring Function Fault Codes Selection Displace-
F3: Special Function Display Screen ment Angle
at Maximum
4. When the Function Selection Screen appears, • Refer to the
Retrial A or B Data Display
select the desired function, then proceed by follow- page T5-4-41.
ing the instructions at the bottom of the display.

Fault Code
NOTE - For Dr.EX operating procedures, refer to the Display
Dr.EX Operator's Manual.

Failure
Description
EX455 T5-1-5
DIAGNOSING PROCEDURE

CLEARING THE SELF-DIAGNOSING

FUNCTION

The PVC self-diagnosing function temporarily stores

information on any abnormality that occurs in the
electrical system. These include such things as a drop
in battery voltage or a sensor connector being discon-
nected for inspection.
Therefore, when a fault code is displayed, it does not
necessarily mean that the machine has a problem. To
check the cause of a fault code, first erase the fault
code and check whether it is displayed again or not.
There are two ways to erase fault codes, depending on
the problem area.

1. Problems with controllers (PVC and EC)

(Retrial "A").

2. Problems with sensors (Retrial "B"). OFF

RETRIAL “A” (FOR PROBLEMS WITH THE

CONTROLLER PVC AND EC)

1. Turn the Dr.EX OFF, with its harness still con-

nected to the diagnosing connector of the PVC.
SM6700

2. Turn the key switch OFF.

SM6701

3. After 10 seconds or more have passed, turn the

key switch to the ON position or start the engine.

SM6702

4. Disconnect the harness from the diagnosing con-

nector.

5. After one second or more has passed, reconnect

the harness to the diagnosing connector.

NOTE - If the harness of the Dr.EX is connected to the

More than
diagnosing connector without an interruption of at least 1 sec.
one second, fault codes may not be erased.
SM6703

6. Check the fault code again, following the normal

method. If the fault code is displayed again, the
problem exists.

SM6704
T5-1-6 EX455
DIAGNOSING PROCEDURE

RETRIAL “B” (FOR PROBLEMS WITH THE

SENSORS) ON

1. Leave the key switch in the ON position.

(The engine may be stopped or may be running.) SM6702

2. Disconnect the harness from the diagnosing con-

nector.

More than
1 sec.
SM6703

3. After one second or more has passed, reconnect

the harness to the diagnosing connector.

NOTE - If the hamess of the Dr.EX is connected to the

diagnosing connector without an interruption of at
least one second, fault codes may not be erased.
SM6704

4. Then, check the fault code again, following the

normal method. If the fault code is displayed again,
the problem exists.

The fault code will be displayed with NO actual prob-

lems existing in the following cases:

1. When a sensor connector was previously discon-

nected with the key switch ON or the engine
running. (This may happen when replacing a part.)

2. When the PVC or EC connector was previously

replaced or disconnected.

3. When the battery was removed, or when fuse No.

2 or No. 8 was previously replaced.

Be sure to perform Retrial "A" in order to erase the fault

codes in the above cases.
EX455 T5-1-7
DIAGNOSING PROCEDURE

EC-RELATED FAULT CODES

Fault Code Trouble Corrective Action

01 Failure (type-1) of EC 1) Retry diagnostic procedure A.

2) Replace EC if engine governor is
uncontrollable

02 Failure (type-2) of EC 1) Retry diagnostic procedure A.

2) Replace EC if engine governor is
uncontrollable

03 Failure (type-3) of EC 1) Retry diagnostic procedure A.

2) Replace EC if engine governor is
uncontrollable

04 Failure (type-4) of EC 1) Retry diagnostic procedure A.

2) Replace EC if engine governor is
uncontrollable with eight or more number of
errors indicated in self-diagnosis.

05 Signal from PVC is not transmitted 1) Retry diagnostic procedure B.

to EC 2) Check harness
3) If auto-idle is abnormal replace PVC or EC.

06 Failure (type-6) of EC 1) Retry diagnostic procedure B.

2) Replace EC if engine governor is
uncontrollable

07* Short-circuit of auxiliary sensor 2 1) Retry diagnostic procedure B.

2) Check harness
3) Replace auxiliary sensor 2.

08* Discontinuity of auxiliary sensor 2. 1) Retry diagnostic procedure B.

2) Check harness
3) Replace auxiliary sensor 2.

09 Short circuit of EC sensor 1) Retry diagnostic procedure B.

2) Check harness
3) Replace EC sensor

10 Discontinuity of EC sensor. 1) Retry diagnostic procedure B.

2) Check harness
3) Replace EC sensor

11 Short-circuit of Eng. Governor 1) Retry diagnostic procedure B.

Dial/Lever angle sensor. 2) Check harness
12 3) Replace Eng. Governor Dial/Lever angle
sensor.

13 N sensor malfunction. 1) Retry diagnostic procedure B.

2) Check harness
3) Replace N sensor

14 Discontinuity of overheat switch 1) Retry diagnostic procedure B.

L and/or Hydraulic Oil 2) Check harness
Temperature sensor. 3) Replace overheat switch and/ or Hydraulic Oil
Temperature sensor.

15 Short-circuit of overheat switch 1) Retry diagnostic procedure B.

L and/or Hydraulic Oil 2) Check harness
Temperature sensor 3) Replace overheat switch and/ or Hydraulic Oil
Temperature sensor.

* No aux. sensors are used on this machine.

T5-1-8 EX455
DIAGNOSING PROCEDURE

PVC-RELATED FAULT CODES

Fault Code Trouble Corrective Action

17 Failure (type-17) of PVC 1) Retry diagnostic procedure A.

18 Failure (type-18) of PVC 2) If engine stalls or working speed is abnormal
19 Failure (type-19) of PVC replace PVC.

20 Signal from EC is not transmitted 1) Retry diagnostic procedure B.

to PVC 2) Check harness
3) If speed sensing control is abnormal replace
PVC and/or EC.

21 Failure (type-21) of PVC 1) Retry diagnostic procedure B.

22 Failure (type-22) of PVC 2) Replace PVC

23 Pump control malfunction 1) Retry diagnostic procedure B.

(4-spool side) 2) If engine stalls or working speed is abnormal
24 Pump control malfunction refer to service manual.
(5-spool side)

25 Short circuit of DP sensor 1) Retry diagnostic procedure B.

(4-spool side) 2) Check harness
26 Discontinuty of DP sensor 3) Replace DP sensor (4-spool side)
(4-spool side).

27 Short-Circuit of P sensor 1) Retry diagnostic procedure B.

(4-spool side). 2) Check harness
28 Discontinuity of P sensor 3) Replace P sensor (4-spool side)
(4-spool side)

29 Short circuit of A sensor 1) Retry diagnostic procedure B.

(4-spool side) 2) Check harness
30 Discontinuity of A sensor 3) Replace A sensor (4-spool side)
(4-spool side)

33 Short circuit of DP sensor 1) Retry diagnostic procedure B.

(5-spool side) 2) Check harness
34 Discontinuity of DP sensor 3) Replace DP sensor (5-spool side)
(5-spool side)

35 Short circuit of P sensor 1) Retry diagnostic procedure B.

(5-spool side) 2) Check harness
36 Discontinuity of P sensor 3) Replace P sensor (5-spool side)
(5-spool side)

37 Short circuit of A sensor 1) Retry diagnostic procedure B.

(5-spool side) 2) Check harness
38 Discontinuty of A sensor 3) Replace A sensor (5-spool side)
(5-spool side)

40* Short-circuit of auxiliary sensor 3. 1) Retry diagnostic procedure B.

2) Check harness
3) Replace auxiliary sensor 3.

* No aux. sensors are used on this machine.

EX455 T5-1-9
DIAGNOSING PROCEDURE

MONITORING FUNCTION

Dr.EX functions to monitor command signals from the

controllers (PVC, EC) and input signals to these (4) 4-Spool Control Valve Side
controllers from various switches and sensors. (5) 5-Spool Control Valve Side

Pat- Key
tern No. Display Corrective Action Unit
No.

1 F6 Differential Pressure (dP4) DP sensor output signal. (4P) kgf/cm 2

F7 Pump Delivery Pressure (Pd4) P sensor output signal. (4P) kgf/cm 2
F8 Approx. Pump Displacement (D4) Calculated pump displacement. (4P) cc/rev

2 F6 Desired Pump Displacement (Dr4) Pump displacement control signal. (4P) cc/rev
F7 Approx. Pump Displacement Calculated torque. (4P) kgf. m
Torque (T4)
F8 Potential Pump Displacement Pump driving torque control signal. (4P) kgf. m
Torque (Tr4)

3 F6 Differential Pressure (dP5) DP sensor output signal. (5P) kgf/cm 2

F7 Pump Delivery Pressure (Pd5) P sensor output signal. (5P) kgf/cm 2
F8 Approx. Pump Displacement (D5) Calculated pump displacement. (5P) cc/rev

4 F6 Desired Pump Displacement (Dr5) Pump displacement control signal. (5P) cc/rev
F7 Approx. Pump Displacement Calculated torque. (5P) kgf. m
Torque (T5)
F8 Potential Pump Displacement Pump driving torque control signal. (5P) kgf. m
Torque (Tr5)

5 F6 Pump Disp. Angle Control signal (I4) Control signal to pump displacement A
control solenoid valve. (4P)
F7 Pump Disp. Angle Control signal (I5) Control signal to pump displacement A
control solenoid valve. (5P)
F8 Relief Pressure Raise Signal (Sf) Control signal to solenoid valve (SA) On

6 F6 Travel High/Low Shift Signal (Sh) Control signal to solenoid valve (SB) On
F7 Swing Parking Brake Release Control signal to solenoid valve (SC) On
Signal (Sbs)
F8 Swing/Boom Operation Signal (Ssb) Control signal to swing/boom circuit On
solenoid valve.

7 F6 Power Boost Switch On

F7 Travel Mode Switch Lo,Hi
F8 Work Mode Selector G, T, P, A

8 F6 Pressure Switch Bm, Am,

Ot, Sw, Tr
F7 E (Econ.) Mode sig. On
F8 SP (Sup. Pow.) Mode Sig. On
T5-1-10 EX455
DIAGNOSING PROCEDURE

Pat- Key
tern No. Display Corrective Action Unit
No.

9 F6 Engine Control Angle (Aec) EC sensor output signal. V

F7 Engine Control Motor EC motor position control signal. Pulse
Position (Ecmp)
F8 Actual Engine Speed (Ea) Actual engine speed. rpm

10 F6 Selected Engine Speed Engine speed control signal. %

F7 Deviation engine speed (dE) rpm

11 F6 Auto-Idle Switch On
F7 Additional Pressure Switch On

12 F6 Engine Control Motor Signal (Ecms) Control signal to EC motor. Dn, St, Up
F7 Engine Control Motor Relay On
Signal (Ecmr)

13 F6* Swing Dampener Valve (sdv) On

F7 Hydraulic Oil Temperature (To) °C

14 F6 Overheat Switch (L) (Ovh) On

F7* Counterweight Switch (Cw) On

15 F6 Dial Angle Sig. Signal from dial angle sig. V

F7* Auxiliary Sensor 2 (Aux2) Signal from auxiliary sensor 2 V
F8* Auxiliary Sensor 3 (Aux3) Signal from auxiliary sensor 3 V

* This item not used on this machine.

NOTE - UNIT ABBREVIATIONS

Lo : Slow Speed Bm : Boom

Hi : Fast Speed Am : Arm
G : General Purpose Mode Ot : Other
T : Trenching Mode Sw : Swing
P : Precision Mode Tr : Travel
A : Atttachment Mode
EX455 T5-2-1
COMPONENT LAYOUT

MAIN COMPONENTS

1
3

35 4
5
6
7
8
9
10
11
12
13
34 14

15

33

16
32
17
31
30 18
29 19
28 20
27 21
26 22
25
24
23 SM5701

1 - Bucket Cylinder 19 - 3 Spool Solenoid Valve Unit

2 - Arm 20 - Pump Device
3 - Arm Cylinder 21 - Pilot Filter
4 - Boom 22 - Hydraulic Oil Tank
5 - Boom Cylinder 23 - Travel Device
6 - Front/Swing Pilot Valve 24 - Shockless Valve (Travel)
7 - Swing Bearing 25 - Upper Roller
8 - Center Joint 26 - Swing Shuttle Valve
9 - Swing Device 27 - Shockless Valve (Front)
10 - Fuel Tank 28 - Lower Roller
11 - Control Valve 29 - Travel Shuttle Valve
12 - Engine 30 - Pilot Shut-Off Valve
13 - Radiator 31 - Track Adjuster
14 - Oil Cooler 32 - Front Idler
15 - Counterweight 33 - Air Filter
16 - Fuel Filters 34 - Travel Pilot Valve
17 - Engine Oil Filters 35 - Bucket
18 - Muffler
T5-2-2 EX455
COMPONENT LAYOUT

ELECTRICAL SYSTEM (1)

(Overall system)

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

31

30
29 14
28
27 15
26
25 16
24 17
23 18
22
21
20
19
SM5735

1 - Work Light (On Boom) 17 - Starter

2 - Monitor 18 - EC Motor
3 - Pressure Switch (Travel) 19 - Coolant Level Switch
4 - Horn 20 - DP Sensor (5-Spool Side)
5 - Work Light 21 - 3-Spool Solenoid Valve Unit
6 - Fuel Sensor with Fuel Low Level Switch 22 - Hydraulic Oil Level Switch
7 - Battery 23 - Hydraulic Oil Temperature Switch
8 - DP Sensor (4-Spool Side) 24 - Pressure Switch (Other)
9 - Air Filter Restriction Switch 25 - Pressure Switch (Swing)
10 - Overheat Switch L 26 - Pressure Switch (Arm Roll-In)
11 - Coolant Temperature Sensor (For Monitor) 27 - Pressure Switch (Boom Raise)
12 - Overheat Switch H 28 - Windshield Washer Motor
13 - Alternator 29 - Fuse Box
14 - Engine Oil Level Switch 30 - Wiper Box
15 - Engine Oil Pressure Switch 31 - Wiper Motor
16 - N (Engine Speed) Sensor
EX455 T5-2-3
COMPONENT LAYOUT

ELECTRICAL SYSTEM (2)

(Monitor and switch panels)

15 16 17

18
1
42 19
20
14
2 41
21
40
22
39 23
24
38

37
3
13 36 25
12
35 26
11 34 27
4 28
10
33
5
9 29
6
30

7
32 31
8

SM6501

1 - Monitor Panel 22 - Preheat Indicator

2 - Switch Panel 23 - Air Filter Restriction Indicator
3 - Cigar Lighter 24 - Fuel Level Indicator
4 - Provision for Hydraulic Breaker Control Switch 25 - Attachment Mode Indicator
5 - Provision for Nordic Kit Control Switch 26 - Precision Mode Indicator
6 - Provision for Rotary Bucket Control Switch 27 - Trenching Mode Indicator
7 - Provision for Load Momentum Alarm Control Switch 28 - General Purpose Mode Indicator
8 - Provision for further option Control Switch 29 - Work Mode Switch
9 - Air Conditioner Control Panel 30 - Buzzer Stop Switch
10 - Engine Control Dial 31 - Travel Mode Switch
11 - E Mode Switch 32 - Auto-Idle Switch
12 - SP Mode Switch 33 - Wiper Switch
13 - Key Switch 34 - Washer Switch
14 - Power Boost Switch 35 - Work Light Switch
15 - Warm Up Complete Indicator 36 - Level Check Switch
16 - Coolant Temperature Gauge 37 - Hydraulic Breaker filter clogging Indicator (opt)
17 - Fuel Gauge 38 - Overheat Indicator
18 - SP Mode Indicator 39 - Engine Oil Pressure Indicator
19 - E Mode Indicator 40 - Alternator Indicator
20 - Auto-Idle Indicator 41 - Engine Oil Level Indicator
21 - Hydraulic Oil Level Indicator 42 - Coolant Level Indicator
T5-2-4 EX455
COMPONENT LAYOUT

ELECTRICAL SYSTEM (3) View C 1

(Relays, diodes, etc.) F

Cab compartment

2
View E

20
3

View B

19
➮ A
4

➮
View D

➮
18
D
➮
17
16 B
➮

15
C

5
Detail F

View A
6
12
7
13
14 8
9
10
11

SM5702

1 - EC controller 11 - Rear Cab light relay (R6)

2 - PVC controller 12 - EC Motor relay (R7)
3 - Air conditioner relays (if installed) 13 - Diodes 1-2
4 - Q.O.S. Controller 14 - Diodes 3-4-5
5 - Relay box 15 - A-B-C junction connector
6 - Load momentum alarm buzzer provision 16 - D-E-F junction connector
7 - Load momentum alarm relay provision (R1) 17 - G-H-I junction connector
8 - R.H. Rotation bucket relay provision (R3) 18 - J-K-L junction connector
9 - L.H. Rotation bucket relay provision (R4) 19 - Dr. EX connector
10 - Cab light relay (R5) 20 - Fuse box
EX455 T5-2-5
COMPONENT LAYOUT

ELECTRICAL SYSTEM (4)

(Relays, batteries, fuses)

1 3

8
7

5
6

SM5703

1 - Fuse Link 1 (50A) 5 - Battery relay

2 - Fuse Link 2 (40A) 6 - Battery
3 - Fuse Link 3 (80A) 7 - Glow relay
4 - Starter relay 8 - Connection box
T5-2-6 EX455
COMPONENT LAYOUT

CONTROL VALVE

1 2 3 43 4 5 6 7 8 9 10 11 12 13 14 15

42

41
Swing Motors

Boom Cylinder

Arm Cylinder
40

39
16
Bucket Cylinder
17
38 18
19
37
20
36 21
22
35
23
34

33

Right Travel Motor

SM6570
32 31 30 29 28 27 26 25 24

1 - Holding Valve Shift Valve (Boom) 23 - DP Sensor (5-Spool Side)

2 - Load Check Valve (Arm 2 Tandem Circuit) 24 - Pump Control Valve (5-Spool Side)
3 - Pump Control Valve (4- Spool Side) 25 - Load Check Valve (Left Travel Parallel Circuit)
4 - Load Check Valve (Arm 2 Parallel Circuit) 26 - Load Check Valve (Aux. Parallel Circuit)
5 - Check Valve (Arm Flow Combining Circuit) 27 - Check Valve (Bucket Flow Combining Circuit)
6 - Check Valve (Aux. Flow Combining Circuit) 28 - Check Valve (Main Relief Pressure Combining Circuit)
7 - Arm Regenerative Flow Control Valve 29 - Flow Combiner Valve
8 - Check Valve (Arm 1 Parallel Circuit) 30 - Check Valve (Travel Flow Combining Circuit)
9 - Load Check Valve (Arm 1 Parallel Circuit) 31 - Check Valve
10 - Load Check Valve (Swing Tandem Circuit) 32 - Shuttle Valve
11 - Arm Regenerative Valve 33 - Main Relief Valve
12 - Load Check Valve (Arm 1 Tandem Circuit) 34 - Load Check Valve (Bucket Tandem Circuit)
13 - Holding Valve Shift Valve (Arm) 35 - Check Valve (Aux. Parallel Circuit)
14 - Overload Relief Valve (Swing) 36 - Load Check Valve (Boom 1 Parallel Circuit)
15 - Overload Relief Valve (Arm) 37 - Overload Relief Valve (Bucket)
16 - Holding Check Valve (Arm) 38 - Check Valve (Boom Flow Combining Circuit)
17 - Make-Up Valve (Boom 2) 39 - Overload Relief Valve (Boom)
18 - Load Check Valve (Boom 2 Tandem Circuit) 40 - Holding Check Valve (Boom)
19 - Load Check Valve (Boom 2 Parallel Circuit) 41 - Make-Up Valve (Arm 2)
20 - Load Check Valve (Aux. Tandem Circuit) 42 - DP Sensor (4-Spool Side)
21 - Overload Relief Valve (Aux.) 43 - Center Bypass Valve
22 - Load Check Valve (Left Travel Tandem Circuit)
EX455 T5-2-7
COMPONENT LAYOUT

Swing Arm 1 32 33 24 23
Boom 2

Aux.

Left Travel
Arm 2
Boom 1

Bucket
31
Right Travel

Front Side
SM6572

SM6571
30 29

44 28 45 37 48 35 49 21

Right Travel Left Travel Bucket Aux.

22 20

34 26

21
25

37 51 6 27 50
47 46
SM6573 SM6574

44 - Right Travel Forward Port 48 - Bucket (Roll-Out) Port

45 - Left Travel Forward Port 49 - Aux. Port
46 - Left Travel Reverse Port 50 - Aux. Port
47 - Right Travel Reverse Port 51 - Bucket (Roll-In) Port
T5-2-8 EX455
COMPONENT LAYOUT

1 2 3 43 4 5 6 7 8 9 10 11 12 13 14 15

42

41
Swing Motors

Boom Cylinder

Arm Cylinder
40

39
16
Bucket Cylinder
17
38 18
19
37
20
36 21
22
35
23
34

33

Right Travel Motor Left Travel Motor

32 31 30 29 28 27 26 25 24 SM6570

1 - Holding Valve Shift Valve (Boom) 23 - DP Sensor (5-Spool Side)

2 - Load Check Valve (Arm 2 Tandem Circuit) 24 - Pump Control Valve (5-Spool Side)
3 - Pump Control Valve (4- Spool Side) 25 - Load Check Valve (Left Travel Parallel Circuit)
4 - Load Check Valve (Arm 2 Parallel Circuit) 26 - Load Check Valve (Aux. Parallel Circuit)
5 - Check Valve (Arm Flow Combining Circuit) 27 - Check Valve (Bucket Flow Combining Circuit)
6 - Check Valve (Aux. Flow Combining Circuit) 28 - Check Valve (Main Relief Pressure Combining Circuit)
7 - Arm Regenerative Flow Control Valve 29 - Flow Combiner Valve
8 - Check Valve (Arm 1 Parallel Circuit) 30 - Check Valve (Travel Flow Combining Circuit)
9 - Load Check Valve (Arm 1 Parallel Circuit) 31 - Check Valve
10 - Load Check Valve (Swing Tandem Circuit) 32 - Shuttle Valve
11 - Arm Regenerative Valve 33 - Main Relief Valve
12 - Load Check Valve (Arm 1 Tandem Circuit) 34 - Load Check Valve (Bucket Tandem Circuit)
13 - Holding Valve Shift Valve (Arm) 35 - Check Valve (Aux. Parallel Circuit)
14 - Overload Relief Valve (Swing) 36 - Load Check Valve (Boom 1 Parallel Circuit)
15 - Overload Relief Valve (Arm) 37 - Overload Relief Valve (Bucket)
16 - Holding Check Valve (Arm) 38 - Check Valve (Boom Flow Combining Circuit)
17 - Make-Up Valve (Boom 2) 39 - Overload Relief Valve (Boom)
18 - Load Check Valve (Boom 2 Tandem Circuit) 40 - Holding Check Valve (Boom)
19 - Load Check Valve (Boom 2 Parallel Circuit) 41 - Make-Up Valve (Arm 2)
20 - Load Check Valve (Aux. Tandem Circuit) 42 - DP Sensor (4-Spool Side)
21 - Overload Relief Valve (Aux.) 43 - Center Bypass Valve
22 - Load Check Valve (Left Travel Tandem Circuit)
EX455 T5-2-9
COMPONENT LAYOUT

56 5 57
52 53
Arm 2 Arm 1
Boom 1 Boom 2 7
17
16 13
41
39
8

36 18 2

1 12

19
4 9

15

40 55 38 54 SM6575 38 59 58 SM6576

42 3 60 14

Swing

15

43
10

14

SM6577 SM6578
40 61

52 - Boom 1 (Lower) Port 57 - Arm 1 (Roll-Out) Port

53 - Boom 2 (Lower) Port 58 - Arm 1 (Roll-In) Port
54 - Boom 2 (Raise) Port 59 - Arm 2 (Roll-In) Port
55 - Boom 1 (Raise) Port 60 - Swing (Left) Port
56 - Arm 2 (Roll-Out) Port 61 - Swing (Right) Port
T5-2-10 EX455
COMPONENT LAYOUT

OTHER COMPONENTS
Pump Device
5 6

➮
A

View A
9

4 7
SM5706

1 - Main pump 1 (front) 6 - Pump 2 delivery pressure sensor (P sensor)

2 - Pilot pump 7 - Pump Control Proportional Solenoid valve 1
3 - Main pump 2 (rear) 8 - Pump Control Proportional Solenoid valve 2
4 - Pump 1 A sensor (Pump Displacement Sensor) 9 - Pump 2 A Sensor (Pump Displacement Sensor)
5 - Pump 1 delivery pressure sensor (P sensor)
EX455 T5-2-11
COMPONENT LAYOUT

Swing Device Travel Device

SM6506

SM6505

3-Spool Solenoid Valve Unit

4 5 6 7

SM6507

1 - Swing Relief Valve 5 - Travel Mode Shift Solenoid Valve (SB)

2 - Counterbalance Valve 6 - Main Relief Pressure Shift Solenoid Valve (SA)
3 - Travel Relief Valve 7 - Pilot Relief Valve
4 - Swing Parking Brake Release Solenoid Valve (SC)
T5-2-12 EX455
COMPONENT LAYOUT

NOTES
EX455 T5-3-1
TROUBLESHOOTING A

TROUBLESHOOTING A PROCEDURE

Use troubleshooting A procedure when fault codes are shown on Dr.EX.

• How to Read the Troubleshoting Flow Charts

YES(OK)
(2)
After checking or measuring item (1), select either YES (OK) or NO (NOT
(1) OK) and proceed to item (2) or (3), as appropriate.

(3)
NO(NOT OK)

Special instructions or reference item are indicated in the spaces under the box. Incorrect
measuring or checking methods will render troubleshooting impossible, and may damage
Key switch: ON components as well.

• Explanation of how to use harness kit required. Refer to "Harness Check" Group
(Group T5-7) in this section.

Use the Dr. EX.

Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes
can be seen without going through the flow chart.

NOTE - For all connector drawings illustrated in

this group, harness end connector terminals
seen from the open end side are shown.

Wire Harness Side

Open End Side

Harness End Connector

SM0630
T5-3-2 EX455
TROUBLESHOOTING A

EC-RELATED FAULT CODES

Fault Code Trouble Corrective Action

01 Failure (type-1) of EC 1) Retry diagnostic procedure A.

2) Replace EC if engine governor is
uncontrollable

02 Failure (type-2) of EC 1) Retry diagnostic procedure A.

2) Replace EC if engine governor is
uncontrollable

03 Failure (type-3) of EC 1) Retry diagnostic procedure A.

2) Replace EC if engine governor is
uncontrollable

04 Failure (type-4) of EC 1) Retry diagnostic procedure A.

2) Replace EC if engine governor is
uncontrollable with eight or more number of
errors indicated in self-diagnosis.

05 Signal from PVC is not transmitted 1) Retry diagnostic procedure B.

to EC 2) Check harness
3) If auto-idle is abnormal replace PVC or EC.

06 Failure (type-6) of EC 1) Retry diagnostic procedure B.

2) Replace EC if engine governor is
uncontrollable

07* Short-circuit of auxiliary sensor 2 1) Retry diagnostic procedure B.

2) Check harness
3) Replace auxiliary sensor 2.

08* Discontinuity of auxiliary sensor 2. 1) Retry diagnostic procedure B.

2) Check harness
3) Replace auxiliary sensor 2.

09 Short circuit of EC sensor 1) Retry diagnostic procedure B.

2) Check harness
3) Replace EC sensor

10 Discontinuity of EC sensor. 1) Retry diagnostic procedure B.

2) Check harness
3) Replace EC sensor

11 Short-circuit of Eng. Governor 1) Retry diagnostic procedure B.

Dial/Lever angle sensor. 2) Check harness
12 3) Replace Eng. Governor Dial/Lever angle
sensor.

13 N sensor malfunction. 1) Retry diagnostic procedure B.

2) Check harness
3) Replace N sensor

14 Discontinuity of overheat switch 1) Retry diagnostic procedure B.

L and/or Hydraulic Oil 2) Check harness
Temperature sensor. 3) Replace overheat switch and/ or Hydraulic Oil
Temperature sensor.

15 Short-circuit of overheat switch 1) Retry diagnostic procedure B.

L and/or Hydraulic Oil 2) Check harness
Temperature sensor 3) Replace overheat switch and/ or Hydraulic Oil
Temperature sensor.

* No aux. sensors are used on this machine.

EX455 T5-3-3
TROUBLESHOOTING A

PVC-RELATED FAULT CODES

Fault Code Trouble Corrective Action

17 Failure (type-17) of PVC 1) Retry diagnostic procedure A.

18 Failure (type-18) of PVC 2) If engine stalls or working speed is abnormal
19 Failure (type-19) of PVC replace PVC.

20 Signal from EC is not transmitted 1) Retry diagnostic procedure B.

to PVC 2) Check harness
3) If speed sensing control is abnormal replace
PVC and/or EC.

21 Failure (type-21) of PVC 1) Retry diagnostic procedure B.

22 Failure (type-22) of PVC 2) Replace PVC

23 Pump control malfunction 1) Retry diagnostic procedure B.

(4-spool side) 2) If engine stalls or working speed is abnormal
24 Pump control malfunction refer to service manual.
(5-spool side)

25 Short circuit of DP sensor 1) Retry diagnostic procedure B.

(4-spool side) 2) Check harness
26 Discontinuty of DP sensor 3) Replace DP sensor (4-spool side)
(4-spool side).

27 Short-Circuit of P sensor 1) Retry diagnostic procedure B.

(4-spool side). 2) Check harness
28 Discontinuity of P sensor 3) Replace P sensor (4-spool side)
(4-spool side)

29 Short circuit of A sensor 1) Retry diagnostic procedure B.

(4-spool side) 2) Check harness
30 Discontinuity of A sensor 3) Replace A sensor (4-spool side)
(4-spool side)

33 Short circuit of DP sensor 1) Retry diagnostic procedure B.

(5-spool side) 2) Check harness
34 Discontinuity of DP sensor 3) Replace DP sensor (5-spool side)
(5-spool side)

35 Short circuit of P sensor 1) Retry diagnostic procedure B.

(5-spool side) 2) Check harness
36 Discontinuity of P sensor 3) Replace P sensor (5-spool side)
(5-spool side)

37 Short circuit of A sensor 1) Retry diagnostic procedure B.

(5-spool side) 2) Check harness
38 Discontinuty of A sensor 3) Replace A sensor (5-spool side)
(5-spool side)

40* Short-circuit of auxiliary sensor 3. 1) Retry diagnostic procedure B.

2) Check harness
3) Replace auxiliary sensor 3.

* No aux. sensors are used on this machine.

T5-3-4 EX455
TROUBLESHOOTING A

FAULT CODES 01, 02, 03, 04, 06

(EC Failure)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• Replace the EC if the machine shows any ab-
normalities and if fault code(s) are still indicated after
performing applicable “Retrial. ”
* However, the machine can be used without replacing
the EC if the machine functions normally despite the
fact that the fault code(s) are indicated after perform-
ing applicable “Retrial. ”

Fault Codes 01, 02, and 03

YES
Normal

Check if fault
code disappears
after Retrial A. Turn auto-idle YES
* EC failure
switch ON and
• Perform Retrial A a OFF. Check if
few times if fault code engine speed
does not disappear NO changes when
after one trial. auto-idle switch is
operated. Replace EC.
NO

Fault Code 04
YES
Normal

Check if fault
code disappears
NO
after Retrial A. * EC failure
Check if the
• Perform Retrial A a number of fault
few times if fault code codes indicated is
NO
does not disappear 8 or more.
after one trial.
Replace EC.
YES

Fault Code 06
YES
Normal

Check if fault
code disappears
after Retrial B. NO
* EC failure
Check if engine
• Perform Retrial B a speed changes
few times if fault code with engine control
does not disappear NO
dial.
after one trial.
Replace EC.
YES
EX455 T5-3-5
TROUBLESHOOTING A

FAULT CODE 05
(Communication Failure between PVC
and EC)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• The PVC, EC, or the harness between the PVC and
EC may have failed if the auto-idle does not function
normally and if fault code 05 is still indicated after
Retrial B.
* However, the machine can be used without replacing
the EC or PVC if the machine functions normally
despite the fact that the fault code is still indicated
after Retrial B.

YES
Normal

Check if fault
code disappears
YES
after Retrial B. * PVC or EC failure
• Perform Retrial B Check if auto-idle
a few times if fault functions normally.
NO
code does not
disappear after Disconnect harness end con- YES Replace PVC and
one trial. nectors from PVC and EC. EC.
Check if continuity exists between
terminals stated below:
NO • PVC harness end connector
terminal No. 4 and EC harness Failure of harness
end connector terminal No. 9 between PVC and
• PVC harness end connector NO EC.
terminal No. 5 and EC harness
end connector terminal No. 3
• PVC harness end connector
terminal No. 11 and EC harness
end connector terminal No. 2
• PVC harness end connector
terminal No. 12 and EC harness
end connector terminal No. 10

• Key switch: OFF

Harness End Connector (Open End Side)

PVC EC

5 4 3 2
12 11 10 9
T5-3-6 EX455
TROUBLESHOOTING A

FAULT CODES 09, 10

(EC sensor failure)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• Fault code 09 indicates the input voltage from the EC Fault code 10 indicates the input voltage from the EC
sensor is 4.75 V or more. sensor is 0.25 V or less.

YES
Normal

Check if
Disconnect EC breakage or NO EC failure
Check if fault Disconnect short circuit
sensor connector.
code disappears EC sensor exists in the line
Check if resist- connector.
after Retrial B. ance between EC YES between EC
YES Check if voltage connector
side connector
between harness terminal No. 34
• Perform Retrial B terminals No. 1 end connector Harness failure
a few times if fault and No. 3 is and EC sensor between EC and
terminals No. 1 connector
code does not 1.7±0.4 kΩ. and No. 3 is YES EC sensor.
disappear after NO Connect test har- terminal No.2.
5±0.5 V.
one trial. ness (75301706D)
to EC sensor. • Fault code 09:
• Key switch: ON
Check if voltage Check for short
varies as specified circuit.
when engine Fault code 10:
control dial is Check for
operated. breakage.

• Specified voltage:
Harness failure
Refer to T5-3-17.
between EC and
NO EC sensor.

EC sensor failure
NO

EC Harness End Connector (Open End Side)

34

Harness End Connector

(Open End Side)
EC Sensor
EC Sensor Side Connector (Open End Side)

(Red)
3 2 1

1 2 3
(Black)

EC 13 34 18
75301706D
SM6705 SM6706 SM6707
EX455 T5-3-7
TROUBLESHOOTING A

FAULT CODES 11, 12

(Engine control dial failure)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

YES
Normal

Disconnect Check if
engine control dial breakage or Harness failure
connector. Check short circuit YES between EC and
Check if fault if resistance Disconnect exists in the line engine control
code disappears between engine engine control between EC dial.
after Retrial B. dial side connec- YES connector
dial connector.
tor terminals No. 5 Check if voltage terminal No. 23
• Perform Retrial B and No. 7 is YES between and engine EC failure
a few times if fault 5.0±0.5 kΩ. harness end control dial NO
code does not Reconnect engine connector connector termi-
disappear after control dial terminals No. 5 nal No.2.
one trial. connector. Insert and No. 7 is
NO test probes from 5±0.5 V.
the back of engine
control dial • Key switch: ON
connector: (-)
probe on terminal
No. 7 and (+)
probe on terminal
No. 5. Check if
voltage varies as Harness failure
specified when between EC and
engine control dial engine control
is operated. NO
dial.

• Specified voltage:
0.3 to 1.0 V with Engine control
engine control dial NO dial failure
at slow idle
4.0 to 4.7 V with
engine control dial
at fast idle

EC Harness Side Connector (Open End Side)

23

Engine Control Dial Side Connector Engine Control Engine Control Dial
(Open End Side) Dial Side (Harness Side) Harness End Connector
(Open End Side)

7 6 5

5 6 7 30 23 27
SM6708
7 6 5 SM6709 SM6710
T5-3-8 EX455
TROUBLESHOOTING A

FAULT CODE 13 (N sensor failure)

Precondition: Checking Instruction:

• Be sure inspect wiring connections prior to trouble-
shooting.
• Be sure to inspect N sensor installation condition.
• Check the engine speed using the Dr. EX monitoring
function. If breakage exists in the harness between
the N sensor and EC, EC judges that the engine
speed is 0 min-1(rpm), in other words, that the engine
is not running. For this reason, no fault code will be
displayed in the case of a wire breakage between the
N sensor and EC.

YES
Normal

Disconnect
connectors from the
N sensor and EC. YES
Check if fault Connect N sensor EC failure
code disappears harness end
after Retrial B. YES connector terminals
No. 1 and No. 2
using a clip. Check
• Perform Retrial B Disconnect N
Harness failure
sensor connector. if continuity exists
a few times if fault between EC and
Check if resistance between EC
code does not NO N sensor
between N sensor harness end
disappear after
NO side connector connector terminals
one trial.
terminals No. 1 and No. 4 and No. 11.
No. 2 is 810±240 Ω.
N sensor failure.
NO

N Sensor Installation

N Sensor
Bolt Harness End Connector
Tightening torque (Open End Side)
77.7-117 Nm
1 2
N Sensor

Engine
Flywheel housing

4
11
EC
Harness End
Connector
(Open End Side)

SM6712

SM6711/R
EX455 T5-3-9
TROUBLESHOOTING A

FAULT CODE 14
(Overheat switch L failure, hydraulic oil tem-
perature sensor failure)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• Fault code 14 indicates that the input voltage from
the sensor is 4.75 V or more. In this case, harness
breakage between the EC and the overheat switch L/
the hydraulic oil temperature sensor may be the
cause. In addition, Dr.EX indicates -45 °C (-49 °F) in
this case.
If the harness between the EC and the overheat
switch L / hydraulic oil temperature sensor short-
circuits, Dr. EX indicates 120 °C (248 °F).
However, if the coolant temperature exceeds 98 °C
(208 °F) causing overheat switch L to turn on, Dr. EX
also indicates 120 °C (248 °F).

Connect hydraulic oil

temperature sensor YES
harness end
connector terminals
No. 1 and No. 2 using
a clip.
YES Disconnect 48P
connector from the
EC. Check if
continuity exists
Disconnect hydraulic between 48P harness
oil temperature sensor end connector
connector. Check if terminals No. 33 and NO
resistance at No. 35.
hydraulic oil
temperature sensor
side connector is
within standard value
range.
EC failure.
Harness breakage
Ground 48P harness between EC and
end connector YES
hydraulic oil
terminals No. 33 to temperature sensor
vehicle frame. Check terminal No. 2.
if continuity exists
between hydraulic oil
temperature sensor
harness end Harness breakage
connector terminal
between EC and
No. 1 and vehicle hydraulic oil
frame. NO temperature sensor
terminal No. 1.

• Standard value: Hydraulic oil

Refer to the table temperature
below. NO sensor failure.

Hydraulic Oil Temperature Sensor Overheat Switch L

Hydraulic Oil Resistance Coolant Switch Operation

Temperature °C (°F) kΩ Temperature °C (°F)
-20 (-4) 16.2±1.6 96 to 100 (205 to 212) ON
0 (32) (5.88) 89 to 100 (192 to 212) OFF
20 (68) 2.45±0.24
40 (104) (1.14)
60 (140) (0.534)
80 (176) 0.322

Harness End Connector (Open End Side)

EC (48P) Hydraulic Oil Temperature Sensor

1 2
35 33
T5-3-10 EX455
TROUBLESHOOTING A

FAULT CODES 17, 18, 19, 21, 22

(PVC Failure)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• Replace the PVC if the machine shows any abnor-
malities and if fault code (s) are still indicated after
performing applicable “Retrial.”

* However, the machine can be used without replac-

ing the PVC if the machine functions normally
despite the fact that the fault code (s) are indicated
after performing applicable “Retrial.”

Fault Codes 17, 18, 19

YES
Normal

Check if fault codes disap-

pear after Retrial A. YES
* PVC failure
• Perform Retrial A a few times if Check if engine stalls or if
fault codes do not disappear operating speed is abnor-
after one trial. NO mal.
Replace PVC.
NO

Fault Codes 21, 22

YES
Normal

Check if fault codes disap-

pear after Retrial B.

• Perform Retrial B a few times if

fault codes do not disappear Replace PVC.
after one trial. NO
EX455 T5-3-11
TROUBLESHOOTING A

FAULT CODE 20
(Communication failure between PVC
and EC)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• If the fault code still appears after “Retrial” B, check
the harness between the PVC and EC.

* Since it is practically impossible to determine

whether the PVC or EC has failed, replace both if a
failure occurs in the PVC/EC.

YES
Normal

Check if fault codes disap-

pear after Retrial B. OK
* Failure of PVC/EC
• Perform Retrial B a few times if Check the harness between
fault codes do not disappear PVC and EC.
after one trial. NO
• Refer to page T5-3-5 Harness failure between
NOT OK PVC and EC
T5-3-12 EX455
TROUBLESHOOTING A

FAULT CODES 23, 24

(Pump control failure)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• Fault codes 23 and 24 are indicated when the target One of the following may be the cause:
pump displacement does not match with the actual 1. Pump control solenoid valve failure.
pump displacement. 2. A sensor failure
3. PVC failure

If any other codes are also indicated, troubleshoot

Harness End Connector (Open End Side) those codes first.

PVC

37 3 106
10 114

Pump Control Solenoid Valve

OK
1
Check harness
NOT OK between fuse
1 2 No. 9 and PVC
Troubleshoot
using indicated terminal No. 37.
YES YES Check fuse 2
fault codes • Be sure to
No. 9. NOT OK
Check if any (other than replace failed
NO fault codes 23 and 24). fuse (No. 9) after
other than 23 the cause is OK
and 24 are found. 3
indicated. Check if fault OK 4
code 23 is
NO NOT OK
indicated.
OK
5
YES Check fuse
No. 9.
Check if fault
codes disap- Check if fault 6
pear after code 24 is NOT OK
Retrial B. NO indicated.
YES Normal
• Perform Retrial Normal
NO
B a few times if
fault codes do
not disappear Disconnect one
after one trial. A sensor. Check
if machine and
Check if ma- engine operate A sensor
chine and en- normally. failure or loose
gine operate Reconnect A YES or incorrect
YES
normally. sensor and connection of
check if ma- A sensor.
chine and
NO engine operate
normally. Failure of PVC
Repeat the or pump.
same procedure NO
for the other A
sensor.

• If machine and
engine operate
normally when one
of A sensors is
disconnected, the
disconnected A
sensor has failed.
EX455 T5-3-13
TROUBLESHOOTING A

NOTE - (4) : 4-Spool Control Valve Side

(5) : 5-Spool Control Valve Side

OK Failure of PVC or
pump (4).

Check if continuity exists OK Check swing/

between pump control sole- Check resistance boom circuit shift Failure of the line
noid valve (4) harness end between pump solenoid valve line. between PVC
connector terminals YES control solenoid terminal No. 112
No. 1 and No. 2.
Connect PVC side harness
valve (4) connector NOT OK and swing/boom
terminals No. 1 Pump control circuit shift sole-
end connector terminal No. 3 noid valve.
1 (No. 10) to vehicle frame and No. 2. valve solenoid
using a clip. Check if conti- NOT OK valve (4) failure.
nuity exists between pump • Standard value:
control solenoid valve (4) 14±3 Ω at 20 °C (68 °F)
harness end connector ter-
minal No. 1 (No. 2) and ve-
hicle frame. Harness failure
between pump
NO control solenoid
Harness failure between valve (4) and PVC.
2 fuse No. 9 and PVC
terminal No. 37. OK Failure of PVC or
Check resistance
pump (4).
between pump
Check if continuity exists YES control solenoid
between pump control sole- valve (4) connector
noid valve (4) harness end terminals No. 1 Pump control
conector terminals and No. 2.
No. 1 and No. 2. valve solenoid
NOT OK valve (4) failure.
Connect PVC side harness • Standard value:
end connector terminal No. 3 14±3 Ω at 20 °C (68 °F)
3 (No. 10) to vehicle frame
using a clip. Check if conti-
nuity exists between pump
control solenoid valve (4) Harness failure
harness end connector ter- between pump
minal No. 1 (No. 2) and ve- NO control solenoid
hicle frame. valve (4) and PVC.

OK Failure of PVC or
Harness failure between Check resistance pump (5).
4 fuse No. 9 and PVC between pump
terminal No. 37 YES control solenoid
valve (5) connector
terminals No. 1 Pump control
Check if continuity exists and No. 2. valve solenoid
between pump control sole- NOT OK
noid valve (5) harness end valve (5) failure.
• Standard value:
connector terminals 14±3 Ω at 20 °C (68 °F)
No. 1 and No. 2.
Connect PVC side harness
OK end connector terminal No.
114 (No. 106) to vehicle
frame using a clip. Check if Harness failure
continuity exists between between pump
pump control solenoid valve control solenoid
(5) harness end connector NO
5 terminal No. 1 (No. 2) and valve (5) and PVC.
vehicle frame.
OK Failure of PVC or
Check if continuity exists Check resistance pump (5).
Harness failure between between pump control between pump
fuse No. 9 and PVC solenoid valve (5) harness YES control solenoid
NOT terminal No. 37. end connector terminals valve (5) connector
OK No. 1 and No. 2. terminals No. 1 Pump control
Connect PVC side harness and No. 2. valve solenoid
OK end connector terminal No. NOT OK valve (5) failure.
114 (No. 106) to vehicle • Standard value:
frame using a clip. Check if 14±3 Ω at 20 °C (68 °F)
continuity exists between
Check harness
pump control solenoid Harness failure
between fuse
6 valve (5) harness end between pump
No. 9 and PVC
connector terminal No. 1 control solenoid
terminal No. 37. NO
(No. 2) and vehicle frame. valve (5) and PVC.

Harness failure between fuse

NOT OK No. 9 and PVC terminal No. 37.
T5-3-14 EX455
TROUBLESHOOTING A

FAULT CODES 26, 34

(DP Sensor Failure)

Precondition:
• Be sure inspect wiring connections prior to trouble- • If input voltage from the DP sensor is 1.0 V or higher
shooting. with the engine stopped, the probable cause is a
faulty DP sensor or broken harness between the
Checking Instruction: DP sensor and PVC.
• Fault codes 26 and 34 indicate input from the DP
sensor is 0.25 V or less. Harness breakage bet-
ween DP sensor and PVC may be the cause.
Check harness NO
lines between PVC failure
PVC connector
YES terminal No. 44
(No. 32) and DP
sensor terminal Harness
No. 2 for breakage
harness between PVC
YES and DP sensor
breakage.
terminal No.2.
• Fault codes 26
Disconnect DP
and 34:
sensor connec-
Check for
tor. Check if
harness
YES voltage between
breakage.
harness end
connector
terminals No. 1
and No. 3 is Harness
5±0.5 V. breakage
NO
Check if voltage between PVC
Attach test har-
• Key switch: ON between the and DP sensor
ness terminal No.1.
(75301706D) harness end
between DP connector
NO NO terminal No.1 and
sensor and Harness
harness end. vehicle frame is
5±0.5 V. breakage
Check if between PVC
indicated volt-
age is 0.4+0.15 • Key switch: ON YES and DP sensor
-0.1 terminal No.3.
or less.

Check if fault • Key switch: ON

code disap- • Fault code 26: DP sensor
pears after 4-spool side DP NO failure.
Retrial B. sensor
Fault code 34:
• Perform Retrial B 5-spool side DP
a few times if fault sensor
codes does not
disappear after Normal
one trial. YES

Harness End Connector (Open End Side)

PVC
(5-Spool Side)
32
Black
Red 44

(4-Spool Side)

75301706D
DP Sensor

1 2 3
SM6713
EX455 T5-3-15
TROUBLESHOOTING A

FAULT CODES 27, 28, 35, 36

(P Sensor Failure)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• Fault codes 27 and 35 indicate the input from the Fault codes 28 and 36 indicate the input from the P
P sensor is 4.75 V or more. Short circuit between sensor is 0.25 V or less. Harness breakage bet-
the P sensor and PVC may be the cause. ween the P sensor and PVC may be the cause.

Check harness
lines between NO
PVC failure
the PVC con-
nector terminal
YES No. 42 (No. 31)
and P sensor
terminal No. 2 Harness failure
for harness between PVC
breakage (short YES and P sensor.
circuit).
Disconnect P
sensor connec-
tor. Check if
voltage between
NO harness end
connector
terminals No. 1
and No. 3 is
5±0.5 V.
Switch pump 1
side P sensor • Key switch: ON
with pump 2
Harness failure
side P sensor.
between PVC
NO Check if NO and P sensor.
indicated fault
code changes
to the one for
the other P
sensor.

Check if fault • Fault codes 27

code disap- and 28: Fault
P sensor failure
pears after codes for pump
1 side P sensor YES
Retrial B.
• Fault codes 35
and 36: Fault
• Perform Retrial B codes for pump
a few times if fault 2 side P sensor
codes does not
disappear after
one trial. Normal
YES

Harness End Connector (Open End Side)

PVC P Sensor
(5-Spool Side)
31
1 2 3
42
(4-Spool Side)
T5-3-16 EX455
TROUBLESHOOTING A

FAULT CODES 29, 30, 37, 38

(A Sensor Failure)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• Fault codes 29 and 37 indicate the input from the Fault codes 30 and 38 indicate the input from the A
A sensor is 4.75 V or more. Short circuit between sensor is 0.25 V or less. Harness breakage bet-
the A sensor and PVC may be the cause. ween the A sensor and PVC may be the cause.

NO Failure of PVC or
Check the harness A sensor
lines between PVC • Refer to T5-4-41.
YES connector terminal
No. 30 (No. 22)
and A sensor Harness failure between
Disconnect the A terminal No. 2 for YES PVC and A sensor.
sensor connector. harness breakage
NO Check if voltage (short circuit).
between the
harness end
connector termi-
nals No. 1 and
No. 3 is 5±0.5 V. Harness failure
NO between PVC and
Check if fault code
• Key switch: ON A sensor.
disappears after
• Fault codes 29 and 30:
Retrial B. Fault codes for pump 1
side A sensor
• Perform Retrial B a few Fault codes 37 and 38:
Fault codes for pump 2
times if fault codes does
side A sensor
not disappear after one
trial.
Normal
YES

Harness End Connector (Open End Side)

PVC
A Sensor
(5-Spool Side)
22
30 1 2 3

(4-Spool Side)
EX455 T5-3-17
TROUBLESHOOTING A

SENSOR OPERATING RANGE LIST SP Mode E

Switch Mode
1. Measurement Preconditions

• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)

• Unless otherwise instructed, set the switches as
follows:
Slow Fast

E Mode
Switch and Work
Engine Mode Auto-Idle
Control Dial SP Mode Switch Switch
Switch
General
Fast Idle
ON Purpose OFF SM6714
(Max.) Engine Control
Mode
Dial

• Monitor using the Dr.EX.

2. Sensor Operating Range

Item Required Control/Switch Operation Specified Range

Slow Idle (Minimum Speed) 0.3 to 1.0 V
Engine Control Dial
Fast Idle (Maximum Speed) 4.0 to 4.7 V
Engine Control Dial at Slow Idle 2.5 to 2.7 V
EC Sensor
Engine Control Dial at Fast Idle 3.9 to 4.3 V
Pump Delivery +15 2
Boom Raised: Full Stroke, Relieved 300 -5 kgf/cm
Pressure Sensor
Control Levers: Neutral 54 cc/rev.
A Sensor One Track Jacked-Up,
Travel Lever (Raised Track Side): 200 cc/rev.
Full Stroke
Control Levers: Neutral 26 kgf/cm2
Pump Control
One Track Jacked-Up,
Pressure Sensor
Travel Lever (Raise Track Side): 0 kgf/cm2
Full Stroke

NOTE - 1 kgf/cm2=0.09807 MPa

T5-3-18 EX455
TROUBLESHOOTING A

NOTES
EX455 T5-4-1
TROUBLESHOOTING B

TROUBLESHOOTING B PROCEDURE

Apply troubleshooting B procedure when no fault code Start the troubleshooting with more probable causes
is displayed on the Dr.EX although the machine's selected by referring to these tables.
operation is abnormal.
On the front section pages of this group T5-4, are
tables indicating the correlation between part failure
and abnormalities that machine may show.

• How to Read the Troubleshooting Flow Charts

YES (OK)
(2)
• After checking or measuring item (1), select either YES (OK) or NO
(1) (NOT OK) and proceed to item (2) or (3), as appropriate.

(3)
NO (NOT OK)

• Special instructions or reference item are indicated in the spaces under the box. Incorrect
measuring or checking methods will render troubleshooting impossible, and may damage
Key switch: ON components as well.

• Explanation of how to use harness kit required. Refer to “Harness Check” Group
(Group T5-7) in this section.

• Use the Dr. EX function.

• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes
can be seen without going through the flow chart.
T5-4-2 EX455
TROUBLESHOOTING B

CORRELATION BETWEEN PART

FAILURE AND ABNORMALITIES THAT
MACHINE MAY SHOW

The table below shows abnormalities that the machine

may show and the effects in the control system if the
listed parts have failed. Also, troubleshooting proce-
dures are shown to find out if the listed parts have
failed in case the indicated abnormalities are found.

Part Name Pump and Valve Engine Controller Differential Pressure Sensor
Controller (PVC) (EC) (DP Sensor)

• Controls main hydraulic • Controls engine speed. • Senses differential pressure for
Designated Function pump and main control pump displacement angle
valve. control.

• Loss of pump and/or valve • Loss of engine speed control. • Loss of main pump
control. (Loss of pump displacement angle control.
Effects in control has resulted more
often than loss of valve
Control System
control.)

• Slow actuator speed.
(Pump fixed to the minimum
displacement angle.)
Abnormalities that • Engine may stall. (Pump
fixed to the maximum
the machine may show.
displacement angle.)
• Actuator speed may vary
unstably. (Displacement
angle varies unstably.)
• Loss of engine speed • Correct metering may not be
control. obtained.
• Abnormal sound is heard from
the control valve with control
levers in neutral.
• Excessively high oil and coolant
temperature.
• Slow actuator speed.
• Machine mistracks.

Dr.EX Self- • Dr.EX may display “Can not • Dr.EX displays fault code 01, • Dr.EX displays fault code 26 or
Diagnosing communicate with PVC” or 02, 03, 04, 05, or 06. 34.
Function one or more of the following
fault codes may be
displayed: 17, 18, 19, 20,
21, and 22.

Dr.EX – – • Check the DP sensor pressure.

Monitor
Function

Trouble-
shooting Test Harness – – –
Pro- Check
cedures
Other – – –

Note • Check fuse No. 8 (for PVC)
output side for wire
breakage.
• Be sure that the bolt on the
PVC connector is tight.
• Check fuse No. 2 (for EC) –
output side for wire
breakage.
• Be sure that the bolt on the
EC connector is tight.
EX455
Engine Speed
Sensor (N Sensor)
• Senses engine (pump)
speed.
• Loss of speed sensing
control. (This happens
when engine speed
signal is not sent to
the EC due to
harness breakage, etc.).
• Engine stalls when
operating under severe
conditions, such as when
operating at high altitude.
• Dr. EX displays fault
code 13 when engine
speed is not within
specification. No fault
code is displayed if
circuit between N
sensor and EC is open.
• Monitor engine speed.
– –
– –
– –
T5-4-3
TROUBLESHOOTING B
Pump Displacement Pressure Sensor Engine Control Sensor
Angle Sensor (A Sensor) (P Sensor) (EC Sensor)
• Senses main hydraulic • Senses main hydraulic pump • Senses governor lever position.
pump displacement angle. delivery pressure.
• Loss of pump control. • Loss of horsepower control. • Loss of learning control for
governor lever maximum speed
position.
• Machine mistracks. • Actuator maximum speed will • Engine speed cannot be
(It may be noticed when decrease. controlled from slow idle to
traveling straight.) • Engine may stall. fast idle with engine speed
• Engine overload or control dial.
decrease in speed may (Engine can be started.)
result. • EC motor moves beyond the
control range.
• Dr. EX displays fault code • Dr. EX displays fault code • Dr. EX displays fault code 09
23, 24, 29, 30, 37, or 38. 27, 28, 35 or 36. or 10.
• Monitor and compare the • Monitor pump delivery –
pump displacement target pressure. If P sensor
angle and the pump harness is open, 0 kgf/cm2
displacement angle. will be indicated.
– –
– –
– If EC sensor fails, the fast idle
speed is set using the previous
learning value or the backup
value. For this reason, the
machine can still operate almost
normally. However, after the EC
is replaced, the machine may
show abnormalities described as
no fast idle values are stored in
a new EC.
T5-4-4 EX455
TROUBLESHOOTING B

Part Name Overheat Switch L,

Pump Control Swing Preference Circuit Shift
Hydraulic Oil
Solenoid Valve Solenoid Valve
Temperature Sensor

• Senses hydraulic oil and • Shifts the pump • Turns on/off the pilot pressure
Designated Function coolant temperatures. displacement angle. to shift (turn on/off) the swing
preference circuit.

• Loss of overheat prevention • Loss of pump control. • Loss of swing preference circuit
Effects in control. shifting (turning on/off) control.
Control System • Loss of auto warm-up
function.

• Slow actuator speed may
result if sensor signal line is
Abnormalities that short-circuited.
the machine may show. • Auto warm-up function is
not operating.
• Pump flow rate becomes
minimum if the harness has
an open.
• Priority is given to swing in
swing/boom raise combined
operation.
• In the trenching mode, priority is
not given to swing in swing/
boom raise combined operation.

Dr.EX Self- • Dr.EX displays fault code • Dr.EX displays fault code 23 –
Diagnosing 14. or 24.
Function

Dr.EX – – • Check signals from the swing

Monitor and boom raise pressure
Function switches and from the work
mode switch for any
abnormalities.
Trouble-
shooting
Pro- Test Harness – – –
cedures Check

Other – – –

Note – – –
EX455
TROUBLESHOOTING B
Travel Mode Shift Main Relief Pressure Shift
Solenoid Valve Solenoid Valve
• Shifts travel motor • Temporarily raises the main
displacement angle. relief pressure.
• Travel motor displace- • Main relief pressure cannot
ment angle is fixed to the be raised.
maximum (slow speed).
• Travel speed mode does • Travel steering power
not shift to the fast speed decreases.
mode with the travel • Main relief pressure cannot
mode switch. be raised even in the
precision work mode.
– –
– • Operate and return the
travel lever, and confirm that
the travel code on Dr. EX
goes to the reverse video
and returns to the normal
display.
– –
– • The solenoid valve function
is considered normal if the
main relief pressure rises
temporarily when a front
function, i.e. boom, arm, or
bucket, is relieved in the
precision mode.
– –
T5-4-5
EC Motor Engine Control Dial
• Operates governor lever. • Controls engine speed.
• Governor lever does not • Engine speed does not change
move. with engine control dial.
• Turning engine control dial, • Engine speed stays at around
engine speed stays at slow 1000 min-1 with no load applied.
idle.
– • Dr.EX displays fault code 11 or
12.
– • Monitor the input signal for
engine control dial angle.
(If it is 1.0 to 4.0 V, engine
control dial is normal.)
– –
• EC motor is considered –
normal if governor lever
moves when key switch is
turned to ON position.
– –
T5-4-6 EX455
TROUBLESHOOTING B

CORRELATION BETWEEN TROUBLES

AND PART FAILURES

Failed Part Engine Control Electrical Parts

Eng. EC EC EC Starter Coolant QOS Pres. Pres.

Cont. Motor Sensor Motor Relay Temp.Sw, Controller Sw. Sw.
Dial Relay (Preheat (Travel) (Swing)
Trouble Sympton (R7) Circuit)

E-1 Starter does not rotate.

•
E-2 Starter rotates but engine
does not start. •
E-3 Engine is hard to start in
cold weather. • •
E-4 Auto-Idle does not function.
• • • • •
E-5 Engine stalls with engine control dial
turned to fast idle position.
With engine control dial turned
to fast idle position and auto-idle
switched turned ON, engine
sometimes stalls while operating.
• •
Slow idle speed is excessively
slow or fast.

E-6 Engine speed does not

change with engine control
dial. • • •
E-7 Engine does not stop.

Failed Part Pump Control Valve Cont. Electrical Parts

Pump P DP A Swing Swing Hyd. Work SP

Cont. Sensor Sensor Sensor Pref. Park. Temp. Mode Mode
Prop. Sol. Brake Sensor Sw. Sw.
Sol. Valve Sol. /Over-
Valve Valve heat
Trouble Sympton Sw. L

A-1 All cylinders and motors move

slowly or do not move • • • • • •
A-2 Cylinders and motors, which
are hydraulically connected to
one particular main pump,
move slowly or do not move.
• • • • •
A-3 Cylinders and motors do not
stop moving with control
levers returned to neutral.

A-4 Boom is slow in swing/boom

raise combined operation. • •
A-5 SP mode cannot be activated
with SP mode switch. •
A-6 E mode cannot be activated
with E mode switch.

A-7 Cylinder or motor

responsiveness is slow. • •

NOTE - The above table shows the correlation be- posing that each trouble occurs independently. If any
tween machine operation trouble and related parts other trouble occur at the same time, find out the faulty
which may cause trouble. However, the correlations in parts causing the trouble by checking all suspected
this table are described based on the condition sup- parts in each symptom.
EX455 T5-4-7
TROUBLESHOOTING B

Electrical Parts Engine

Pres. Pres. Pres. Key Pre-Heat Battery Starter Monitor/ EC Eng. Governor Fuel Filter Gauze EC
Sw. Sw. Sw. Sw. Relay Relay Auto-Idle Filter Monitor
(Boom (Arm (Others) Sw. (Strainer) Link
Raise) Roll-In)

• • •
• • • • •
• •
• • • • •

• • • • • •

• •
• • • •

Electrical Parts Pump Cont. Valve Others

E PVC Pump Servo Pilot Main Main Shock- Pilot Pilot Pilot
Mode Unit Piston Pump Spool Relief less Shut- Valve Relief
Sw. Valve Valve Off Valve
Valve

• • • • • • •

• • •

• •

•
• •
• • • •
T5-4-8 EX455
TROUBLESHOOTING B

Failed Part Pump Control Valve Control Electrical Parts

P DP A Swing Main Travel Power Pres. Monitor PVC

Sensor Sensor Sensor Pref. Relief Speed Boost Sw. /Auto-
Sol. Pres. Sol. Sw. Travel idle Sw.
Valve Sol. Valve
Trouble Sympton Valve

F-1 Front attachment cylinder(s)

move slowly or do not move. •
F-2 Bucket drops excessively.

F-3 In the beginning of front

attachment operation,
bucket drops slightly.

F-4 Power does not increase with

power boost switch turned on. • •
S-1 Upperstructure does not
rotate, rotates slowly, or
swing power is weak.
• •
S-2 Upperstructure coasts
excessively when stopping
swing operation or when
machine is parked on a slope.

T-1 Both tracks move slowly.

• •
T-2 Travel mode does not shift.
• • • •
T-3 Machine mistracks.
• • • • •
Failed Part Pump Control Valve Cont. Pressure Switch Electrical Parts

P DP A Swing Main Swing Bom Arm Work Monitor

Sensor Sensor Sensor Pref. Relief Raise Roll- Mode /Auto-
Sol. Pres. In Sw. Idle
Valve Sol. Sw.
Valve

Trouble Sympton

O-1 Work mode does not shift.

• • • • • • •
O-2 Pump emits abnormal
sound or vibration. • • • •
O-3 Wiper does not operate
or does not retract.

NOTE - The above table shows the correlation be- posing that each trouble occurs independently. If any
tween machine operation trouble and related parts other trouble occur at the same time, find out the faulty
which may cause trouble. However, the correlations in parts causing the trouble by checking all suspected
this table are described based on the condition sup- parts in each symptom.
EX455 T5-4-9
TROUBLESHOOTING B

Pump Control Valve Others

Pump Main Main Over- Load Hold- Swing Travel Center Shuttle Shock- Lock Pilot Pilot Cylin-
Unit Spool Relief load Check ing Device Device Joint Valve less Valve Shut- Valve der
Valve Relief Valve Valve Valve Off
Valve Valve

• • • • • • •
• • • •
• • • •
•
• • • • • • •

• • •
• •
•
• • • • • •
Electrical Parts Pump Control Valve Others

Wiper PVC Pump Main Main Over- Pilot

Sw. Unit Spool Relief load Valve
Valve Relief
Valve

•
•
•
T5-4-10 EX455
TROUBLESHOOTING B

ENGINE SYSTEM TROUBLESHOOTING

E-1 Starter does not rotate.

Related Fault Code: None

YES Faulty starter or
Checking Instructions disconnected starter ground
line.
• Measure each voltage by referring to the tables
below.
• Electronic system such as EC has nothing to do Regardless of key switch
with the trouble obstructing the rotation of starter. position ON or START,
voltage at terminal B is 0
(zero).

• Key switch: ON↔START

Check if each terminal
voltage on starter is normal
YES
with key switch turned to the
positions in the following
table. With key switch With key switch
positioned at positioned as shown
START, voltage at in the following table,
Starter Terminal Voltage Unit: V terminal C does check if each
not increase to 24 terminal voltage is
Terminal ON START RUNNING volts. normal.
C 0 24 0
Starter Relay Terminal Voltage Unit: V
B 24 24 24
NO Terminal ON START RUNNING
Check if battery B 24 24 24
voltage and
electrolyte density C 0 24 0
are normal. E 0 0 0
R 0 0 12
• Voltage:
24 volts or more S 0 24 0
• Density:
1.26 or more With key switch
positioned at
Faulty starter or
START, voltage at
disconnected
terminal S does
starter ground line.
not increase to 24
volts.

Faulty Battery
NO
(When key switch is turned to START, in
case voltage at terminal B is 18 V or lower,
battery is faulty.)

• Starter Terminal Voltage Check. • Starter Relay Voltage Check.

(Seen from the back of the connector.)

SM6116 SM6117
EX455 T5-4-11
TROUBLESHOOTING B

YES Faulty harness between

battery relay and starter.
Check if battery relay clicks
when key switch is turned
OFF from the ON position.
Faulty battery relay
• Key switch: ON↔OFF NO

YES Faulty harness between

Terminal No.1 fusible link and key switch.
With key switch in
voltage: 0 V
START, voltage at Check if fusible link
terminal S does not (50 A) has blown.
Measure voltage
increase to 24 V.
at key switch
terminals No. 1 Blown fusible link 1 (50A).
and No. 6. NO

• Key switch: START

Terminal No.1 voltage: 24 V
Terminal No.6 voltage: 0 V
Faulty key switch.

Terminal No.1 voltage: 24 V

Terminal No.6 voltage: 24 V Faulty harness between key
switch terminal No. 6 and
starter relay terminal S.

Voltage at terminal B is 0 V. Broken harness between

both terminals B on starter
and starter relay.
With key switch in START, voltage at
terminal C is 0 V but voltage at starter
relay terminal C is 24 V. Broken harness between
both terminals C on starter
With key switch in START, voltage at all and starter relay.
terminals other than C is normal. Voltage at
terminal C does not increase to 24 V.
Faulty starter relay.

• Key Switch Voltage Check

NOTE - Remove the key switch from the console.

View A

ST G1 ACC

B G2 M

SM0633
T5-4-12 EX455
TROUBLESHOOTING B

E-2 Starter rotates but engine does not start.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• Check the governor lever and fuel cut lever position
while cranking the engine. If the both levers position
are normal, the engine unit or fuel system may have
failed.

YES
Faulty engine.

• Refer to engine Section.

With key switch ON, check if
governor lever moves to the
starting position.
• Key switch : ON
Check EC motor activating
NO circuit.

• Governor Lever and Fuel Shut-Off Lever

1 SM5725
1 - Governor Control Cable
(From EC Motor)
2 - Fuel Shut-Off Cable
[Handle (Emergency Engine Stop)]
3 - Fuel Shut-Off Lever
4 - Governor Lever
EX455 T5-4-13
TROUBLESHOOTING B

• Governor Lever Position

A - Key Switch OFF (Engine Stop Position)

B - Key Switch ON (Engine Start Position)

STO
A: STOP P
B FULL

FUL
L SM5726

• Fuel Shut-Off Lever

A - Fuel Cut Handle Pulled Position

B - Fuel Cut Handle Returned Position

A B

SM5727
T5-4-14 EX455
TROUBLESHOOTING B

E-3 Engine is hard to start in cold weather.

(Fails to preheat)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

YES Faulty engine coolant tempe-

rature switch.

Disconnect engine coolant

temperature switch. Check if
voltage at glow plug is 20 to YES
24 V. Faulty QOS controller.
With engine coolant tempera-
• Key switch: ON ture switch
disconnected, ground glow
NO relay terminal No.4 to vehicle
frame. Check if voltage at
With engine coolant
glow plug is 20 to 24 V.
temperature switch, and glow
relay disconnected, check if
• Key switch : ON NO voltage at glow relay harness
• Without removing connector, end connector terminal No.1
ground the terminal to vehicle and No.3 is 20 to 24 V.
frame using a jumper wire,
like a clip, from the reverse
side of the connector.

• Measurement of Glow Plug Voltage and Resistance

Remove
Copper
Plates.

Standard: 20 to 24 V Standard: 10 Ω or Less

SM4049 SM4050
EX455 T5-4-15
TROUBLESHOOTING B

YES
Faulty glow relay.

10 Ω or less
Faulty engine.

• Refer to engine shop section.

Measure glow plug

NO resistance.

• Key switch: OFF

• After removing copper
plates connecting glow
plugs, measure the glow Replace glow plug.
plug resistance. ∞Ω
T5-4-16 EX455
TROUBLESHOOTING B

E-4 Auto-idle does not function.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

NOTE - EC motor and EC sensor are functioning

normally.

Checking Instruction:
• If E-1 to E-3 has occurred, troubleshoot them first.
• Refer to “Auto-Idle Control” in the Control System
Group, the SYSTEM section, the Operation Princi-
ple book.
• If the auto-idle function has failed after EC had been
replaced, increase the engine speed to the maxi-
mum (fast idle) speed.

Pressure switch (travel,

NO
Monitor pressure switches
(travel, swing, boom raise,
arm roll-in, and others).
YES Check if letters “Tr”, “Sw”,
“Bm”, “Am”, and “Ot” turn
reverse video when
respective control lever is
operated.
Monitor auto-idle switch.
Check if letters “On” turn • Monitor item:
reverse video. Pressure switch (#8-F6)
YES
• Monitor item:
Auto-Idle switch
(#11-F6)
NO
swing, boom raise, arm
roll-in, and/or others)
failure.
Harness failure between
PVC and pressure
switches.
NOTE - Pressure switch location:
Pressure switch (travel): Travel shuttle valve
Pressure switch (swing): Swing shuttle valve
Pressure switch (boom raise): Shockless valve
Pressure switch (arm roll-in): Shockless valve
Pressure switch (others): Swing shuttle valve
EC Failure.
Auto-idle switch failure, or
harness breakage between
auto-idle switch and EC.
EX455 T5-4-17
TROUBLESHOOTING B

E-5 Engine stalls with engine control dial turned

to fast idle position.
With engine control dial turned to fast idle
position and auto-idle switch turned ON, en-
gine sometimes stalls while operating.
Engine speed is slow in general.
Slow idle speed is excessively slow or fast.

Related Fault Codes: 09, 10

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• If the EC sensor has failed, the governor lever fast Moreover, because the fast idle position may vary
idle position learning will not be performed when the depending on the governor lever position when the
key switch is turned to the ON position. (The slow key switch is turned to the ON position, the trouble
idle position learning will be performed.) For this may not appear constantly.
reason, the fast idle is set referring to the previously
performed fast idle position learning or the preset
fast idle.

YES EC sensor
failure.

• Refer to page
T5-4-40.

Check if fault YES

code 09 or 10 is End
indicated.

Restart engine. Check if Failure of

YES
Check if the governor lever engine unit and
NO trouble comes into fuel system.
disappears. contact with
YES stopper when the
key switch is
Control cable
turned to the ON
failure. Incorrect
position (when
Turn engine engine governor
the slow idle
control dial and NO lever adjustment.
position learning
Torque limiter
monitor EC is performed).
angle. Check if failure.

NO EC angle
changes as
engine speed
changes. EC failure,
harness failure
• Monitor items: between EC
- Engine control motor and EC, or
angle (#9-F6) NO EC Motor Relay
- Selected speed (R7) failure, or
engine (#10-F6) blown fuse No. 2
or No. 3.
T5-4-18 EX455
TROUBLESHOOTING B

E-6 Engine speed does not change with engine

control dial.

Checking Instruction:
• If the above phenomenon occurs after the EC
controller is replaced, EC sensor failure may be the
cause.

Related Fault Codes: 11, 12

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

YES Engine control dial failure,

or harness breakage
between engine control dial

Check if fault code 11 or 12

is indicated. YES
Connect test harness EC motor failure.
(75301706B) to EC motor.
Turn engine control dial and • Refer to page T5-4-40.
check if voltages between
NO terminals 103 and 107 and
EC failure, or harness
between terminals 104 and
breakage between EC and
108 of EC are 8-8,5V.
NO EC motor, or EC Motor
Relay (R7) failure.
EX455 T5-4-19
TROUBLESHOOTING B

E-7 Engine does not stop.

If the engine does not stop with the key switch,

manually move the fuel cut lever to the engine stop
position to stop the engine. Be sure to troubleshoot
after stopping the engine.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

YES
Fuel injection pump failure.

• Refer to the workshop

Check if both the governor
lever and fuel cut lever are
in the engine stop position.
• Key switch: OFF
NO
manual, engine section.
YES
EC motor failure.
Check lack of voltage at
terminal 5 of key switch.

• Key switch: OFF Key switch failure.

NO
(24V)

• How to Stop Engine Manually Fuel Cut Lever Fuel Cut Lever
(Engine Stop Position) (Engine Start Position)
Manually pull the fuel cut lever to the engine stop
(fuel cut) position. The engine will stop.

SM5728
T5-4-20 EX455
TROUBLESHOOTING B

TOTAL ACTUATOR SYSTEM TROUBLE-

SHOOTING

A-1 All cylinders and motors move slowly or do

not move.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• Pilot system (pilot pump, pilot relief valve, pilot
shut-off valve), relief valve circuit, work mode se-
lect switch circuit, or overheat switch L/hydraulic oil
sensor circuit may have failed.

Move pilot
NO control shut-off
lever to
UNLOCK
position.

Check if pilot
control shut-off NO Work mode
lever is in selector failure.
UNLOCK
position.

Remove, NO
End
Check if work disassemble,
mode can be NO clean, and
YES shifted. reassemble pilot
relief valve.
Check if trouble Pilot pump
• Key switch: ON failure.
• Monitor Item: still exists.
Work Mode Check if primary
Selector (#7-F8) pilot pressure is
YES normal. NO Main relief valve
failure.
• Engine speed:
SP mode Check if main
• Refer to relief pressure Check if
Operational YES is normal. letters “ON”
Performance Test for overheat
section for pressure • Monitor items: switch L A
measurement Pump delivery YES turn reverse
procedure. pressure N.1 and N. 2 video.
(#1-F7, #3-F7)
• Refer to Operational
• Key switch: ON
Performance Test
• Monitor item:
section for pressure
Overheat switch (L)
measurement
(#14-F6)
procedure.
Check if YES Overheat of coolant
coolant
and/or hydraulic oil.
temperature
exceeds 98 °C
A (208 °F) or if
hydraulic oil
temperature Check overheat
exceeds 120 °C switch L / hydraulic
(248 °F). NO oil temperature
sensor circuit.
EX455 T5-4-21
TROUBLESHOOTING B

A-2 Cylinders and motors, which are hydrauli-

cally connected to one particular main pump,
move slowly or do not move.

Precondition:
• Be sure inspect wiring connections prior to trouble- • Pump control sensors (DP sensor, A sensor),
shooting. pump control solenoid valve circuit, or main pump
have failed.
Checking Instruction:
• Switching part(s) in 4-spool control valve side with
those in 5-spool side, it can be judged that switched
part(s) have failed if the trouble appears on the
other side.

NOTE - 1 kgf/cm2 = 98.07 kPa

NO
DP sensor failure.
Monitor DP
sensor
NO pressure again
with engine
stopped.
Is it 4 kgf/cm2
Operate one or less?
control lever DP sensor circuit
and monitor YES harness failure.
the • Key switch: ON
corresponding • Monitor items:
DP sensor Differential Pressure YES
(#1-F6, #3-F6) DP sensor failure.
pressure.
Is it 4 kgf/cm2
or less? Switch DP
sensors with
• Engine: Running each other. Insecure or
• Monitor items: YES Check if slower YES incorrect A sensor
Differential Pressure side becomes installation, or A
(#1-F6, #3-F6) normal. Remove A sensor failure
sensor. Check
if slower side
NO becomes • Refer to T5-4-41
normal.

A
NO

Check if target pump

flow rate is the Insecure A sensor
YES installation or the
minimum value with
control levers in corresponding main
neutral. pump failure.
Also, check if target
A pump flow rate is • Refer to T5-4-41
the maximum when
one travel lever is Pump control
operated full stroke solenoid valve
while the NO circuit failure
corresponding track
is jacked up.

• Control levers in neutral:

Minimum value: 54 ± 10 L/rev.
Travel lever full stroke:
Maximum value: 200 ± 10 L/rev.
• Monitor Items:
Desired pump N. 1 and N. 2 displacement
(#2-F6, #4-F6)
T5-4-22 EX455
TROUBLESHOOTING B

A-3 Cylinders and motors do not stop moving

when control levers are returned to neutral.

Checking Instruction:
• Sticking of spools in pilot valve and/or control valve
may be the cause.

YES
Pilot valve failure.

• Pilot pressure has been falsely

Pull up pilot control shut-off routed to the control valve.
lever and check if cylinders
and motors stop moving.

Control valve failure.

NO
• Although pilot pressure was not
routed to the control valve, control
valve spool(s) were open due to
sticking.

A-4 Boom is slow in swing/boom raise combined

operation.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• If operations other than swing/boom raise are
normal, the swing preference circuit may have
failed.

NOTE - 1 kgf/cm2 = 98.07 kPa

NO Swing preference circuit shift

Check if boom speed
changes in swing/boom
raise combined operation
when general purpose mode
and trenching mode are
selected.
• Monitor item:
solenoid valve failure
(Sticking or seizure).
Check if the swing
preference circuit shift
solenoid valve indication
(On) turns reverse video
when swing/ boom raise
functions are operated
simultaneously.
Harness breakage between the
PVC and swing preference
Swing/Boom Operation Signal YES circuit shift solenoid valve.
(#6-F8)
EX455 T5-4-23
TROUBLESHOOTING B

A-5 SP mode cannot be activated with SP mode

switch.
(Other controls are normal.)

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• If only SP mode is the one does not function,
related switches or controller may have failed.
• Refer to “SP Mode Control” in the Control System
Group, the SYSTEM section, the Operation Princi-
ple book.

NO SP mode switch failure, or

harness breakage between SP
mode switch and PVC.
Monitor SP mode switch.
Operate SP mode switch
and check if the letters
“On” turn reverse video.

• Monitor item: PVC failure.

SP Mode Signal (#8-F8) YES

A-6 E mode cannot be activated with E mode

switch.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• Refer to “E Mode Control” in the Control System
Group, the SYSTEM section, the Operation Princi-
ple book.

NO E mode switch failure, or

harness breakage between E
mode switch and PVC.
Monitor E mode switch.
Operate E mode switch
and check if the letters
“On” turn reverse video.
PVC failure.
• Monitor item:
YES
E Mode signal (#8-F7)
T5-4-24
A-7 Cylinder or motor responsiveness is slow.
While monitoring
pump displacement angle
value, operate
corresponding control
lever and measure time
lag between lever opera-
tion and change in
displacement angle value.
• Monitor items:
Approx Pump N. 1 and N. 2
Displacement (#1-F8, #3-F8)
EX455
TROUBLESHOOTING B
More than 1 second.
Pump servo piston mechanism
failure.
More than
1 second. Pilot system failure (Excessive
drop in pilot pressure, pilot
valve failure, etc.)
Operate the slow
responding lever and
measure time lag between
lever operation and the
Less than moment the
1 second. corresponding pressure
switch letters turn into
reverse video. Control valve failure.
Less than
• Monitor items: 1 second.
Pressure switch (#8-F6)
EX455 T5-4-25
TROUBLESHOOTING B

FRONT ATTACHMENT SYSTEM TROUBLE-

SHOOTING

F-1 Front attachment cylinder(s) move slowly or

do not move.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• The corresponding pilot valve, overload relief
valve, or pressure switches may have failed.
• If only boom raise in swing/boom raise combined
operation is slow, go to troubleshooting A-4.

NO
Pilot valve failure.

Check if corresponding
secondary pilot pressure is NO Corresponding overload relief
normal. valve failure.

• Refer to Operational
Performance Test section
for pressure measurement
procedure.
Check if corresponding
overload relief pressure is
YES normal.
• Refer to Operational
Performance Test section Control valve failure (sticking,
for pressure measurement etc.)
YES
procedure.
T5-4-26 EX455
TROUBLESHOOTING B

F-2 Bucket drops excessively.

YES
Normal.

Damaged control
NO valve spool,
Remove holding broken spring, or
check valve and Check if loose spool end.
holding check YES excessive
Check if valve shift valve cylinder internal
cylinders for drift from control leakage exists.
Cylinder sealing
quantity. Are drift YES valve. failure.
values within the Disassemble, YES
specifications? clean,
reassemble, and
• Refer to Failure of holding
Replace the reinstall them.
Operational check valve or
overload relief Check if bucket
Performance Test NO holding valve
valve(s) for still drops shift valve.
section for cylinder
cylinder(s) which excessively.
drift measurement
procedure. shown excessive • If holding valve shift valve is sticking:
drift, with one(s) Arm cylinder: Roll-out: Operable
NO from other Roll-in: Inoperable
function(s). Boom cylinder:Raise: Operable
Check if Lower: Inoperable
excessive • If holding check valve has failed, responsiveness of both the arm
cylinder drift is and boom becomes slow.
still observed.

Overload relief
NO valve failure.

F-3 In the beginning of front attachment opera-

tion (boom raise, arm roll-out or bucket
open), bucket drops slightly.

NO Damaged control valve spool,

broken spring, or loose spool
YES end.
Check if excessive cylinder
internal leakage is found.

Cylinder sealing failure.

Check if load check valve YES
located in control valve is
normal.

• Disassemble and visually check.

Load check valve failure.
NO
EX455 T5-4-27
TROUBLESHOOTING B

• Boom Cylinder Internal Leakage Check

1. With the bucket cylinder fully retracted and the arm

cylinder slightly extended from the fully retracted
position, lower the bucket tooth tips onto the
ground.

2. Disconnect hoses to the boom cylinder rod side. SM0636

Then, drain oil from hoses and cylinders. (Plug the

disconnected hose ports.)

3. Retract the arm cylinder to lift the bucket above the

ground.

At this time, if oil flows out of the pipes from which

the hoses were disconnected and the boom cylin-
der is retracted, internal leakage in the boom cylin-
der exists.
If no oil flows out of the pipes from which the hoses
were disconnected but the boom cylinder is re-
tracted, internal leakage in the control valve exists.

NOTE - 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve is
malfunctioning, the oil in the bottom side of (B)
the boom cylinder flows back into the
circuit through the load check valve, caus- When the load check
ing the boom cylinder to temporarily re- valve is malfunctioning:
tract. (A)
2. If the clearance between the piston and
the cylinder barrel is poor, oil pressure in
the bottom side (A) leaks to rod side (B).
As oil pressure and flow rate from the
pump is low during the initial stage of
operation, and if the amount of oil leaking
through the gap between the piston and SM0635

the barrel is large, the cylinder is tempo-

rarily retracted. In addition, cylinder force
is reduced. In this case, the cylinder drift is
also increased.
T5-4-28 EX455
TROUBLESHOOTING B

F-4 Power does not increase with power boost

switch turned on.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• Refer to the heading “Power Boost” in the Control
System group, the SYSTEM section, the Technical
Manual (Operating Principle).

NOTE - 1 kgf/cm2 = 0.09807 MPa

Pressure increases
from 300 kgf/cm2 or
less to 325 kgf/cm2.
Normal.

Power boost
switch failure or
Monitor delivery harness
NO
pressure for breakage
pumps 1 and 2. between power
boost switch and
• Monitor items: PVC.
Pump 1 and 2
delivery pressure Monitor power
Disconnect the
(#1-F7, #3-F7) boost switch.
harness end from YES Solenoid valve
• Push the power Check if the
solenoid valve SA failure.
boost switch to letters “ON” Pressure SA. Connect test
monitor change turn reverse does not harness
in pressure. video when the change. (75301706A)
Pressure power boost
between solenoid
does not switch is
valve SA and the
increase. pressed. Harness failure
harness end. between
Measure the Check the
• Monitor items: solenoid valve
pilot pressure at voltage with a NO
Power Boost switch SA and PVC.
solenoid valve tester.
(#7-F6) SA port in the
YES solenoid valve • Power boost switch: ON
unit (3 solenoid
valves used).

• Push the power

boost switch to Main relief valve
observe pressure Pressure changes from failure.
change. 0 to max. 40 kgf/cm2.
• Refer to the
PERFORMANCE
TEST section for
the measurement
procedure.
EX455 T5-4-29
TROUBLESHOOTING B
T5-4-30 EX455
TROUBLESHOOTING B

SWING SYSTEM TROUBLESHOOTING

S-1 Upperstructure does not rotate, rotates

slowly, or swing power is weak.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• If other functions (front attachment and travel)
operate normally, the pilot pump is considered to
be normal. If the pilot system has failed, the trouble
exists in the pilot circuit after the pilot pump (the
pilot valve and thereafter).

Check if swing
YES
relief pressure is
normal.

• Refer to Operational
Check if oil Performance Test
YES quantity draining section for swing
from swing relief pressure
motor is normal. measurement
Monitor DP procedure.
sensor pressure.
Operate control • Refer to Operational
YES lever slowly to Performance Test Swing motor
the stroke end section for swing failure.
NO
and check if DP motor draining oil
sensor pressure quantity measurement
changes procedure.
smoothly.
Check if Control valve
• Monitor item: spool sticking.
secondary pilot Differential Pressure NO
pressure is (#3-F6)
normal.
NO Pilot valve
• Refer to failure.
Operational
Performance Test Disassemble,
section for clean, and
secondary pilot reassemble the
pressure NO pilot valve. Check
measurement if the trouble still
procedure. exists.
Check if sticking
or seizure exists
in swing shuttle
YES valve.
EX455 T5-4-31
TROUBLESHOOTING B

NOTE - 1 kgf/cm2 = 98.07 kPa

Failure of swing
YES overload relief
Switch swing
motor relief valve valve located in
with the other control valve.
NO
swing relief
valve. Check if
the trouble still Corresponding
exists. swing relief
NO valve failure.

Swing reduction
gear failure.
YES

YES Swing shuttle

valve failure.

Swing
preference
NO circuit shift
Check if the swing solenoid valve
preference circuit failure (sticking
shift solenoid valve or seizure).
indication (On) turns
reverse video when
NO swing/boom raise Harness
functions are breakage
operated between the
simultaneously. PVC and swing
YES preference
• Monitor item: circuit shift
Swing/Boom operation solenoid valve.
signal (#6-F8)
T5-4-32 EX455
TROUBLESHOOTING B

S-2 Upperstructure coasts excessively when

stopping swing operation or when machine
is parked on a slope.

Checking Instruction:
• If upperstructure jerks when coasting, valve re-
lated failure is suspected. If it coasts smoothly (but
excessively), spool related failure is suspected.

YES
Swing motor failure.
Monitor DP
sensor pressure.
Operate control
YES lever slowly to
the stroke end
and check if DP
sensor pressure
changes
Check if swing
smoothly.
secondary pilot
YES pressure is Swing spool failure.
0 kgf/cm2 with • Monitor item: NO
swing lever in Differential pressure
neutral. (#3-F6)

• Refer to Operational
Performance Test
Check if swing Pilot valve failure.
section for swing NO
relief pressure is secondary pilot
normal. pressure
measurement
• Refer to procedure.
Operational
Performance Test Failure of overload
section for relief valve in control
secondary pilot NO valve, or swing relief
pressure valve failure.
measurement
procedure.
EX455 T5-4-33
TROUBLESHOOTING B

TRAVEL SYSTEM TROUBLESHOOTING

T-1 Both tracks move slowly.

Checking Instruction:
• It is unlikely that both sides (left and right) of the pilot Note, however, that the front attachment operation
valves, travel motors, or travel control valve spools will also have difficulty if the primary pilot pressure
fail simultaneously. If both tracks are slow, the pilot is abnormal. (Refer to troubleshooting A-1.)
system which is commonly used for left and right
travel motors may have failed.
NOTE - 1 kgf/cm2 = 98.07 kPa

Restriction of filter located

NO
at outlet of pilot shut-off
valve.

Check if pilot valve inlet

pressure is normal. NO
Travel pilot valve failure.
• Engine: Running Check if secondary travel
• In SP mode: pilot pressure is normal.
YES Go to Troubleshooting A-1.
more than 40 kgf/cm2
• Engine: Running Switch swing motor relief
YES
• In SP mode:
more than 35 kgf/cm2
T-2 Travel mode does not shift.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• The switch circuit may have failed if the travel mode If the indicator shifts but actual travel mode (speed)
indicator does not shift in accordance to the travel does not shift, the travel motor displacement angle
mode switch operation. shift circuit may have failed.

NOTE - 1 kgf/cm2 = 98.07 kPa

Switch failure, or
NO harness
breakage
between switch
and PVC.
Check if monitor
indicates Hi and
Lo alternately NO PVC failure.
when travel
mode switch is
operated.
Check if travel Travel mode
• Monitor items: mode shift shift solenoid
Travel Mode Switch solenoid valve valve failure, or
shifts as travel NO harness failure
(#7-F7) YES
• Key switch: ON mode switch is between PVC
operated. and travel mode
shift solenoid
• Monitor item: Check if travel valve.
Travel Mode Shift mode shift
Signal (#6-F6) YES pressure (SB) is
normal. Travel motor
YES displacement
• SP mode Check if sticking angle shift valve
• Auto-idle: OFF or seizure exists failure.
• Refer to in travel motor
Operational YES displacement Failure of travel
Performance Test angle shift valve. motor or travel
section for NO reduction gear.
SB pressure
measurement
procedure.
T5-4-34 EX455
TROUBLESHOOTING B

T-3 Machine mistracks.

Precondition: Checking Instruction:

• Be sure inspect wiring connections prior to trouble- • Refer to troubleshooting A-2 if swing or bucket
shooting. function is slow in addition.
• The flow combiner valve may have failed if ma-
chine mistracks only during front attachment func-
tion combined operations.

NO
Disassemble, clean, Shuttle valve failure.
NO and reassemble
travel shuttle valve.
Check if the trouble
still exists. Pilot valve failure.
YES
Check if
secondary travel
pilot pressure is NO
Operate left and DP sensor failure.
normal. right travel levers
the same distance
• SP mode and check if pump
• Travel lever: target YES
ful stroke displacement Switch the P P sensor failure.
• Refer to Operational YES
angle on 5-spool sensor on
Performance Test side is the same 5-spool side with
section for travel as that on 4-spool that on 4-spool
secondary pilot side. side. Check if Switch the left and
pressure YES machine right travel hoses
measurement mistracks in the with each other at
• Monitor item:
procedure. Desired pump 1 and 2 opposite the upper side of
displacement direction. center joint.
(#2-F6, #4-F6) NO Check if machine
mistracks
to the opposite
direction.

Relation between Faulty Seal Position

and Mistrack Direction Seal Location

Seal Traveling Pivot Turn

NO. 1
2
1 External oil leakage ←

2
Right Travel
(Reverse)
Left Travel
3 (Forward) 3
Right Travel
(Forward)
Left Travel
4 (Reverse) 4
5
5 6

6
7
7 External oil leakage ←

SM6718
EX455 T5-4-35
TROUBLESHOOTING B

Disassemble, NO Control valve

clean, spool sticking.
reassemble
YES corresponding
spool in control Control valve
valve. Check if failure (internal
the trouble still leak), A sensor
exists. YES failure, or main
pump failure.

YES Travel relief

Switch the right and left travel
valve failure.
NO relief valves with each other.
Check if machine mistracks in
the opposite direction. Center joint
NO failure.
Check if
slowerside travel
relief pressure is NO Travel motor
NO
normal. failure.
Check if quantity
• Refer to of oil draining Disassem- YES
Operational Travel brake
YES from travel motor ble travel
Performance Test valve failure.
is normal. motor brake
section for travel valve and
relief pressure • Refer to check if any YES Travel motor tilt
YES Remove travel
measurement Operational abnormali- motor tilt pistons piston failure.
procedure. Performance Test ties are and check if any
section for travel found. NO abnormalities are Travel reduction
motor drain oil found.
NO gear failure.
quantity
measurement
procedure.

Travel Hose Connections

2
1 3
4

1 - Left Travel Reverse

2 - Left Travel Forward
3 - Right Travel Reverse
4 - Right Travel Forward
5 - Pilot Hose (Travel Mode Shift)
6 - Drain Hose

6
5
SM6719
T5-4-36 EX455
TROUBLESHOOTING B

TROUBLESHOOTING FOR OTHER FUNC-

TIONS

O-1 Work mode does not shift.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

Checking Instruction:
• The work mode switch may have failed if the work
mode indicators do not shift with the work mode
switch. The pressure switch or solenoid valve may
have failed if the work mode indicators shift but
actual work mode does not shift.

YES
Monitor work mode
switch. Check if
work mode letters
turn reverse video • Monitor item:
when work mode
switch is operated.
• Monitor item:
Work mod selector
(#7-F8)
NO
YES
Monitor pressure
switches (travel,
swing, boom raise,
arm roll-in, and
others).
Check if letters
“Bm”, “Tr”, “Sw”,
“Am”, and “Ot”
turn reverse video
when respective
control lever is
operated.
NO
Pressure switch
(#8-F6)
Disconnect the
harness end from
swing preference YES
circuit shift solenoid Solenoid valve
valve, solenoid valve, failure.
and main relief
pressure shift solenoid
valve one by one.
Connect test harness
(75301706A) between Harness breakage
between solenoid
each solenoid valve
and harness end, and NO valve and PVC.
check if voltage is
power on.
Disconnect the YES Pressure switch
harness end from failure.
each pressure switch
one by one.
Connect test harness
(75301706A) between
each pressure switch
and harness end, and Harness breakage
check if voltage is between PVC and
power on. NO pressure switch.
Work mode switch
failure.

NOTE -

Work Mode Designed Application

General Purpose Mode Designed for general digging and truck loading.

Attachment Mode Select this mode when using breakers.

Precision Mode All front functions are slow for easy load lifting work.

Trenching Mode Swing is given priority in swing/boom raise combined operation.

EX455 T5-4-37
TROUBLESHOOTING B

O-2 Pump emits abnormal sound or vibration.

Precondition:
• Be sure inspect wiring connections prior to trouble-
shooting.

YES Main pump

failure.

YES Main pump

Check if Check if failure.
indicated indicated pump
pump differential
displacement YES
pressure and
angle value pump pressure NO DP sensor or P
stays stable. values stay sensor failure.
Replace the
stable. sensor obtained
• Monitor items: unstable values
Approx pump 1 Check if A sensor • Monitor items: NO and check if the
and 2 is installed Differential pression trouble still exists. Main pump
displacement NO securely. and Pump delivery failure.
(#1-F8, #3-F8) • Replace DP YES
pressure pump 1
• Refer to T5-4-41. and 2 sensor and/or P
(#1-F6, F7 sensor.
#3-F6, F7) Insecure A
sensor
NO installation.

• Refer to T5-4-41.
T5-4-38 EX455
TROUBLESHOOTING B

O-3 Wiper does not operate or does not retract.

Related Fault Code: None

Checking Instructions
• The wiper is controlled by a wiper box in which the
relay circuit are operated by the monitor panel.
• When the wiper does not work, check first that the
motor and the relevant linkage are operative, using
an auxiliary power source and the test herness.
• If the wiper motor works properly when is powered
throught the test harness, check the upper latch of
front window and wiper cut-off switch for proper
operation.
• The windshield wiper motor and washer pump con-
trol relays are moulded inside the wiper controller
and cannot be replaced. The wiper controller must
be considered as an assembly.

YES Faulty wiper box.

Remove the test

harness and
YES reconnect the
disconnected
harness to the YES End
As illustrated to the original position.
Replace the
right, connect test
monitor assembly.
harness • Key switch: ON Check if wiper
(75301706C) NO
operates. Faulty cab
between power
outlet and wiper NO harness
motor. Check if
wiper operates.

• Key switch: ON
NO, or lamp
does not light
normally.
YES Faulty wiper
motor or link
NOTE - When the wiper motor is
normal, lamp S comes ON while Check correct
the wiper is moving within the operation of wiper
cut-off switch.
operating range. Then, only when
the wiper reaches the intermittent Faulty wiper cut-
stop position, both lamps B and S NO off switch.
light for a moment at the same
time.
EX455 T5-4-39
TROUBLESHOOTING B

• Electrical Circuit When Test Harness is Connected.

Power outlet

Led
Lamp S

Wiper Motor
Led Lamp B

Ground

SM6736

• Wiper’s Operating Range

Intermittent Stop Position

Retracted Position

Wiper Range

SM0641

• Test Harness Connection

Led Lamp B

Led Lamp S
Wiper Motor

To power
outlet

Test Harness

SM6737
T5-4-40 EX455
TROUBLESHOOTING B

EC SENSOR INSTALLATION AND VOLTAGE

ADJUSTMENT
Control Cable
1. Install M8 bolt into the T link positioning hole. Note
that this position will be the idle position.
2. Temporarily connect EC sensor at the middle of the
EC sensor mounting slit. Connect the connector.
3. Connect Dr. EX to the monitor terminal. Install test
harness (75301706D) between EC sensor and
harness.
4. Turn the key switch to the ON position. Turn the
engine control dial to the slow idle position. Meas-
ure the EC sensor output voltage using Dr. EX or a
digital type tester.
5. Adjust EC sensor position so that the output volt-
age is within the specified range. Secure EC sen-
sor.
Specified Voltage: 2.50±0.05 V
T Link Positioning Hole T Link

SM6720
EX455 T5-4-41
TROUBLESHOOTING B

INSTALLATION AND ADJUSTMENT OF THE Pump 2

A Sensor
A SENSOR (PUMP DISPLACEMENT (Pump 2
SENSOR) Displacement
Sensor)
Removal
1. Put matching mark on the A sensor (Pump dis-
placement sensor) and pump housing. Remove the
A sensor connector from its harness.

2. Remove two A sensor mounting bolts (1) and

washers (2).

3. Remove the A sensor (Pump displacement sen- Pump 1

sor). Take care not to lose internal spacer (3) and A Sensor
fastener spring (4). O-ring (5) is provided on the A (Pump 1
Displacement
sensor side. Sensor)
1
Installation and Adjustment
1. Apply a film of grease to the surface of fastener
spring (4) and install it into the cavity on the
feedback shaft end.

2. With the key switch turned OFF, connect the

connector of the A sensor. Then, connect the Dr.
EX to the diagnosing connector located in the
operator’s cab.

3. Start the engine and operate it in the slow idle

speed. Maintain hydraulic oil temperature at
SM6721
50±5 °C (122±9 °F).

4. Operate the Dr. EX. Select information for “A 3

Sensor Mounting Angle Adjustment” (Push F3 key).
Then, increase displacement angle to the maxi-
mum by pushing F1 key on the next display. Wait 4
about one second. The pump displacement angle is
set to the maximum.

5. Select information for “Monitor Data”. Then, push

F8 key to indicate the approx. Pump displacement
(D4 or D5) on the next display.

6. Before installing the A sensor to the pump, turn the

punch mark on the A sensor shaft towards the SM6722
opposite side of the harness so that the reading of
the Dr.EX display indicates 200 ± 10 mL/rev.

7. Insert the A sensor shaft into the feedback shaft

and tentatively tighten bolts (1). The bolt holes of
the A sensor are made in a ellipse form. Adjust the
A sensor position using ellipse holes so that the
reading of 1-F8 (D4) and/or 3-F8 (D5) on the Dr. EX
display indicates 200 ± 10 mL/rev.
5
8. Tighten bolts (1) and washers (2) to 9.8 N⋅m
(1.0 kgf⋅m, 7.2 lbf⋅ft).
Punch Mark 3
4 Feedback Shaft
SM6740
T5-4-42 EX455
TROUBLESHOOTING B

NOTES
EX455 T5-5-1
TROUBLESHOOTING C

TROUBLESHOOTING C
(TROUBLESHOOTING FOR MONITOR)
PROCEDURE

Use troubleshooting C when any monitors, such as

gauges or indicators malfunction.

• How to Read Troubleshooting Flow Charts

YES(OK)
(2)

• After checking or measuring item (1), select either YES (OK) or NO

(1)
(NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO (NOT OK)

• Special instructions or reference item are indicated in the spaces under the box. Incorrect
measuring or checking methods will render troubleshooting impossible, and may damage
• Key switch: ON components as well.

• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes
can be seen without going through the flow chart.

NOTE - For all connector drawings illustrated in this

group, harness end connector terminals seen from
the open end side are shown.

Wire Harness Side

Open End
Side Harness End Connector

SM0646
T5-5-2 EX455
TROUBLESHOOTING C

MALFUNCTION OF COOLANT
TEMPERATURE GAUGE

Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.

YES
Remove coolant
temperature sensor
Gauge pointer does not
terminal, ground harness
move at all. (It does not rise
side terminal to vehicle.
from zero.) With sensor terminal
Does pointer swing to the
(H) side? disconnected, remove 20P
NO connector from monitor, and
• Key switch : ON check continuity between
terminal No.47 and sensor
terminal.

YES

When removing coolant NOT OK

Gauge pointer swings over temperature sensor, does (Continuity)
scale. pointer swing back to With sensor terminal
zero? disconnected, remove 20P
connector of monitor, and
• Key switch : ON NO check continuity between
harness side terminal and
ground.
OK
(No continuity)

Remove coolant YES

temperature sensor
terminal, and ground
Gauge pointer swings
unstably. harness side terminal to
vehicle. Does the pointer
swing to [H] side, and
stably? NO
• Key switch : ON
EX455 T5-5-3
TROUBLESHOOTING C

Approximate Temperature on Coolant Temperature

Gauge

105 °C (221 °F)

95 °C (203 °F)

Faulty coolant temperature 70 °C (158 °F)

sensor.
OK
(Continuity) Failure in monitor.

Faulty harness (breakage)

NOT OK between monitor and
(No continuity) sensor.
SM0647

Coolant Temperature Sensor

Coolant Resistance
Faulty coolant temperature Temperature
sensor.
(50 °C) (153.9 Ω)
Faulty harness (short circuit) (122 °F)
between monitor and 80 °C 51.9±10 Ω
sensor.
(176 °F)
Failure in monitor. 100 °C 27.4±4 Ω
(212 °F)
(120 °C) (16.1 Ω)
(248 °F)

NOTE - The value indicated in parentheses is only

a reference value.
Faulty coolant temperature
sensor.

Failure in monitor.

Connector (harness end connector terminals seen

from the open end side)

Monitor (20P)

29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
T5-5-4 EX455
TROUBLESHOOTING C

MALFUNCTION FUEL GAUGE

Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.

Gauge pointer does not
swing. (It does not rise from
zero.)
• Key switch : ON
YES
Remove connector of fuel
sensor, short-circuit
terminals C and A of
harness side connector by
using a jumper wire. Does With sensor connector
pointer swing to (FULL) disconnected, remove 20P
side? connector of monitor, and
NO
check continuity between
terminal No.46 of monitor
and terminal C of fuel
sensor.

YES

When fuel sensor NOT OK

Gauge pointer swings over connector is removed,
scale. does pointer swing back to
zero?
• Key switch : ON
(Continuity)
With sensor connector dis-
connected, remove the 20P
connector of monitor, and
NO check continuity between
terminal C of harness side
connector and ground.
OK
(No continuity)

Remove connector of fuel YES

sensor, and short-circuit
terminals C and A of
Gauge pointer swings
unstably. harness side connector by
using jumper wire. Does
pointer swing to [FULL] side,
and stably? NO
• Key switch : ON
EX455 T5-5-5
TROUBLESHOOTING C

Fuel Sensor 1 mm=0.03937 in

Float

FULL

257 mm
3/4

22°
138.6 mm
R370
33°
Faulty fuel sensor.
70.5 mm
OK
(Continuity) Failure in monitor. 27°
1/2
228 mm 28°

1/4 Resistance
292 mm
Faulty harness (breakage) Reserve
NOT OK between monitor and fuel 338 mm
sensor. EMPTY
(No continuity)
SM0648

Float Resistance (Ω)

Faulty fuel sensor.
FULL 10+0
-4

3/4 26
Faulty harness (short- 1/2 38±5
circuit) between monitor and
fuel sensor. 1/4 53
EMPTY 90+100
Failure in monitor.

Connector (harness end connector terminals seen

from the open end side)

Faulty fuel sensor. Monitor (20P)

Fuel Sensor

29 30 31 32 33 34 35 36 37 38
Failure in monitor. 39 40 41 42 43 44 45 46 47 48 C B A

C
Level signal
B
Reserve signal
A
Ground
T5-5-6 EX455
TROUBLESHOOTING C

MALFUNCTION OF FUEL LEVEL

INDICATOR (RESERVE)

Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.
YES

With fuel sensor

connector
removed, short
Reconnect fuel
YES circuit terminals B
level sensor
and A of harness connector
Although fuel side connector by
Check if indicator Remove 12P
gauge pointer using a jumper
comes ON when connector of
shows E, the wire. Does
indicator does key witch is monitor, and
turned ON indicator light? NO
not come ON. check continuity
• Key switch : ON between terminal
• Key switch : ON No.2 of connector
and vehicle
ground.

NO

YES

Check if indicator
Even if fuel is in goes OFF when
tank, the indicator fuel level sensor Disconnect fuel
comes ON. connector is NOT OK (Continuity)
level sensor
removed. connector and
12P connector of
• Key switch : ON monitor, and
NO check continuity
between terminal
No.2 of connector
and vehicle OK (No Continuity)
ground.
EX455 T5-5-7
TROUBLESHOOTING C

Faulty fuel level

sensor.

YES Failure in
monitor.

Faulty harness
(breakage)
between monitor
and low fuel level
NO
switch.

Burned out
indicator light.

Faulty fuel level

sensor.

Faulty harness
(short circuit)
between monitor
and fuel level
sensor.

Failure in
monitor.

Connector (harness end connector terminals seen

from the open end side)

Monitor (12P)

1 2 3 4 5 6
7 8 9 10 11 12
T5-5-8 EX455
TROUBLESHOOTING C

MALFUNCTION OF INDICATOR LIGHT

CHECK SYSTEM

Precondition:
Check power line.
• Be sure to inspect wiring connections prior to
• Fuse
troubleshooting. • Disconnect 20P monitor
YES
connector. Then, check
continuity between harness
side terminal No.30 and
Indicator does not come ON
Check if all indicators do not fuse terminal No.9.
when indicator light check
come ON.
switch is turned ON.
Perform troubleshooting for
the individual indicator which
NO does not come ON.

Connector (harness end connector terminals seen

from the open end side)

Monitor (20P)

29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48

MALFUNCTION OF LEVEL CHECK SWITCH

Process to be taken:
• This troubleshooting is applied when only the level
check switch malfunctions.
If power is not supplied at all when key switch is
turned ON, or indicator does not come ON when
indicator light check is conducted, perform trouble-
shooting for these failures first.

Precondition:
• Park the machine on a level surface.
• Be sure to inspect wiring connections prior to
troubleshooting.

YES Faulty level

switch or harness
(breakage).
YES Check if oil and
coolant levels are
Check if indicator correct.
does not come Check if all Refill engine oil,
ON when level indicators do not hydraulic oil, or
NO coolant.
check switch is come ON.
depressed.
Perform
troubleshooting
for individual
NO indicator which
does not come
ON.
EX455 T5-5-9
TROUBLESHOOTING C

MALFUNCTION OF PREHEAT INDICATOR

Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.

Reference:
• The preheat system operates when the coolant
temperature is 10 °C (50 °F) or lower.
• During preheat operation, the preheat indicator
stays ON for 8 seconds.

YES
Faulty QOS controller

Preheat indicator Check if preheat Short-circuited harness

comes ON even if indicator goes OFF With QOS controller YES
between QOS controller and
preheat system is when QOS controller disconnected, remove
monitor.
not in operation. is disconnected. 20P connector from
monitor. Check for
• Key switch : ON continuity between
NO monitor harness end
connector terminal
No.43 and vehicle
frame. Faulty monitor.
NO

YES
With QOS controller
disconnected, ground
Preheat indicator
harness end con-
does not come ON
nector terminal No.6
during preheat op-
to vehicle frame.
eration.
Check if preheat indi-
cator comes ON.
• Key switch : ON NO
• Without disconnecting
Faulty QOS controller
YES Broken harness be-
With QOS controller
tween QOS control-
disconnected, remove
ler and monitor.
20P connector from
monitor. Check for
continuity between
monitor harness end
connector terminal
No.43 and vehicle
frame. Faulty monitor.
NO
the connector, insert a
jumper wire such as a
clip into the back of the
connector and ground
to the vehicle frame.

Connector (harness end connector terminals seen

from the open end side)

Monitor (20P) Q.O.S. Controller

29 30 31 32 33 34 35 36 37 38 3 2 1
39 40 41 42 43 44 45 46 47 48 6 5 4
T5-5-10 EX455
TROUBLESHOOTING C

MALFUNCTION OF ENGINE OIL LEVEL

INDICATOR

Precondition:
• Indicator light is not burned out.
• Other indicators work correctly.
• The machine is parked on a level surface.
• Be sure to inspect wiring connections prior to
troubleshooting.

YES
With engine oil level
switch disconnected,
Indicator does not check continuity
come ON even if the between engine oil
level check switch is level switch
depressed. connector and
vehicle frame.
YES
Reconnect engine oil
level switch. Discon-
nect 12 P connector
from monitor. Check
for continuity be-
tween harness end
terminal No. 7 and
vehicle frame.
NO

NO

With engine oil level

switch disconnected,
disconnect 12P con-
YES nector from monitor.
Check for continuity
Disconnect engine
Lower than 3 mm between harness
oil level switch.
below LOW level Check if indicator end terminal No.7
and vehicle frame.
comes ON when
Indicator comes ON level check switch is
even if oil level is depressed.
lower than the Check oil level with oil
specified level when level gauge.
level check switch is NO
depressed.

Higher than 3 mm
below LOW level
EX455 T5-5-11
TROUBLESHOOTING C

Engine Oil Level Switch

Faulty in monitor.

H (Indicator
ON)
L
Broken harness be-
tween engine oil level
3 mm (Indicator
switch and monitor.
(0.12 in) OFF)

Faulty engine oil level SM6723

switch.

Connector (harness end connector terminals seen

from the open end side)
YES Short-circuited harness
between engine oil level Monitor (12P)
switch and monitor.

1 2 3 4 5 6
7 8 9 10 11 12
Faulty monitor.
NO

Faulty engine oil level

switch.

Normal.
T5-5-12 EX455
TROUBLESHOOTING C

MALFUNCTION OF COOLANT LEVEL

INDICATOR

Precondition:
• The bulb of the coolant level indicator has not blown.
• Other indicators are functioning normally.
• Park the machine on a level surface.
• Be sure to inspect wiring connections prior to
troubleshooting.

Reconnect
coolant level
switch 3P
connector. YES
Disconnect 12P
YES connector from
monitor. Check if
continuity exists
Disconnect between harness
coolant level end 12P connec-
NO
Coolant level switch 3P tor terminal No. 8
indicator does not connector. Check and vehicle
come on when if continuity exists frame.
level check between coolant
switch is pressed. level switch 3P • Be sure that coolant
connector level switch 3P
terminals. connector is
reconnected.

NO

With coolant level

switch connector
disconnected,
disconnect 12P
connector from
YES monitor. Check if
Disconnect continuity exists
coolant level between harness
switch end 12P
YES connector. connector
Press level terminal No.8
check switch. and vehicle
Although coolant Check if coolant frame.
is insufficient,
Check if coolant level indicator
coolant level comes on.
indicator comes level on reservoir
is lower than NO
on when level
check switch is LOW mark.
pressed.

NO
EX455 T5-5-13
TROUBLESHOOTING C

Coolant Level Switch

Reservoir

Monitor failure.
ON
FULL

Harness breakage. LOW

Radiator
OFF

SM6738

Coolant level switch failure.

Connector (harness end connector terminals seen

from the open end side)
YES Short circuit between
coolant level switch and
monitor Monitor (12P)

1 2 3 4 5 6
7 8 9 10 11 12
NO Monitor failure.

Coolant Level Switch

Coolant level switch failure.

1 2

Normal.
T5-5-14 EX455
TROUBLESHOOTING C

MALFUNCTION OF HYDRAULIC OIL LEVEL

INDICATOR

Precondition:
• The bulb of the hydraulic oil level indicator has not
blown.
• Other indicators are functioning normally.
• Park the machine on a level surface.
• Be sure to inspect wiring connections prior to
troubleshooting.

Reconnect
hydraulic oil level
switch 2P
connector. YES
Disconnect 12P
YES connector from
Disconnect
monitor. Check if
hydraulic oil level
continuity exists
switch 2P
between harness
Hydraulic oil level connector.
end 12P
indicator does not Check if NO
connector
come on when continuity exists
terminal No. 9 and
level check between
vehicle frame.
switch is pressed. hydraulic oil level
switch 2P
connector
terminals.
NO

With hydraulic oil

level switch
connector
disconnected,
disconnect 12P
connector from
YES monitor. Check if
Disconnect continuity exists
hydraulic oil level between harness
switch end 12P
NO connector. Press connector
level check terminal No.9
Although switch. Check if and vehicle
hydraulic oil is hydraulic oil level frame.
insufficient, Check oil level on indicator comes
hydraulic oil level the level gauge. on.
indicator comes Check if oil can
NO
on when level be seen on the
check switch is level gauge.
pressed.

YES
EX455 T5-5-15
TROUBLESHOOTING C

Hydraulic Oil Level Switch

1 mm=0.03937 in

ON

6.2 mm

Failure OFF
in monitor.

Broken harness
between hydraulic
oil level switch SM0650
and monitor

Connector (harness end connector terminals seen

Faulty hydraulic
oil level switch.
from the open end side)

Monitor (12P) Hydraulic Oil Level Switch

Short-circuited
YES harness between
1 2 3 4 5 6
hydraulic oil level 1 2
7 8 9 10 11 12
switch and
monitor

Failure in
NO monitor.

Faulty hydraulic
oil level switch.

Normal
T5-5-16 EX455
TROUBLESHOOTING C

MALFUNCTION OF ALTERNATOR
INDICATOR

Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.

NOTE - (*) Regulator terminals L is water-resistance

type connectors so that it is not practical to measure
voltage at these terminals. Measure voltage at starter
relay terminal R.
Before measuring voltage, check continuity between
the starter relay terminal R and regulator terminal L.
13 V or higher

13 V or Measure voltage at
higher monitor 20 P
connector terminal
No.42.

• Engine: Running
Alternator
Measure voltage
indicator does not
go off after at regulator Less than 13 V
terminal L.
engine is started.
• Engine: Running

Less than
13 V

Less than 10 V.

YES Check voltage at

regulator terminal L
(*).
• Key switch: ON
Although Check if indicator • Engine: Stopped
alternator output comes on when
is low, alternator key switch is
indicator does turned to ON po-
not come on. sition. 10 V or more

• Key switch: ON

NO
EX455 T5-5-17
TROUBLESHOOTING C

Connector (harness end connector terminals seen

Faulty monitor.
from the open end side)
Starter Relay

E
S R
Harness breakage
between regulator
terminal L and
monitor terminal Monitor (20P)
No.42.
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
Faulty regulator or
faulty alternator.

Faulty monitor.

Faulty regulator.

Blown indicator bulb.

T5-5-18 EX455
TROUBLESHOOTING C

MALFUNCTION OF ENGINE OIL

PRESSURE INDICATOR

Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.

YES

With engine oil

pressure switch
YES disconnected, check
if indicator comes
ON when terminal
of wire number 33 is
grounded to vehicle.
Although engine Check if indicator NO
oil pressure is comes ON when • Key switch: ON
lower than key switch is
specification, turned to ON
indicator does position.
not come ON
• Key switch: ON
• Key switch: ON

NO

YES

Check if indicator
Indicator stays goes OFF when
ON after engine engine oil
is started. pressure switch is
disconnected.
• Check if oil filter is
clogged or not. • Key switch: ON
• Engine: Stopped
NO
EX455 T5-5-19
TROUBLESHOOTING C

Engine Oil Pressure Switch

Pressure Indicator
Approx. ON
98 kPa (1.0 kgf/cm2,
14.2 psi) or Less
More than Approx. OFF
98 kPa (1.0 kgf/cm2,
14.2 psi)
Faulty engine oil
pressure switch.

Reconnect engine oil

pressure switch. Broken harness
YES between monitor
Check if indicator
comes ON when mo- and engine oil Connector (harness end connector terminals seen
nitor terminal No.10 is pressure switch. from the open end side)
grounded to vehicle.

• Key switch: ON Monitor (12P)

• Without disconnecting, Faulty
ground connector to monitor.
vehicle using a clip from NO 1 2 3 4 5 6
the back of connector. 7 8 9 10 11 12

Burned out
indicator light.

Faulty engine oil

pressure switch,
faulty engine oil
lubrication
system, or
clogged oil filter.

With engine oil Short-circuited

pressure switch YES harness between
connected, remove monitor and
12P connector from engine oil
monitor. Check for pressure switch.
continuity between
harness end
connector terminal Faulty monitor.
No.10 and vehicle NO
frame.
T5-5-20 EX455
TROUBLESHOOTING C

MALFUNCTION OF OVERHEAT
INDICATOR

Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.

YES Overheat switch

Disconnect H failure.
overheat switch H
terminal. Ground
YES Harness
the harness end YES
terminal to vehicle Reconnect breakage
overheat switch H between monitor
frame. Check if
terminal. Connect and overheat
overheat indicator
comes on. the monitor 12P switch H or
connector terminal diodes 3-4 failure.
• Key switch: ON NO No. 1 to vehicle
• Engine: Stopped frame. Check if
Check if overheat indicator
Although engine overheat Monitor failure.
overheats, comes on.
indicator comes NO
overheat on when key • Key switch: ON
indicator does switch is turned • Engine: Stopped
not come on. ON. • Insert a clip from the
back of 12P
• Key switch: ON connector to reach
• Engine: Stopped the terminal. Ground
the other end of the
clip to vehicle frame.
Blown indicator
NO bulb.

YES Overheat switch

H failure.

Overheat
indicator comes Disconnect overheat
on even when switch H. Check if Short circuit
YES between monitor
coolant overheat indicator
temperature is goes off. and overheat
low. switch H.
With overheat switch
• Key switch: ON H disconnected,
• Engine: Stopped disconnect 12P
connector from
monitor. Check if
NO continuity exists
between 12P connec-
tor terminal No. 1 and
vehicle frame.

Monitor failure.
NO

Connector (Harness end connector terminals seen Overheat Switch

from the open end side)
ON/OFF Threshold Coolant Indicator
Monitor (12P) Temperature
Lower than 101 °C (214 °F) OFF
1 2 3 4 5 6
7 8 9 10 11 12 101°C (214 °F) or higher ON
EX455 T5-5-21
TROUBLESHOOTING C

MALFUNCTION OF AIR FILTER

RESTRICTION INDICATOR

Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.

Disconnect the Air filter

YES
harness end plug restriction
from the air filter switch failure.
restriction switch.
Ground the
YES harness end (+) YES
Reconnect the Monitor failure
terminal (wire 203)
harness end plug.
to vehicle frame.
Disconnect 12P
Check if air
connector from
filter restriction
monitor. Check if
indicator comes
NO continuity exists
on. Harness
between 12
connector terminal breakage
Check if air • Key switch: ON
Although air filter No. 3 and vehicle between monitor
filter restriction • Engine: Stopped
is clogged, air frame. NO and air filter
indicator comes
filter restriction restriction
on when key
indicator does not switch.
switch is turned
come on.
ON.

• Key switch: ON
• Engine: Stopped

Blown indicator
bulb.
NO

YES Air filter

restriction switch
failure.

Disconnect the
Although air filter
harness end plug from Short circuit
is not clogged,
the air filter restriction YES between monitor
air filter restriction
switch. Check if air and air filter
indicator comes
filter restriction With air filter restriction
on.
indicator goes off. restriction switch switch.
• Remove and disconnected,
visually check the • Key switch: ON disconnect 12P
air filter. • Engine: Stopped connector from
• Confirm that the air monitor. Check if
filter is not damp. NO continuity exists
between harness end
12P connector
terminal No. 3 and
vehicle frame.
Monitor failure.
NO

Connector (Harness end connector terminals seen Air Filter Restriction Switch
from the open end side)
Indicator ON/OFF Pressure Indicator
Monitor (12P)
5.1 kPa (520 mm H2O) OFF

1 2 3 4 5 6
6.2 kPa (630 mm H2O) ON
7 8 9 10 11 12
T5-5-22 EX455
TROUBLESHOOTING C

MALFUNCTION OF BUZZER

Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.

NOTE - (*) Regulator terminals L is water-resistance

type connectors so that it is not practical to measure
voltage at these terminals. Measure voltage at starter
relay terminal R.
Before measuring voltage, check continuity between
the starter relay terminal R and regulator terminal L.

13 V or more
Faulty regulator.
Buzzer keeps
Check voltage
sounding when
at monitor
key switch is
terminal No.42.
turned ON.
Failure in
• Key switch: ON monitor.
(Engine is stopped.) Less than 13 V

YES Failure in engine

oil pressure
system.
Buzzer keeps Check if engine
sounding when oil pressure YES Overheat of
engine is started. indicator is ON. engine.
Check if overheat
NO indicator is ON.
Check if buzzer
stops when
buzzer stop
NO switch is
depressed.

NO Normal
Buzzer does not
sound even if
Check if engine is
engine oil
running at 1000
pressure indicator NO Normal
min-1 (rpm) or
or overheat
faster.
indicator comes Check if
ON. alternator
YES indicator is ON.

Check voltage at
alternator
YES terminal L (*).

• Engine speed:
1000 min-1 (rpm) or
faster.
EX455 T5-5-23
TROUBLESHOOTING C

Connector (harness end connector terminals seen

from the open end side)

Monitor (20P) Starter Relay

E
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48 S R

YES Normal

Failure in monitor.
NO

Less than 13 V Faulty regulator or

alternator.

Broken harness
Less than 13 V between alternator
Check voltage at
monitor 20P terminal L and monitor
terminal No.42.
connector terminal
13 V or more No.42.
• Engine speed:
1000 min-1 (rpm) or Failure in monitor.
faster.
13 V or more
T5-5-24 EX455
TROUBLESHOOTING C

MALFUNCTION OF HOUR METER

Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.

NOTE - (*) Regulator terminals L is water-resistance

type connectors so that it is not practical to measure
voltage at these terminals. Measure voltage at starter
relay terminal R.
Before measuring voltage, check continuity between
the starter relay terminal R and regulator terminal L.
Broken harness
between monitor
0V
terminal No.29
and No.6 fuse.
Check voltage at
NO monitor 20P
connector terminal
No.29.
Failure in
24 V monitor.

Hour meter
does not count Check if
operating hours alternator
when engine is indicator is ON.
running.
Less than 13 V
Faulty regulator
• Engine : Running or alternator.

Check voltage at
alternator terminal L
YES (*).

• Engine speed: 13 to 14.5 V

1 000 min-1 (rpm) or or more Failure in
faster monitor.
Check voltage at
monitor 20P
connector
Broken harness
terminal No.42.
between alternator
13 V or more terminal L and
Less than monitor terminal
13 V No.42.

Connector (harness end connector terminals seen

from the open end side)

Monitor (20P) Starter Relay

29 30 31 32 33 34 35 36 37 38
E
39 40 41 42 43 44 45 46 47 48 S R
EX455 T5-6-1
ELECTRICAL SYSTEM INSPECTION

PRECAUTIONS FOR INSPECTION AND

MAINTENANCE

1. Disconnect the power source.

Be sure to remove the negative terminals from the
batteries first when taking wire harnesses and
connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
A
2. Wire harnesses identification.
The wire harnesses used on electrical system of the
machine are of three colours: red, white and brown. 0511 0511 0511
– The wire harnesses red coloured are used for 20 ÷ 30 mm
the main power supply distribution and for direct
connection to the positive not controlled by key
switch. B C
– The wire harnesses white coloured are used for
2.5 R 0679
the all other functions.

0511
– The wire harnesses brown coloured are used for 0511
ground connection.
Each wire is identified by a four digit numerical
coding printed on the whole lenght every 20 to 30
mm (A).
This coding is also shown on the wiring diagrams of
electrical system (B).
On the general electrical system diagram attached,
numbers and letters are shown before the four digit Right Wrong
coding.
Numbers mean the wire section shown in mm2.
The following letters indicate the wire colours;
where W stands for white, R for Red and Br for
Brown. See detail (C).
SM0651
3. Precautions for connecting and disconnecting ter-
minal connectors.
1) When disconnecting harnesses, grasp them by
their connectors. Do not pull on the wire itself.
Be sure to release the lock first before attempt-
ing to separate connectors, if a lock is provided.
2) Water-resistant connectors keep water out so
that if water enters them, water will not easily Right
drain from them. When checking water-resi- Rust
stant connectors, take extra care not to allow
Wrong
water to enter the connectors. In case water (deformation)
should enter the connectors, reconnect only
after the connectors are thoroughly dried. Wrong
(Separation)
3) Before connecting terminal connectors, check
that no terminals are bent or coming off. In SM0652
addition, as most connectors are made of
brass, check that no terminals are rusting.
4) When connecting terminal connectors pro-
vided with a lock, be sure to insert them to-
gether until the lock “clicks.”
T5-6-2 EX455
ELECTRICAL SYSTEM INSPECTION

4. Precaution for using a circuit tester.

1) Before using a circuit tester, refer to the in- Wind a Piece of Wire Tester Probe
structions in the circuit tester manual.
Then, set the circuit tester to meet the object to
be measured, voltage range and current pola-
rity.
2) Before starting the connector test, always Sharpen the end of the Wire
check the connector terminal numbers, refer-
ring to the circuit diagram. SM0653

When the connector size is very small, and the

standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or
a pin around the probe to make the test easier.
EX455 T5-6-3
ELECTRICAL SYSTEM INSPECTION

INSTRUCTIONS FOR DISCONNECTING

CONNECTORS

• Push the lock to disconnect

NOTE - 1) Connector may not separate if the lock is

pushed while the connector is being
pulled. Be sure to push the lock first before
pulling the connector.
2) The lock is provided on the female connec- SM6724
tor side (the harness end).

Locations of This Type Connector

Fuel Sensor Swing Preference Solenoid Harness Connections Thermoguard Switch

Valve in Cab
A Sensor General Purpose Relay Pressure Switch Diode Box
(Displacement Angle Sensor)
EC Sensor P Sensor Wiper
EC Motor Monitor Speaker Diode
Coolant Level Switch Starter Relay Radio Lubricator
Pump Control Pressure Sensor Air Conditioner Blower Motor
Engine Oil level Switch Air Conditioner Controller Key Switch Power Line between
Engine/Cab
Hydraulic Oil Level Switch Engine Control Dial Buzzer Fusible Link
N Sensor

• Pull to disconnect.

Locations of This Type Connector

Hydraulic Oil Temperature Sensor

Dr.EX
SM6725

• Remove screw to disconnect

Use a 10 mm wrench and a ratchet wrench.
Projection
When connecting, tighten until the torque mark
(a projection) is seen.

Locations of This Type Connector

EC
PVC
Connections between Cab/Engine

SM6726
T5-6-4 EX455
ELECTRICAL SYSTEM INSPECTION

FUSE CONTINUITY TEST

Fuse failure is often caused by a fine crack in the fuse,
and such fine cracks are very hard to detect by visual
inspection.
Checking fuse continuity with a tester is far superior to
sight inspection.
(3) Connect the negative probe to the vehicle ground,
and touch the outside terminal of each fuse with the
positive probe of the tester.
When normal continuity of a fuse is intact, the
tester will indicate 20 to 25 V.

(1) Turn the key switch ON

In doing so, the battery relay is activated by the
current from key switch terminal M and power is
supplied to all circuits.
NOTE - All the inside terminals of the fuses in the
(2) Remove the fuse box cover and set the correct fuse boxes are connected to the power
voltage measurement range of the tester. source, while the outside terminals are con-
(Measurement range: 0 to 30 V) nected to the accessories.

Power Source (Inside) Accessory (Outside)

Accessory (Outside)

SM0657
EX455 T5-6-5
ELECTRICAL SYSTEM INSPECTION

FUSIBLE MAXI LINK INSPECTION AND

REPLACEMENT

Inspection

1. Open the tools and batteries compartment door.

2. Remove the negative cable from the battery.

3. Loosen the four screws of tool container and remove

it to localize the maxi fuse link box.

4. Slide the front cover of maxi fuse box, and visually

check if fuse links have blown.

Replacement

1. Open the tools and batteries compartment door.

2. Remove the negative cable from the battery.

3. Loosen the four screws of tools container and

remove it to localize the maxi fuse link box.

4. Slide the front cover from maxi fuse link and

replace.

5. Withdraw the maxi fuse link and replace it.

6. Reinstall the tools container and tighten the four

screws.

7. Reconnect the negative cable to the battery.

Front
8. Close the tools and batteries compartment door. Cover

Maxi
Fuse

Body

Rear
Cover

SM5729
T5-6-6 EX455
ELECTRICAL SYSTEM INSPECTION

BATTERY VOLTAGE CHECK

1. Turn the key switch OFF. Check voltage between

the battery positive terminal and the vehicle frame.

Normal Voltage: 24 V

NOTE - If voltage is abnormal, recharge or replace

the battery.

2. Start the engine. Check voltage between the bat-

tery positive terminal and the vehicle frame.

Normal Voltage: 26 to 28 V

NOTE - If voltage is abnormal, check the charging SM5730

system.
EX455 T5-6-7
ELECTRICAL SYSTEM INSPECTION

HOW TO TROUBLESHOOT ALTERNATOR Terminal R Terminal L

MALFUNCTIONS

The alternator indicator remains off if the alternator is

generating power. If the alternator indicator comes on
while the engine is running, the alternator may have Terminal B
failed.

How to check the alternator circuit

1. Turn the key switch ot the ON position. Confirm that

the alternator indicator comes on.

2. Measure voltage between alternator terminal B and

the alternator body. If the measured voltage is
approximately 24 V, the alternator circuit can be
considered normal. If it is low, insuffienet battery
capacity or a loose connection between the battery
and the alternator may be the cause.
If it is 0 V, disconnection or wire breakage between
the battery relay and the alternator or in alternator
ground line may be the cause.

3. Next, start the engine. Measure alternator generat-

ing voltage (voltage between alternator terminals B
and alternator body). If the measured voltage is
approximately 28 V, the alternator is normal. If it is
SM5736
the same as the one measured in step 2 (around 24 E
V), the alternator or the regulator may have failed.
T5-6-8 EX455
ELECTRICAL SYSTEM INSPECTION

CONTINUITY CHECK
Harness
Single-line continuity check
A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity Ω

NOTE - When the one end connector is far apart from

the other, connect one end of connector (A) to the Connect to the A a
machine chassis using a clip. Then, check continuity machine
of the harness through the vehicle frame as illus- chassis.
trated.
Connect to the
Ω
If the ohm-meter reading is: 0 Ω = Continuity machine
chassis.
∞ Ω = Discontinuity

Single-line short-circuit check A a

Disconnect both end connectors of the harness and Short-circuit
check continuity between one end connector of the between the
harness and the vehicle frame: harness and
the vehicle
If the ohm-meter reading is: Ω frame
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
SM0660

Multi-line continuity check

Disconnect both end connectors of the harness, and First short-circuit
short-circuit two terminals, (A) and (B), at one end
connector, as illustrated. Then, check continuity be-
tween terminals (a) and (b) at the other connector. If A a
B b
the ohm-meter reading is ∞ Ω, either line (A) - (a), or C c
(B) - (b) is in discontinuity. To find out which line is
discontinued, conduct the single line continuity check Second short-circuit
on both lines individually, or, after changing the short-
circuit terminals from (A) - (B) to (A) - (C), check
continuity once more between terminals (a) and (c).
Ω

NOTE - By conducting the multi-line continuity check

SM0661
twice, it is possible to find out which line is disconti-
nued. With terminals (A) and (C) short-circuited,
check continuity between terminals (a) and (c). Short-circuit between harnesses.

If the ohm-meter reading is:

A a
0 Ω = Line (B) - (b) has discontinuity. B b
∞ Ω = Line (A) - (a) has discontinuity. C c

Multi-line short-circuit check

Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or (C).
If the ohm-meter reading is: Ω
0 Ω = Short-circuit exists between the lines.
∞ Ω = No short-circuit exists between the lines.
SM0662
EX455 T5-6-9
ELECTRICAL SYSTEM INSPECTION
T5-6-10 EX455
ELECTRICAL SYSTEM INSPECTION

VOLTAGE AND CURRENT CHECK

Turn switch ON so that the specified voltage (current) 24 Voltage Circuit

is applied to the point to be measured. Then start Start checking in order up to the point where voltage
measuring either voltage or current. Judge if the is measured from either power source or actuator
specified voltage is applied. side. Thereby, the faulty location in the circuit will be
found.
Black Probe (Minus) of Tester : To ground (vehicle
frame).
Red Probe (Plus) of Tester : To location to be
measured.

Engine Key Check Point Standard

Switch
Power Source Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Power Source 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current (*) 6 mA
Preheat Circuit
Stopped ON Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON Between (7) and Ground: Glow plugs 20 to 25 V
Stopped ON Between (20) and Ground: QOS Controller power supply 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator Generating Voltage (B) 26 to 30 V
Fast Speed ON Between (10) and Ground: Alternator Generating Voltage 26 to 30 V
Fast Speed ON Between (15) and Ground: Alternator Generating Voltage 26 to 30 V
Fast Speed ON Between (16) and Ground: Alternator Generating Voltage (L) 13 to 30 V
Fast Speed ON Between (17) and Ground: Monitor 13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idling ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idling ON Between (16) and Ground: Alternator (L) 13 to 30 V
Slow Idling ON Between (18) and Ground: Anti Load Dump Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Air Conditioning 20 to 25 V
Stopped ON Between (21) and Ground: Horn 20 to 25 V
Stopped ON Between (22) and Ground: Lighter 20 to 25 V
Stopped ON Between (23) and Ground: Radio 20 to 25 V

(*) After disconnection the minus cable to the battery, start measuring.
EX455 T5-6-11
ELECTRICAL SYSTEM INSPECTION

17

19
18
20
8

22 21
15
6

23
9
5

10

12
3

14
11
2

13
16
1
7

SM5734
T5-6-12 EX455
ELECTRICAL SYSTEM INSPECTION

5 Voltage Circuit
Signal or
• Voltage between terminal No.1 and the vehicle Two polarities Power source ground
frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
• Key switch position: ON
• Tester black terminal (negative):
Connected to the vehicle (ground)
• Tester red terminal (positive):
SM0664
Connected to terminal No.1
Three polarities Power source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 is normal.

• Voltage between terminal No.1 and the ground SM0665

terminal Two polarities

With the key switch turned OFF, disconnect the
1 2
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the ground
terminal (terminal No.2 for two polarities, or termi-
nal No.3 for three polarities) under the following V
conditions.

• Key switch position: ON

• Tester black terminal (negative):
Connected to the ground terminal
(terminal No.2 or 3)
SM0666
• Tester red terminal (positive):
Connected to terminal No.1 Three polarities

1 2 3
Evaluation:
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 or the ground terminal is
normal.
V

SM0667
EX455 T5-6-13
ELECTRICAL SYSTEM INSPECTION

• Check Using False Signal

Two polarities
IMPORTANT - On three-polarity connectors, do not
short-circuit terminals No.1 and No.2 to No.3 or the 1 2
vehicle frame (ground), causing harnesses, control-
lers and fuses to burn due to current overload.
(Pressure switch)
(N sensor)
With the key switch turned OFF, disconnect the
sensor connector.
Short-circuit terminal No.1 (power source) and No.2
Short circuit
(signal) on the machine harness side connector and
supply the power source voltage as a false signal to
the controller. Check the controller under this condi- SM0668

tion, using the Dr.EX monitor function.

Evaluation: Three polarities

Except for the pressure switch circuits, if the maxi- 1 2 3
mum value is displayed, the MC (Main Controller)
and the circuits up to the machine harness side (EC sensor)
(Pilot pressure sensor)
connector are normal. When the pressure switch (Pump control pressure sensor)
circuits are normal, the Dr.EX monitor displays “ON”. (Pump delivery pressure sensor)

Short circuit

SM0669
T5-6-14 EX455
ELECTRICAL SYSTEM INSPECTION

WIPER CONTROLLER

SMW0465

5
To wiper
motor

To washer
pump

SMW0466
1 - Connector 5 - Board
2 - Box 6 - Diode 1N4007
3 - Diode 1n5408 (q.ty 3) 7 - Wiper controller connector, harness side
4 - Relay
EX455 T5-6-15
ELECTRICAL SYSTEM INSPECTION

Replacement of wiper controller

1. Remove screw (1) under the right console to detach

cover (2).

2. Remove bolt (3) and turn the console around pin (4).
Then, take out lock pin (5). Push pin (4) to the seat
side, then remove spacer (6).
: 17 mm

3. Move the console to the seat side.

4. Using a sharp-pointed tool, remove cap (9) from 13

SM5620
cover (7) and duct cover (8) located under the
monitor.

5. Remove cover (7) and duct cover (8).

6. Remove ashtray (10) and the ashtray screw.

Remove aux. switch panel (11).

7. Remove wiper controller cover (12).

8. Replace the wiper controller (13).

a

5 2 3 1
View a
SM0670
4 6

7 10 11

SM0671

9 8 12

1 - Screw 16 - Spacer 11 - Aux. Switch Panel

2 - Cover 17 - Cover 12 - Wiper controller cover
3 - Bolt 18 - Duct Cover 13 - Wiper controller
4 - Pin 19 - Cap
5 - Lock Pin 10 - Ashtray
T5-6-16 EX455
ELECTRICAL SYSTEM INSPECTION

REPLACEMENT OF RELAY

(R1, R3, R4, R5, R6 and R7)

1. Remove the rear cover (1) by loosen the 3 bolts (3)

and the four bolts (2).
: 13 mm

2. Remove the bolt (4 and 5) fixing the support (6)

: 13 mm

R1-R3-R4-R5-R6-R7

SM5731

3. Lift the support (6). 1 2

SM1126

4. Lift the protection sheet (7).

5 4

SM3039
EX455 T5-6-17
ELECTRICAL SYSTEM INSPECTION

5. Identify the relay on the terminal board.

6. Replace the relay.

SM5737
T5-6-18 EX455
ELECTRICAL SYSTEM INSPECTION

RELAY BOX

SM5623

1 - Relay box 2 - Relay box connector harness side

SM5624

- Diodes
d1, d2, d3, d4 : Diode IN4007
D1, D2, D3, D4, D5, D6 : Diode IN5408

- Relay
R1: Anti Load Dump
R2: Horn
R3: Light 2
R4: Light 1
EX455 T5-6-19
ELECTRICAL SYSTEM INSPECTION

Replacement of relay box

1. Remove the rear cover (1) by loosening the three

bolts (3) and the four bolts (2).

1 2

2. Identify the relay box (4).

3
3. Remove the hexagonal screw M6 and the two
washer (5). SM1126

A
4. Disconnect the connector (6).

5. Remove the relay box (4).

SM3039

6. Install the new relay box (4). View from A

5

7. Fix the relay box with hexagonal screw M6 and the

two washer (5).

8. Install the connector (6) on the relay box.

9. Reinstall the rear cover by tightening the four bolts SM5625

(2) and the three bolts (3).
T5-6-20 EX455
ELECTRICAL SYSTEM INSPECTION

REPLACEMENT OF QOS CONTROLLER

1. Remove the rear cover (1) by loosening the 3 bolts

(3) and the four bolts (2).

2. Remove the bolts (4 and 5) fixing the support (6). 1 2

3. Lift the support (6).

4. Lift the protection sheet (7).

3

5. Remove the QOS controller (10) by loosening the

SM1126
two bolts (11).
Disconnect the connector.

6
6. Install the new QOS controller (10) and secure by
tightening the two bolts (11). Properly route the
QOS controller cable tail and fix by tie-wrap.
Connect the connector. 5 4

7. Reinstall the protection sheet (7) and the support 7

(6).

8. Reinstall the rear cover by tightening the four bolts SM3039

(2) and the three bolts (3).

11

10
SM5738
EX455 T5-6-21
ELECTRICAL SYSTEM INSPECTION

REPLACEMENT OF POWER OUTLET

1. Gain the access to the rear of panel and disconnect

the connector from power outlet.

2. Open the guard.

Power outlet
OM0376

3. Using the special plier (Fiat Auto code No.

1876044000) unlock the sleeve from the lock ring.
Panel

Power outlet

4. Withdraw the sleeve from the rear of the panel.

Guard

SM3041

5. Install the new power outlet inserting the sleeve

from the rear of the panel and pushing the lock ring
on the front of the panel.

SM3042

Special plier Fiat Auto Code No. 1876044000

6. Reconnect the connector to the power outlet.
T5-6-22 EX455
ELECTRICAL SYSTEM INSPECTION

NOTES
EX455 T5-7-1
HARNESS CHECK

CIRCUIT CHECK

Connect the harness kit between connectors. Then,

check if the circuit is normal or abnormal depending on
whether the tester detects power ON or OFF during
operation.

Part Number 75301706A

Use when checking the solenoid valve unit circuit.
(Refer to page T5-4-28, T5-4-36)

SM6732

Part Number 75301706A

Part Number 75301706B

Use when checking EC motor circuit.
(Refer to page T5-4-18)

SM6733

Part Number 75301706B

Part Number 75301706FD

Use when measuring the signal cable voltage (be- (Red)
tween terminal No.2 and 3) in the EC sensor, DP
sensor or A sensor (Pump displacement angle)
circuit. (Refer to page T5-3-6, T5-3-14, T5-4-40)

(Blue)
(Black)

SM6734

Part Number 75301706D

T5-7-2 EX455
HARNESS CHECK

Parts Number 75301706C

Use when checking the wiper circuit.
(Refer to page T5-4-38)

SM6735

Part Number 75301706C

HYDRAULIC SYSTEM CIRCUIT DIAGRAM
READING KEY

11 Right pilot valve

12 Left pilot valve
13 Travel pilot valve
14 Solenoid valve unit (3 spool)
15 Check valve
16 Pilot shut-off valve
17 Accumulator
18 Pilot filter
19 Travel shuttle valve
10 Travel shockless valve
11 Front shockless valve
12 Swing/Bucket shuttle valve
13 Boom cylinders
14 Bucket cylinder
15 Control valve
16 Arm cylinder
18 Pilot pump
19 Main pump 1 (Front)
20 Main pump 2 (Rear)
21 Swing preference circuit shift solenoid valve
22 Hydraulic oil tank
23 Full flow filter
24 Oil cooler
25 By-pass valve
26 Check valve
27 Check valve
28 Swing motors
29 Center joint
30 Right travel motor
31 Left travel motor
32 Return hydraulic filter
ELECTRICAL SYSTEM CIRCUIT DIAGRAM
READING KEY
1 Batteries 99 Air conditioner control panel (opt)
2 Battery relay 100 Air conditioning system (opt)
3 Starter motor 101 Auto - idle control button
4 Starter relay 102 Engine speed sensor (N)
6 Key switch 108 Pressure switch (boom raise)
7 Diode 5 109 Pressure switch (front attachment)
11 Horn button 110 Pressure switch (travel)
14 Horns (2 off) 111 Unused indicator light
15 Fuse link 1 - 50A 112 Unused indicator light
16 EC motor 114 Compressor engage control (opt)
17 Power outlet 24V - 180W 123 Hydraulic Breaker filter clogging indicator light
20 Windscreen wiper motor 124 POWER BOOST control button
21 Windscreen washer electrical pump 126 Load momentum alarm relay (R17) (opt)
22 Cab light 127 Load momentum alarm buzzer (opt)
23 Fuse box 128 Load momentum alarm switch (opt)
24 Cab light relay (R5) (opt) 129 Load momentum alarm pressure switch (opt)
25 Radio 130 Cab lights (opt)
26 Cigar lighter 131 Cab lights switch (opt)
28 Upperstructure light 134 Pre-heat indicator light
29 Boom light 138 Diode 1
32 Alternator 143 Loud-speakers
33 Fuse link 2 - 40A 144 Aerial
34 Fuse link 3 - 80A 149 Monitor
35 Electrical fan and control 150 Travel speed switch
39 Air filter restriction switch 151 Automatic windscreen wiper connector
40 Engine coolant overheat switch (H) 160 EC Controller
41 Hydraulic oil level switch 161 SC Solenoid valve (Swing parking brake release)
42 Engine coolant level switch 167 Preheat relay
43 Engine oil level switch 168 Glow plugs
44 Fuel level sensor 169 Coolant temperature switch (preheat circuit)
45 Engine coolant temperature sensor 170 QOS Controller
46 Low engine oil pressure switch 171 Rear cab light switch (opt)
47 LH bucket rotation relay (R4) (opt) 172 Rear cab light switch relay (R6) (opt)
48 RH bucket rotation relay (R3) (opt) 173 Rear cab light
49 Rotary bucket solenoid valve provision (opt) 174 EC (Step) Motor Relay (R7)
50 Rotary bucket switch (opt) 175 Pump/Valve Controller (PVC)
51 Diagnostic tester connector (Dr. EX) 176 Diode 2
52 Engine control dial 177 Diodes 3-4
54 E button (Economy mode) 178 Diagostic EX2
55 S/P button (Super-Power mode) 179 Diagostic EX3
56 Engine speed control panel 180 Breaker Filter clogging pressure switch
59 Seat heating resistors and control (opt) 181 Lubricator
60 Electrical fuel lift pump (opt) 182 Relay box
61 Engine speed control panel light 183 Swing Preference Circuit Shift solenoid valve
65 Hour-meter 184 Swing pressure switch
66 Engine coolant temperature gauge 185 Other pressure switch
67 Fuel level gauge 186 Attachement pressure switch (opt)
68 Instrument panel lighting 187 Overheat switch (L)
69 Engine oil level indicator light 188 Hydraulic oil temperature sensor
70 Engine coolant level indicator light 189 Differential pressure sensor (4 spool side)
71 Hydraulic oil level indicator light 190 Differential pressure sensor (5 spool side)
72 Alternator (Battery charge) indicator light 191 Pump 2 displacement control solenoid valve
73 Engine oil low pressure indicator light 192 Pump 2 delivery pressure sensor (P sensor)
74 Overheat indicator light 193 Pump 2 angle sensor (A sensor)
75 Buzzer 194 Pump 1 displacement control solenoid valve
76 Rotary bucket selector (opt) 195 Pump 1 delivery pressure sensor (P sensor)
77 Air filter restriction indicator light 196 Pump 1 angle sensor (A sensor)
78 Low fuel level indicator light 197 Auxiliary connection
79 Windscreen wiper safety switch 198 Wiper controller
80 EC sensor 200 Junction connection A
81 Auto-idle engaged light (led) 201 Junction connection B
82 E mode engaged light (led) 202 Junction connection C
83 S/P mode engaged light (led) 203 Junction connection D
85 Level check button (CHECK) 204 Junction connection E
86 Buzzer stop button 205 Junction connection F
87 Windscreen washer control button 206 Junction connection G
88 Windscreen wiper control button 207 Junction connection H
89 Lights control button 208 Junction connection I
90 WORK MODE selector button 209 Junction connection J
91 GENERAL PURPOSE work mode light (led) 210 Junction connection K
92 TRENCING work mode light (led) 211 Junction connection L
93 PRECISION work mode light (led) 212 Ground junction connection A
94 ATTACHMENT work mode light (led) 213 Ground junction connection B
95 SB solenoid valve (Travel mode shift) 214 Junction box
96 SA solenoid valve (Main relief pressure shift)

NOTE - Pressure switches, sensors and control switches in the electrical wiring diagram are shown in the position
related to engine stop condition, without failure and with key switch (6) in OFF position.
COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.
Documentation Centre
Strada di Settimo, 323 - S. MAURO T.SE (TO) ITALY

Reproduction of text or illustrations,

in whole or in part, is strictly prohibited

Print No. 604.13.226 - VII - 2002

Printed by Satiz - Turin (Italy)

Coordinamento Editoriale Satiz - Torino
EXCAVATOR
WORKSHOP MANUAL
(Tier 2)

All information, illustrations and specifications in this manual are based on the latest product information avail-
able at the time of publication.
The right is reserved to make changes at any time without notice.

FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. - ENGINEERING -

FORM No. 604.13.231 Edition - July 2002
EX455 IN-1

INTRODUCTION

TO THE READER

• This manual is written for an experienced technician - If you have any questions or comments, or if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact:

- Be sure to thoroughly read this manual for correct FIAT KOBELCO CONSTRUCTION
information concerning the service procedures. MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALY
PRODUCT SUPPORT
Fax. ++39 011 6877357

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition

to this service manual:

- Operation and Maintenance Instruction

Manual
- Spare Parts Catalog

SERVICE MANUAL COMPOSITION

• The complete service manual consists of three
books:
- Technical Manual - Operational Principle
- Technical Manual - Troubleshooting
- Workshop Manual
- The Workshop Manual includes information needed
for maintenance and repair of the machine, tools and
devices needed for maintenance and repair, mainte-
nance standards, removal/installation and assem-
bly/disassembly procedures.

- The Technical Manual - Operational Principle in- • The Service Manual for EX455 Excavator consists
cludes the technical information concerning the of the following book/print numbers:
operation of main devices and systems.

- The Technical Manual -Troubleshooting includes

the technical information needed for operational
performance tests, and troubleshooting procedures.

BOOK PRINT NUMBER

- Technical Manual - Operational Principle 604.13.221
- Technical Manual - Troubleshooting 604.13.226
- Workshop Manual 604.13.231
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.

To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 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
Masse kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N.m kgf.m 0.10197 mL/rev Cc/rev 1.0
N.m lbf.ft 0.7375
EX455 S-1

SAFETY PRECAUTIONS

RECOGNISE SAFETY INFORMATION

• This is your SAFETY ALERT SYMBOL.

- When you see this symbol on your machine or in

this Manual, be alert of the potential for personal
injury.
- Follow recommended precautions and safe
operating practices.

S0021

UNDERSTAND SIGNAL WORDS

• In this Manual you will find the following words:

- DANGER;
- WARNING;
- CAUTION.
referring to different hazard risks. DANGER
These words are always accompanied by the safety
alert symbol.
WARNING
DANGER: indicates an imminent hazardous
situation which, if not avoided, will result in death or
serious injury. CAUTION
WARNING: indicated a potential hazardous
situation which, if not avoided, could result in death or
serious injury. IMPORTANT
CAUTION: indicates a potential hazardous situation
which, if not avoided, may result in minor or moderate NOTE
injury.

IMPORTANT: indicates a situation which, if not

avoided, may cause damage to the machine.

NOTE: indicates an additional explanation for

information purposes.

ENVIRONMENTAL PROTECTION

• This Manual also contains this symbol

accompanying instructions for correct behaviour
as regards environmental protection.

S0024
S-2 EX455

SAFETY PRECAUTIONS

FOLLOW SAFETY PRECAUTIONS

• Carefully read and observe all safety signs on the

machine and read all safety precautions in this
Manual.
• Safety signs should be installed, maintained, and
replaced when necessary.
- If a safety sign or this Manual are damaged or
missing, obtain a replacement from your FIAT
KOBELCO Dealer in the same way you order a
spare part (be sure to detail machine model and
serial number upon ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorised personnel S0022
to operate the machine.
• Keep the machine in proper working conditions.
- Unauthorised changes to the machine may
impair function and/or safety and affect machine
life.
• Safety messages in this Chapter “SAFETY
PRECAUTIONS”, are intended to illustrate basic
safety procedures of the machine. However, it is
impossible for these safety messages to cover
every hazardous situation you may encounter. If
you have any doubts, consult your direct
supervisor prior to operating or servicing the
machine.

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or an accident occurs.

- Keep the first-aid kit and fire extinguisher on
hand.
- Thoroughly read and understand the label
attached to the fire extinguisher to use it properly.
- Establish emergency priority procedures to cope
with fires and accidents.
- Keep emergency numbers for doctors,
ambulance service, hospitals and fire
department posted near the telephone.

S0023
EX455 S-3

SAFETY PRECAUTIONS

WEAR PROTECTIVE CLOTHING

• Wear close-fitting clothing and safety equipment

appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask.
Be sure to correctly wear equipment and clothing
for the job.
- Do not take any chances. S0025

- Avoid wearing loose clothing, jewellery, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
- Wear a suitable hearing protection such as
earmuffs or earplugs to protect objectionable or
uncomfortably loud noise.

S0026

INSPECT THE MACHINE

• Inspect the machine carefully every day or work-

shift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.

- In the walk-around inspection, be sure to cover all

points detailed in the Chapter "MAINTENANCE",
paragraph "EXTERNAL VISUAL INSPECTION"
of the OPERATION AND MAINTENANCE
S0027
INSTRUCTION MANUAL.
S-4 EX455

SAFETY PRECAUTIONS

USE HAND HOLDS AND STEPS

• Falling is one of the major causes of personal injury.

- When you get on and off the machine, always

face the machine and maintain a three-point
contact with the steps and handrails.

- Do not use any control as a handhold.

- Never jump off the machine. Never get on and

off a moving machine.
S0028
- Be careful of slippery conditions of platforms,
steps, and handrails when leaving the machine.

ADJUST THE OPERATOR'S SEAT

• A seat poorly adjusted for operator or work

requirements may quickly fatigue the operator
leading to improper operations.

- The seat should be adjusted whenever machine

operator changes.

- The operator should be able to fully press the

pedals and correctly move the control levers with
his back resting against the seat back.

- If not, move the seat fore and aft, and check

again.

S0029
EX455 S-5

SAFETY PRECAUTIONS

FASTEN SEAT BELT

• Should the machine overturn, the operator may

become injured and/or thrown from the cab. Not
only, the operator may be crushed by the
overturning machine resulting in serious injury or
even death.

- Prior to operating the machine, thoroughly

examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
S0030

- Be sure to remain seated with the seat belt

securely fastened at all times when the machine
is in operation to minimise injury hazard in case
of accident.

- After a significant accident, replace the seat belts

even though they do not look damaged.

MOVE AND OPERATE MACHINE

SAFELY

• Bystanders can be run over.

- Pay the utmost attention not to run over

bystanders.

- Be sure and aware of the location of bystanders

before moving, swinging or operating the
machine.

- If fitted, keep the travel alarm and horn sounding

to warn people that the machine is about to move.
S0031

- When operating, swinging, or moving the

machine in a congested area use a signal man.

- Co-ordinate hand signals before starting the

machine.
S-6 EX455

SAFETY PRECAUTIONS

OPERATE ONLY FROM THE DRIVER'S

SEAT

• Inappropriate engine starting procedures may

cause the machine unexpected movement,
possibly resulting in serious injury and even death.
- Start the engine only from the operator’s seat.

- NEVER start the engine while standing on the

track or on the ground.

- Do not start the engine by shorting across starter

motor terminals.
S0032
- Before starting the engine, ensure that all control
levers are in the neutral position.

KEEP RIDERS OFF THE MACHINE

• Riders on the machine are subject to injuries such

as being struck by foreign objects and being thrown
off the machine.

- Only machine operator is allowed on the

machine. Keep riders off.

- Riders also obstruct the operator’s visibility,

resulting in the machine being operated
unsafely.
S0033

CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN

• Incorrect travel controls operation may result in

serious injury and even death.

- Before driving the machine, be aware of the

undercarriage position relative to the operator’s
position. If travel motors are located at the front
of the cab, the machine will move reverse when
travel controls are moved towards cab front.
S0037
EX455 S-7

SAFETY PRECAUTIONS

AVOID INJURY FROM BACK-OVER AND

SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.

• To avoid back-over and swing accidents:

- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.

- Keep the travel alarm in working condition (if

equipped).

- ALWAYS BE ALERT FOR BYSTANDERS

S0042
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.

- USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.

- Use hand signals, which conform to your local

regulations, when work conditions require a
signal person.

- No machine motions shall be made unless S0043

signals are clearly understood by both signalman
and operator.

- Learn the meanings of all flags, signs, and

markings used on the job and confirm with the
person in charge of signalling.

- Keep windows, mirrors, and lights clean and in

good condition.

- Dust, heavy rain, fog, etc., can reduce visibility.

As visibility decreases, reduce speed and use
proper lighting.

- Read and understand all operating instructions in

the OPERATION AND MAINTENANCE
INSTRUCTION MANUAL.
S-8 EX455

SAFETY PRECAUTIONS

DRIVE MACHINE SAFELY

• Before starting the machine carefully read the

OPERATION AND MAINTENANCE INSTRUC-
TION MANUAL. (Refer to the OPERATING IN-
STRUCTIONS chapter).

• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.

- Pushing down on the front of the travel pedals or

S0038
pushing the levers forward moves the machine
towards the idlers. (Refer to the OPERATION
AND MAINTENANCE INSTRUCTION
MANUAL).

• Traveling on a grade may cause the machine to slip

or to overturn, possibly resulting in serious injury or
death.

- When traveling up or down a grade, keep the

bucket in the direction of travel, approximately 20
to 30 cm (A) above the ground.

- If machine starts to skid or becomes unstable,

lower the bucket immediately. S0039

- Traveling across the face of a slope may cause

the machine to skid or to overturn. When
travelling (ascending/descending) on a slope, be
sure to point the tracks uphill/downhill.

S0004

- Turning on an incline may cause the machine to

tip over.
If turning on an incline is absolutely unavoidable,
do so at a place where the slope is gentle and the
surface is firm.

- When operating on a grade and the fuel reserve

indicator light lights, immediately refuel.

WRONG
S0005
EX455 S-9

SAFETY PRECAUTIONS

AVOID OVERTURNING

• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death.

• To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the bucket low to the ground and close to
the machine.
- Reduce machine operating speed to avoid
tipping or slipping.
- Avoid changing direction when travelling on
grades. S0002
- NEVER attempt to travel across a grade steeper
than 15 degrees.
- Reduce swing speed as necessary when
swinging loads.

• Be careful when working on frozen ground.

- Temperature increases will cause the ground to
become soft and make ground travel unstable.

S0047

PARK MACHINE SAFELY

• To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Turn auto-idle (A/I) switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Pull the safety lever (pilot-control shut-off lever) to
the LOCK position.
- Close windows, roof window, and cab door.
- Lock all access doors and compartments. S0049
S-10 EX455

SAFETY PRECAUTIONS

AVOID INJURY FROM UNEXPECTED

MACHINE MOVEMENT

• Death or serious injury may result if you attempt to

get on or off a moving machine.

• To avoid roll-aways:
- Select level ground when possible to park
machine.
- Do not park the machine on a grade.
- Lower the bucket and/or other work tools to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
- Turn the auto-idle switch off.
- Run the engine at slow idle speed without load for
S0040
5 minutes to cool down the engine.
- Stop the engine and remove the key from the key
switch.
- Pull the pilot shut-off lever to LOCK position.
- Block both tracks.
- Position the machine to prevent overturning.
- Park a reasonable distance from other machines.

S0041

PROVIDE SIGNALS FOR JOBS

INVOLVING A NUMBER OF MACHINES

• For jobs involving several machines, provide

signals commonly known by all personnel involved.
Also, appoint a signal person to co-ordinate the job
site. Make sure that all personnel obey the signal
person’s directions.

S0036
EX455 S-11

SAFETY PRECAUTIONS

INVESTIGATE JOB SITE BEFORE HAND

• When working at the edge of an excavation or on

a road shoulder, the machine could overturn,
possibly resulting in serious injury or death.
- Investigate the configuration and ground
conditions of the job site beforehand to prevent
the machine from overturning and prevent the
ground, stockpiles, or banks from collapsing.
- Make a work plan. Use machines appropriate to
the work and job site.
- Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
- When working on an incline or road shoulder,
employ a signal person as required.
Confirm that your machine is equipped with a S0034

F.O.P.S. (Falling Object Protective Structure)

cab before working in areas where there is the
possibility of falling stones or landslides.
- When footing is weak, reinforce the ground
before starting the work.
- When working on frozen ground, be extremely
alert. As ambient temperature rises, footing
becomes loose and slipped.

PROTECT AGAINST FALLING STONES

AND LANDSLIDES

• Confirm that your machine is equipped with a

F.O.P.S. (Falling Object Protective Structure) cab
before working in areas where there is the
possibility of falling stones.

S0035
S-12 EX455

SAFETY PRECAUTIONS

DIG WITH CAUTION

• Accidental severing of underground cables or gas

lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
- Before digging, check the location of cables, gas
lines, and water lines.
- Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic
cable should be accidentally severed, do not look
into the end. Doing so may result in serious eye
injury.
- Contact local authorities and/or the utility
companies directly (electric power, gas,
telephone, water, sewers, telecommunications,
etc.) to obtain information about underground S0009

utility lines.

OPERATE WITH CAUTION

• If the front attachment or any other part of the

machine hits against an overhead obstacle, such
as a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury may
results as well.

- Take care to avoid hitting overhead obstacles

with the boom or arm.

S0008

AVOID ELECTRIC LINES

• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines. L
- When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m plus twice the line insulator length (L).
- Check and comply with any local regulations that
may apply.
- Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
- Keep all bystanders or co-workers away from the
site.

S0205
EX455 S-13

SAFETY PRECAUTIONS

KEEP PERSONNEL CLEAR FROM

WORKING AREA

• A person may be hit severely by the swinging front

attachment or counterweight and/or may be
crushed against an other object, resulting in serious
injury or death.

- Keep all persons clear from the area of operation

and machine movement.
- Before operating the machine, set up barriers to
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.

S0044

NEVER MOVE THE BUCKET OVER ANY

ONE

• Never lift, move, or swing bucket above anyone or

a truck cab.
Serious injury or machine damage may result due
to bucket load spill or due to collision with the
bucket.

S0045

AVOID UNDERCUTTING

• In order to retreat from the edge of an excavation if

the footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.

- If the footing starts to collapse and if sufficient

retreat is not possible, do not panic. Often, the
machine can be secured by lowering the front
attachment, in such cases.

S0011
S-14 EX455

SAFETY PRECAUTIONS

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could

occur causing serious injury or death.

S0048

SAFETY LOADS MOVING

• The excavator is no lifting and transportation

means, therefore it should not be used to position
loads accurately. Should it be exceptionally used to
lift and lay building components, special caution
must be taken as follows:

- The machine must be equipped without failure

with the appropriate variant supplied, upon
request, by FIAT KOBELCO. Also, totally comply
with the safety precautions for the operation of the
excavator as a lifting equipment.

- Secure the loads to be raised using cables or

chains fastened with appropriate hooking
mechanisms.

- Never hook cables or chains to the bucket teeth.

- Nobody should be allowed to remain under the

raised load or within the excavator operating
range for any reason whatever.
S0165

- Never exceed specified loading capacity.

Incorrect fastening of slings or chains may cause
boom/arm failure or failure of the lifting means
with consequent bodily injuries and even death.

- Always ensure that slings and chains used for

lifting are adequate to the load and in good
condition.

- All loading capacities are referred to the

machine on a level surface and should be
disregarded when working on a slope.
EX455 S-15

SAFETY PRECAUTIONS

SAFETY TRANSPORTING

• The danger of tipping is present when loading/

unloading the machine onto/from a truck or trailer
bed.
- Be sure to observe local regulations when
transporting the machine on public roads.
- Provide an appropriate truck or trailer for
transporting the machine.

• Take the following precautions when loading/

unloading the machine:
1. Select firm level ground.
2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when loading/ S0052

unloading the machine.

4. Always turn the auto-idle (A/I) switch OFF when
loading or unloading the machine, to avoid
unexpected speed increase due to unintentional
operation of a control lever.
5. Always select the slow speed mode with the
travel speed selector. In the high speed mode,
travel speed may automatically increase.
6. Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify travelling direction, and begin to
drive again.
7. Do not operate any levers besides the travel
levers when driving up or down the ramp.
8. The top end of the ramp where it meets the
flatbed is a sudden jolt. Take care when traveling
over it.
9. Prevent possible injury from machine tipping
while the upperstructure is rotating.
10. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11. Securely fasten machine frame using chains or
cables. Refer to “TRANSPORT” chapter in the
OPERATION AND MAINTENANCE
INSTRUCTION MANUAL for details.
S-16 EX455

SAFETY PRECAUTIONS

SAFE MAINTENANCE
• To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Kepp the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it is
in motion.
- Kepp hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Switch off the Auto-Idle (A/I).
4. Let the engine idle with no load for at least five
minutes until it has cooled down.
5. Move the key-start switch to the OFF position
to stop the engine.
6. Relieve pressure from the hydraulic system by
S0053
cycling control levers several times.
7. Remove the ignition key from the start switch.
8. Apply the "Maintenance in progress" tag .
This tag can be applied o the left-hand control
lever, safety lever or cab door.
9. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
10. Let the engine cool down.
- Do not leave the machine unattended if servicing
requires the engine running .
- If the machine is to be raised, place boom and arm
at an angle 90 to 110°. Lock machine components
which should be raised for maintenance or repair
using suitable supporting means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary. S0054
Refer to the the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL.
- Keep all components in good condition and
properly install. Immediately repair any fault.
- Immediately repair any damage.Replace worn or
failed components. Remove grease, oil, debris
build-ups.
- Disconnect the negative cable (−) from the battery
before carry out any work on the electrical system
or arc-welding on the machine.
EX455 S-17

SAFETY PRECAUTIONS

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause

serious injury.

- Before performing any work on the machine,

attach a maintenance in progress tag. This tag
can be applied o the left-hand control lever,
safety lever or cab door.

S0055

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without

securing the machine first.

- Always lower the attachment or tool to the ground

before working on the machine.
- If you must work on a lifted machine or
attachment, securely support the machine or
attachment.
- Do not support the machine on cinder blocks,
bollow tires, or props that may crumble under
continuous load.
- Do not work under a machine that is supported S0054
solely by a jack.

STAY CLEAR OF MOVING PARTS

• Entanglements in moving parts can cause serious

injury.

• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working near
rotating parts.

S0056
S-18 EX455

SAFETY PRECAUTIONS

DISPOSE OF WASTE IN THE

APPROPRIATE MANNER

• Waste improperly disposed of represents a danger

for the envinronment. Potentially dangerous waste
used on the FIAT KOBELCO excavators includes
lubricants, fuel, coolant, brake fluid, filters and
batteries.

- Used sealed containers when discharging fluids.

Do not use containers for food or beverages
which may induce drinking.

- Do not spill waste over the ground, into drains, or

water beds.
S0064

- Obtain information about the correct methods to

recycle or dispose of waste from local
Authorities, collection centres or your Dealer.

WORK IN A CLEAN AREA

• Before starting an operation, clean the working

area.
Clear the area from all the objects that can be
dangerous for mechanics or people in the working
area.

S0166

PROPERLY LIGHT THE WORKING AREA

• Properly and safely light the working area.

- Use safe portable lamps in order to work inside

and under the machine.

- Make sure that the lamp is shielded by a cage;

the incandescent filament of a lamp, accidentally
broken, can cause fuel or oil fire. F1480

S0167
EX455 S-19

SAFETY PRECAUTIONS

REGULARLY WASH THE MACHINE

• Remove all the traces of grease, oil and deposits,

in order to avoid people accidents or damages to
things.

- Do not spray water or steam in the cab.

F1462 S0153

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

breakers and blades can fall and cause serious
injury or death.

- Securely store attachments and implements to

prevent falling.

- Keep bystanders away from storage areas.

F1463 S0058

PREVENT ACID SCALDS

• The sulphuric acid, contained in the battery, is
poisonous.
It is strong enough to scald the skin, corrode
clothes and cause blindness, if it is sprayed into
the eyes.
To avoid dangers:
- Fill the batteries in airy areas.
- Wear eye protections and rubber gloves.
- Avoid breathing the electrolyte vapours when
topping up.
- Avoid spilling or dripping the electrolyte.
- Use proper emergency starting techniques.
If you are touched with acid sprays:
- Rinse your skin well with water.
- Put on your skin sodium bicarbonate or clay to F1474 S0168

help the acid neutralization.

- Rinse your eyes with water for 10-15 minutes.
- Immediately see a doctor.
If you have swallowed the acid:
- Drink a big quantity of water or milk, swallow
milk of magnesia, scrabbled eggs or vegetal oil.
- Immediately see a doctor.
S-20 EX455

SAFETY PRECAUTIONS

STARTING THE ENGINE WITH

BOOSTER BATTERIES

• Battery gas may explode causing serious damages

and injuries.

- If the engine is to be started using booster

batteries, ensure to comply with all procedures
detailed in the chapter “OPERATING
INSTRUCTIONS” of the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL.

- The operator should be sitting in the driver’s seat

to keep the machine under control when the
engine starts. Starting the engine with booster
S0001
batteries is a two man operation.

- Do not use batteries that have been stored in the

cold for a long time.

- Mistakes in following procedures detailed for

starting the engine with slave batteries may
cause the batteries to explode or machine to
move unexpectedly.

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

- Keep sparks, lighted matches, and flames away

from the top of battery.

- Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.

- Do not charge a frozen battery; it may explode.

Warm battery to 16 °C.

• Battery electrolyte is poisonous. If the battery

should explode, battery electrolyte may be S0001

splashed into eyes, possibly resulting in blindness.

- Be sure to wear eye protection when checking

electrolyte specific gravity.
EX455 S-21

SAFETY PRECAUTIONS

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.

- To prevent possible injury from hot spraying

water. DO NOT remove the radiator cap until the
engine is cool. When opening, turn the cap slowly
to the stop. Allow all pressure to be released
before removing the cap.
- The hydraulic oil tank is pressurized. Again, be S0019

sure to release all pressure before removing the

cap.

Hot fluids and surfaces:

• Engine oil, reduction gear oil and hydraulic oil also

become hot during operation.
The engine, hoses, lines and other parts become
hot as well.

- Wait for the oil and components to cool down

before starting any maintenance or inspection
work.

S0059

KEEP CLEAN THE MACHINE

Keep clean the engine compartment, radiator,

batteries, hydraulic pipes, fuel tank and operator's
position.
The engine compartment temperature can quickly
rise, after stopping the engine.
IN THESE CASES, BE CAREFUL TO POSSIBLE
FIRES.
Open the access doors in order to quicken the engine
cooling process and clean the compartment.

S0177
S-22 EX455

SAFETY PRECAUTIONS

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.

- Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
SA0016

- Relieve the pressure by moving the control levers

several times.

- Tighten all connections before applying pressure.

- Search for leaks with a piece of cardboard; take

care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles for
SA0017
eye protection.

- In an accident occurs, see a doctor familiar with

this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.

SA0018

PREVENT PARTS FROM FLYING OFF

• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result
in serious injury, blindness, or death.

- NEVER attempt to remove GREASE FITTING

or VALVE ASSEMBLY.
- As pieces may fly off, be sure to keep body and
face away from valve.

• Travel reduction gears are under pressure. F3635

S0178
- As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. REDUCTION GEAR OIL is hot. Wait for
gear oil to cool down, then gradually loosen the air
release plug to release pressure.
EX455 S-23

SAFETY PRECAUTIONS

PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body,

serious injury may result.

- Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.

S0046

HANDLE FLUIDS SAFELY - AVOID FIRES

• Handle fuel with care: it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.

- Do not refuel the machine while smoking or when

near open flame or sparks.
- Always stop the engine before refuelling the
machine.
- Fill the tank outdoors.

S0050
• All fuels, most lubrificants, and some antifreeze
fluids are flammable.

- Store flammable fluids well away from fire

hazards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn
spontaneously.

S0051
S-24 EX455

SAFETY PRECAUTIONS

PREVENT FIRES

• Check for Oil Leaks:

- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other,
damage to the oil-cooler, and loose oil-cooler
flange bolts which may cause oil leaks.
- Tighten, repair or replace any missing, loose or S0051
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.

• Check for Shorts circuits which could cause fires:

- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..

• Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.

• Check Key-start Switch:

- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF position
to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.

• Check Heat Shields:

- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
EX455 S-25

SAFETY PRECAUTIONS

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the

following way:

- Stop the engine by turning the key-start switch to

the OFF position if there is time.

- Use a fire extinguisher if there is time.

- Exit the machine.

S0060

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.

- If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.

S0061

USE APPROPRIATE TOOLS

• Use tools appropriate for the job to be performed.

- Inappropriate tools, parts and procedures might

generate dangerous conditions.

- Use tools of correct size to tighten or loosening

securing elements, in order to avoid injuries
caused by a wrench getting out of control.

- Do not use U.S. Standard or British Standard

tools on metric fasteners and vice versa.

• Use only FIAT KOBELCO genuine spare parts

(please refer to the PARTS CATALOG). S0120
S-26 EX455

SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.

Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable ma-
terials.

Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area. Install tem-
porary fire resistant guards to protect hoses or other
materials when welding, soldering, etc.

S0062

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

- Do not weld or flame cut pipes or tubes that contain

flammable fluids.

- Clean them thoroughly with non-flammable solvent

before welding or flame cutting them.

REMOVE PAINT BEFORE WELDING OR

HEATING

• Hazardous fumes can be generated when paints is

heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.

- Avoid breathing potentially toxic fumes and dust.

- Do all such work outside or in a well-ventilated

area.

- Dispose of paint and solvents properly.

- Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the S0063
dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
WORKSHOP MANUAL EX455

ESCAVATOR

SECTION AND GROUP CONTENTS

Section 1 - GENERAL INFORMATION

Group 1 - Precautions for Disassembly and Assembly
Group 2 - Tightening Torque

Section 2 - TORRETTA
Group 1 - Cab
Group 2 - Counterweight
Group 3 - Main Frame
Group 4 - Pump Device
Group 5 - Control Valve
Group 6 - Swing Device
Group 7 - Pilot Valve
Group 8 - Pilot Shut-Off Valve
Group 9 - Shockless Valve
Group 10 - Solenoid Valve Unit

Section 3 - UNDERCARRIAGE
Group 1 - Swing Bearing
Group 2 - Travel Device
Group 3 - Center Joint
Group 4 - Track Adjuster
Group 5 - Front Idler
Group 6 - Upper and Lower Roller
Group 7 - Tracks

Section 4 - FRONT ATTACHMENT

Group 1 - Front Attachment
Group 2 - Cylinders
Section 5 - ENGINE AND ACCESSORY
Group 1 - General Information
Group 2 - Maintenance
Group 3 - Engine Overhaul
Group 4 - Engine Lubrication
Group 5 - Engine Cooling
Group 6 - Engine Fuel
Group 7 - Engine Induction
Group 8 - Starting and Charging
Group 9 - Troubleshooting
SECTION 1 EX455

GENERAL INFORMATION

CONTENTS

Group 1 - Precautions for Disas- Group 2 - Tightening Torque

sembly and Assembly
Tightening Torque Specification ............ W1-2-1
Precautions for Disassembly and Torque Chart ........................................ W1-2-2
Assembly ............................................. W1-1-1
Piping joint ........................................... W1-2-5
Maintenance Standard Terminology ...... W1-1-4
EX455
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
PRECAUTIONS FOR DISASSEMBLY
AND ASSEMBLY
Precautions for Disassembly
• Clean the Machine
Thoroughly wash the machine before bringing it
into the shop. Bringing a dirty machine into the
shop may cause machine components to be con-
taminated during disassembling/assembling, re-
sulting in damage to machine components, as well
as decreased efficiency in service work.
• Inspect the Machine
Be sure to thoroughly understand all disassem-
bling/assembling procedures beforehand, to help
avoid incorrect disassembling of components as
well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
- The machine model, machine serial number, and
hour meter reading.
- Reason for disassembly (symptoms, failed
parts, and causes).
- Clogging of filters and oil, water or air leaks, if
any.
- Capacities and condition of lubricants.
- Loose or damaged parts.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the
area for disassembling work.
W1-1-1
Precautions for Disassembly and Assembly
• Precautions for Disassembly
- To prevent dirt from entering, cap or plug the
removed pipes.
- Before disassembling, clean the exterior of the
components and place it on a work bench.
- Before disassembling, drain gear oil from the
reduction gear.
- Be sure to provide appropriate containers for
draining fluids.
- Use matching marks for easier reassembling.
- Be sure to use the specified special tools, when
instructed.
- If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
- Orderly arrange disassembled parts. Mark and
tag them as necessary.
- Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
- Inspect the contact or sliding surfaces of disas-
sembled parts for abnormal wear, sticking, or
other damage.
- Measure and record the degree of wear and
clearances.
• Precautions for Assembly
- Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace it.
- Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
- Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassem-
bled. Apply a film of grease before installing.
- Be sure that liquid-gasket-applied surfaces are
clean and dry.
- If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to
remove the agent.
- Utilize matching marks when assembling.
- Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
- Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no tools are missing.
W1-1-2 EX455

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

Bleeding Air from Hydraulic System

When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and instal-
lation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:

• Bleeding Air from Hydraulic Pump

IMPORTANT - If the engine is started with air trapped

in the hydraulic pump housing, damage to the pump
may result. Be sure to bleed air before starting the
engine.

- Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
- After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the
engine and run at slow idle speed.
- Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
- After bleeding all the air, securely tighten the
plug.

• Bleeding Air from Travel Motor / Swing Motor

- With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.

• Bleeding Air from Hydraulic Circuit

- After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each
operation (never fully stroke the cylinders during
initial operation stage). As the pilot oil circuit has
an air bleed device, air trapped in the pilot oil
circuit will be bled while performing the above
operation for approx. 5 minutes.
- Reposition the front attachment to check hydrau-
lic oil level.
SM1000
- Stop the engine. Recheck hydraulic oil level.
Replenish oil as necessary.
EX455 W1-1-3

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

Floating Seal Precautions A

1. In general, replace the floating seal with a new one.

If the floating is to be reused, follow these proce-
dures:

(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces.

(2) Check the seal ring face (A) for scuffing, scor- B SM1001

ing, corrosion, deformation or uneven wear.

(3) Check O-ring (B) for tears, breaks, deformation

or hardening.

2. If incorrectly assembled, oil leakage or damage will

occur. Be sure to do the following, to prevent
trouble.

(1) Clean the floating seal and seal mounting bores

with cleaning solvent. RIGHT
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with com-
pressed air.
WRONG
(2) Clean the floating seal and seal mounting bores,
as dust on them tends to enter the floating seal
when installing it.

(3) Check that the O-ring is not twisted, and that it SM1002

is installed correctly on the seal ring.

(4) After installing the floating seal, check that seal

RIGHT WRONG
ring surface (C) is parallel with mating face (A)
by measuring the distances (A) and (C) at point A
(a) and (b), as illustrated. If these distances a a
differ, correct the O-ring seating.
C

b b
a=b a≠b
SM1003
W1-1-4 EX455

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

MAINTENANCE STANDARD
TERMINOLOGY

"Standard"
1. Dimension for parts on a new machine.
2. Dimension of components or assemblies adjusted
to specification.

Both dimensions are shown with tolerances as nec-

essary.

"Allowable Limit"
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or replacement is required before reaching
this limit.

Machine performance will decrease, and mainte-

nance and down time expense will increase as ma-
chine operating hours accumulate. It is recom-
mended that parts are repaired or replaced before
reaching the "Allowable Limit".
EX455 W1-2-1

TIGHTENING TORQUE

TIGHTENING TORQUE SPECIFICATIONS

No. Descriptions Bolt Diam. Wrench Torque

Size
mm mm Nm kgf m lbf ft

1 Engine cushion rubber mounting bolt 16 24 205 21 152

20 30 540 55 398

2 Engine bracket mounting bolt 14 22 175 18 130

22 32 740 75 540

3 Hydraulic oil tank mounting bolt 16 24 205 21 152

4 Fuel tank mounting bolt 16 24 205 21 152

5 ORS fittings for hydraulic hoses and piping * 1-3/16"-12 36 175 18 130
* 1-7/16"-12 41 205 21 152
* 1-11/16"-12 50 324 33 239

6 Pump device mounting bolt 12 19 90 9.2 65

7 Control valve bracket mounting bolt 20 17 390 40 290

8 Swing device mounting bolt 22 32 740 75 540

9 Battery mounting bolt 10 17 9.8 1 7

10 Cab mounting nut 16 24 205 21 152

11 Swing bearing mounting bolt to upperst. 27 41 1375 140 1010

Swing bearing mounting bolt to undercar. 27 41 1375 140 1010

12 Travel device mounting bolt 22 32 665 68 490

13 Sprocket mounting bolt 22 32 740 75 540

14 Upper roller mounting bolt 18 27 340 34.7 250

15 Lower roller mounting bolt 22 32 550 56 811

16 Track shoe mounting bolt 7/8" 14 33 1100 112 811

UNF-2A

17 Low pressure coupling and clamp 8 13 10.3to12.4 1.05to1.26 8 to 16

5 8 2.90 0.30 2
6 10 4.40 0.45 3

*: UNF thread

NOTE - (1) Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to stabilize friction
coefficient of them.
(2) Make sure bolt and nut threads are clean before installing.
(3) Apply Loctite to threads before installing and tightening swing bearing mounting bolts.
W1-2-2 EX455

TIGHTENING TORQUE

TORQUE CHART

WARNING
Use tools appropriate for the work to be done.
Makeshift tools and procedures can create safety
hazards. For loosening and tightening nuts and
bolts, use the correct tools. Avoid bodily injury
caused by slipping wrenches.

Bolt Types

Tighten nuts or bolts correctly to torque specifications.

Four kinds of bolts, hexagon bolts T, H, M and socket
bolt, each made of different material, are used. Make SM1004
sure to employ the correct bolts and tighten them to
specification when assembling the machine or compo-
nents.

Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

SM1005

Specified Tightening Torque Chart

Bolt Wrench Hexagon T Bolt, Socket bolt H Bolt M Bolt

Dia. Size Wrench
Size Nm kgf m lbf ft Nm kgf m lbf ft Nm kgf m lbf ft

M8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2

M10 17 8 64 6.5 47 49 5 36 19.5 2 14.5
M12 19 10 108 11 80 88 9 65 34 3.5 25.5
M14 22 12 175 18 130 137 14 101 54 5.5 40
M16 24 14 265 27 195 205 21 152 78 8 58
M18 27 14 390 40 290 295 30 220 118 12 87
M20 30 17 540 55 400 390 40 290 167 17 123
M22 32 17 740 75 540 540 55 400 215 22 159
M24 36 19 930 95 690 690 70 505 275 28 205
M27 41 19 1 370 140 1 010 1 030 105 760 390 40 290
M30 46 22 1 910 195 1 410 1 420 145 1 050 540 55 400
M33 50 24 2 550 260 1 880 1 910 195 1 410 740 75 540
M36 55 27 3 140 320 2 310 2 400 245 1 770 930 95 690
EX455 W1-2-3

TIGHTENING TORQUE

IMPORTANT
(1) Apply lubricant (i. e. white zinc B dissolved into
spindle oil) to nuts and bolts to stabilize their
friction coefficients.
(2) Torque tolerance is ±10 %.
(3) Be sure to use bolts of correct length. Bolts that are
too long cannot be tightened, as the bolt tip comes
into contact with the bottom of the bolt hole. Bolts
that are too short cannot develop sufficient tighten-
ing force.
(4) The torques given in the chart are for general use
only.
Do not use these torques if a different torque is
given for a specific application.
(5) Make sure that the nut and bolt threads are clean
before installing. Remove dirt or corrosion, if any.

Bolt Tightening Order

When tightening two or more bolts, tighten them

alternately, as shown, to ensure even tightening.

Equally tighten upper

Tighten diagonally Tighten from center and diagonally
and lower alternately

1 12 9 4 1 6 7 14
1,4 6 3

2,3 4 5
2 13 8 5 2 3 10 11

SM1006
W1-2-4 EX455

TIGHTENING TORQUE

Service Recommendations for Split Flange

IMPORTANT
(1) Be sure to clean and inspect sealing surfaces.
Scratches / roughness cause leaks and seal wear.
SM1007
Unevenness causes seal extrusion. If defects
cannot be polished out, replace the component.
(2) Be sure to use only specified O-rings. Inspect O-
rings for any damage. Take care not to file O-ring WRONG
surfaces. When installing an O-ring into a groove,
use grease to hold it in place.
(3) Loosely assemble split flange halves. Make sure
that the split is centrally located and perpendicular
to the port. Hand-tighten the bolts to hold the parts
in place. Take care not to pinch the O-ring.
(4) Tighten bolts alternately and diagonally, as shown,
to ensure even tightening.
(5) Do not use air wrenches. Using an air wrench often SM1008

causes tightening of one bolt fully before tighten

the others, resulting in damage to O-rings or un-
even tightening of bolts.

Nut and Bolt Lockings

• Lock Plate

SM1009
IMPORTANT - Do not reuse lock plates. Do not try to
bend the same point twice.
RIGHT WRONG

• Cotter Pin

IMPORTANT - Do not reuse cotter pins. Match the Bend along edge Do not bend it round
holes in the bolt and nut while tightening, not while sharply
loosening.
RIGHT RIGHT WRONG

• Lock Wire

IMPORTANT - Apply wire to bolts in the bolt-tightening

direction, not in the bolt-loosening direction.
Bend along edge SM1010
sharply

RIGHT RIGHT WRONG

RIGHT WRONG
Loosen
Tighten

SM1011
EX455 W1-2-5

TIGHTENING TORQUE

PIPING JOINT

Pipe Thread Connection / Union Joint Tightening 1 4 3 5 2

Torque Specifications

Union Joint

Metal sealing faces (4) and (5) of adaptor (1) and hose
(2) fit together to seal pressure oil. Union joints are used
to join small-diameter lines.

Joint Body
SM1012
IMPORTANT
(1) Do not over-tighten union nut (3). Excessive force
will be applied to metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be sure to tighten
union nut (3) to specifications. 37°

(2) Scratches or other damage to sealing surfaces (4) or 37°

(5) will cause oil leakage at the joint. Take care not
to damage them when connecting /disconnecting.

Male Union Joint Female Union Joint

SM1013

Wrench Size Tightening Torque

Type
Union Nut Joint Body Nm kgf m lbf ft
37° Union Joint 19 17 29 3 22
22 19 39 4 29
27 22 78.5 8 69
36 30, 32 157 16 116
41 36 205 21 152.5
50 46 255 26 188

NOTE - Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.
W1-2-6 EX455

TIGHTENING TORQUE

O-ring Seal Joint

O-ring (6) seats against the end face of adaptor (7) to 7 6 9

seal pressure oil.

IMPORTANT
(1) Be sure to replace O-ring (6) with a new one when
reconnecting.

(2) Before tightening union nut (9), confirm that O-ring 8 10 Joint body
(6) is seated correctly in O-ring groove (8). Tighten-
SM1014
ing union nut (9) with O-ring (6) displaced will
damage O-ring (6), resulting in oil leakage.
Wrench Size Tightening Torque
(3) Take care not to damage O-ring groove (8) or
sealing face (10). Damage to O-ring (6) will cause Union Joint Nm kgf m lbf ft
oil leakage. Nut Body
27 22 93 9.5 69
(4) If union nut (9) is found to be loose, causing oil
leakage, do not tighten it to stop the leak. Instead, 36 30, 32 175 18 130
replace O-ring (6) with a new one, then tighten union 41 36 205 21 152
nut (9) after confirming that O-ring (6) is securely 50 46 320 33 240
seated in place.
EX455 W1-2-7

TIGHTENING TORQUE

Screwed-In Connection PT PF

30°

IMPORTANT - Many types of screwed-in connec-

tions are used for hose connections.
Be sure to confirm that the thread pitch and thread type
(tapered or straight) are the correct type before using
any screw-in connection. Male Tapered Thread Male Straight Thread
SM1015

Male Tapered Thread

Wrench Tightening Torque
Joint Body Nm kgf m lbf ft
17, 19 34 3.5 25
19, 22 49 5 36
27, 22 93 9.5 69
36, 32 157 16 116
41 205 21 152.5
50 320 33 240
60 410 42 300

Seal Tape Application

Internal Thread

Seal tape is used to seal clearances between male and

female threads, so as to prevent any leakage between
threads.
Clearance External Thread
Be sure to apply just enough seal tape to fill up thread SM1016
clearances. Do not overwrap.

Leave one to two pitch threads uncovered

• Application Procedure

Confirm that the thread surface is clean, free of dirt

or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque SM1017

Low-pressure-hose clamp tightening torque differs

depending on the type of clamp.
See below for correct tightening torque of each type of T-Bolt Type Worm Gear Type
low-pressure-hose clamp.

T-Bolt Type Band Clamp:

4.4 N m (0.45 kgf m, 3.25 lbf ft )
Worm Gear Type Band Clamp:
5.9 to 6.9 N m (0.6 to 0.7 kgf m, 4.3 to 5.1 lbf ft)

SM1018 SM1019
W1-2-8 EX455

TIGHTENING TORQUE

Connecting Hose WRONG RIGHT

WARNING
(1) When replacing hoses, be sure to use only
genuine parts. Using hoses other than genuine
hoses may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in a fire
on the machine. SM1020
(2) Do not install hoses kinked. Application of high
oil pressure, vibration, or an impact to a kinked
hose may result in oil leakage, hose rupture or
WRONG RIGHT
separation of fitting. Utilize print marks on hoses
when installing hoses to prevent hose from Rubbing Against Each Other
being installed kinked.
(3) If hoses rub against each other, wear to the
hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other.
SM1021
Take care that hoses do not come into contact
with moving parts or sharp objects.

WRONG RIGHT

Clamp Clamp

Rubbing

SM1022

WRONG RIGHT

Rubbing
Clamp
SM1023
SECTION 2 EX455

UPPERSTRUCTURE

CONTENTS

Group 1 - Cab Group 7 - Pilot Valve

Remove and Install Cab ....................... W2-1-1
Group 2 - Counterweight
Remove and Install Counterweight ....... W2-2-1
Group 3 - Main Frame
Remove and Install Main Frame ........... W2-3-1
Group 4 - Pump Device
Remove and Install Pump Device ........ W2-4-1
Disassemble Pump Transmission ......... W2-4-2
Group 8 -
Assemble Pump Transmission ............. W2-4-6
Disassemble Main Pump ................... W2-4-12
Assemble Main Pump ........................ W2-4-18
Disassemble and Assemble
Pilot Pump ........................................ W2-4-24
Remove and Install Right Pilot Valve .... W2-7-1
Remove and Install Left Pilot Valve ...... W2-7-4
Remove and Install Travel Pilot Valve ... W2-7-7
Disassemble Right and Left
Pilot Valve ........................................... W2-7-8
Assemble Right and Left
Pilot Valve ......................................... W2-7-10
Disassemble Travel Pilot Valve ........... W2-7-14
Assemble Travel Pilot Valve ............... W2-7-16
Pilot Shut-Off Valve
Remove and Install
Pilot Shut-off Valve .............................. W2-8-1
Disassemble Pilot Shut-off Valve ......... W2-8-2
Assemble Pilot Shut-off Valve .............. W2-8-4

Group 9 - Shockless Valve

Group 5 - Control Valve Remove and Install
Remove and Install Control Valve ......... W2-5-1 Shockless Valve .................................. W2-9-1
Disassemble Control Valve (1) ............ W2-5-2 Disassemble and Assemble Front
Assemble Control Valve (1) .................. W2-5-6 Attachment Shockless Valve ............... W2-9-2
Disassemble Control Valve (2) ........... W2-5-12 Remove and Install Travel
Assemble Control Valve (2) ................ W2-5-14 Shockless Valve .................................. W2-9-5
Disassemble Control Valve (3) ........... W2-5-16
Assemble Control Valve (3) ................ W2-5-22
Group 10 - Solenoid Valve Unit
Disassemble Control Valve (4) ........... W2-5-28
Assemble Control Valve (4) ................ W2-5-30 Remove and Install Three-Spool
Solenoid Valve Unit ............................ W2-10-1
Disassemble Control Valve (5) ........... W2-5-32
Assemble Control Valve (5) ................ W2-5-34

Group 6 - Swing Device

Remove and Install Swing Device ........ W2-6-1
Disassemble Swing Device .................. W2-6-2
Assemble Swing Device ...................... W2-6-6
Disassemble Swing Motor .................. W2-6-10
Assemble Swing Motor ...................... W2-6-14
Maintenance Standard ....................... W2-6-18
EX455 W2-1-1

CAB

REMOVE AND INSTALL CAB

Remove Cab

1. Remove nuts (2) and seat (1).

: 13 mm

SM1125

8 7 8
2. Loosen bolts (6) (3 used) and bolts (4) (4 used)
behind the cab and remove rear cover (5).
: 13 mm
4 5

3. Loosen bolts (8) to remove rear under cover (7).

: 13 mm

6
SM1126

4. Remove filter (20). Loosen screws (9) to remove

duct (10) from the cab.

20
9

10
SM1127
W2-1-2 EX455

CAB

5. Disconnect cable connectors (11, relais), (12, an-

tenna, ceiling lamp and windshield wiper), (13, 12
loudspeaker) behind the cab and ground (14) inside
the cab. 13

11

SM5740

6. Remove washer vinyl hose (15) behind the cab.

15

SM5741

7. Remove cap (21) from duct cover (16). Loosen

screws (17) to remove duct cover (16).
21 17 16

SM1130

8. While pushing the mating surface of duct (18)

toward the rear side of the cab, remove duct (18). Mating Surface of Duct

18

SM1131
EX455 W2-1-3

CAB

9. Attach cab to hoist using lifting straps.

WARNING
The approximate weight of cab:
250 kg (551 lb)

SM1132

10. Remove bolts (19) and nuts (22).

: 17 mm
19
: 24 mm
: 8 mm
22

SM1133

11. Carefully remove cab.

SM1134
W2-1-4 EX455

CAB

Installation

WARNING
The approximate weight of cab:
250 kg (551 lb)

1. Attach cab to hoist using straps.

Install cab onto frame.

SM1134

2. Tighten bolts (19) and nuts (22).

19
: 17 mm

: 49 N m (5 kgfm, 36 lbf ft)

22
: 24 mm

: 205 N m (21 kgf m, 152 lbf ft)

: 8 mm
SM1133
: 64 N m (6.5 kgf m, 47 lbf ft)

3. Install duct (10) to the cab with screws (9).

Install filter (20) into duct (10).

: 4.9 N m (0.5 kgf m, 3.6 lbf ft)

20
9

10 SM1127

12
4. Install harness connectors (11, relais), (12, an-
tenna, ceiling lamp and windshield wiper), (13, 13
loudspeaker) behind the cab and ground (14) inside
the cab.

: 19.5 N m (2 kgf m, 14.5 lbf ft)

11

SM5740
EX455 W2-1-5

CAB

5. Connect washer vinyl hose (15) at the rear of the

cab inside.

15

SM5741

6. Install rear under cover (7) with bolts (8).

: 13 mm 8 7 8
: 19.5 N m (2 kgf m, 14.5 lbf ft)

4 5

7. Install rear cover (5) with bolts (6) (3 used) and bolts
(4) (4 used).
: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)

6
SM1126

8. Push duct (18) toward the front of the cab to insert Mating Surface of Duct
it into the front duct.
18

SM1131
W2-1-6 EX455

CAB

9. Install duct cover (16) with screws (17).

Install caps (21) onto duct cover (16).
21 17 16

SM1130

10. Secure seat (1) with nuts (2).

: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)

SM1125
EX455 W2-2-1

COUNTERWEIGHT

REMOVE AND INSTALL COUNTERWEIGHT

Removal

WARNING
Approximate weight of counterweight:
8 700 kg (19 175 lb)

1. Install lifting accessories and wire ropes to sling

brackets on the top of the counterweight. Set the
wire rope taut using a crane.

WARNING
SM6800
Watch out the power-wrench reaction bar move-
ment. Take care not to be hit the reaction bar.

2. Loosen bolts (10) using a power wrench to remove

bolts (10), nuts (8), shims (7), and washers (9).

NOTE - Shims (7) are used only when any gap between
nuts (8) and the lock brackets exist. When no gap
exists, shims are not required.

: 65 mm

3. Loosen bolts (1) to remove lock washers (2),

washers (3), and spacers (4). If shims (5 and 6) are
provided, remove shims (5 and 6).

: 36 mm

4. Remove the counterweight using a crane. SM6801

SM6802
W2-2-2 EX455

COUNTERWEIGHT

Install counterweight

WARNING
Approximate weight of counterweight:
8700 kg (19175 lb)

1. Install lifting accessories and wire ropes to sling

brackets on the top of the counterweight. Then, lift
the counterweight by crane.

WARNING
Do not allow anyone under the lifted
counterweight.

SM6800
2. Insert protrusions on the counterweight into holes
on the frame to install the counterweight.

WARNING
Watch out the power-wrench reaction bar move-
ment. Take care not to be hit the
reaction bar.

IMPORTANT - Apply lubricant to bolts (10) before

installing. Install shims (7) between nuts (4) and the
lock brackets with the flange positioned in the upper
side.

3. Install bolts (10), nuts (4), shims (7), and washers

(9). Using a power wrench, tighten bolts (10).

: 65 mm
: 1962 N•m (200 kgf•m, 1447 lbf•ft)
SM6801

4. Install shims (5) and (6), spacers (4), washers (3)

lock washers (2), and bolts (1). Remove wire ropes
and lifting accessories.

: 36 mm
: 490 N•m (50 kgf•m, 362 lbf•ft)

SM6802
EX455 W2-3-1

MAIN FRAME

REMOVE AND INSTALL MAIN FRAME

WARNING
Escaping pressure hydraulic oil can penetrate the skin or eyes, causing serious injury. Avoid this hazard by
relieving pressure before disconnecting hydraulic lines.
Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure
to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off due to internal pressure if turned quickly. Slowly turn the cap to release
internal pressure before completely removing the cap.

Preparation

1. Park the machine on firm, level surface.
Lower the front attachment to the ground.
2. Stop the engine. Move all control levers to release
any pressure remaining in the system. Slowly turn
the hydraulic oil tank cap approx. 30 degrees
counterclockwise to release any remaining pres-
sure from the hydraulic oil tank.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump (75298347) to maintain negative pressure in
the hydraulic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal

WARNING
Approximate weight of cab: 250 kg (551 lb)

1. Remove cab assembly. (See Cab section)

: 24 mm, 17 mm, 13 mm
: 8 mm
SM1134

WARNING
Approximate weight of counterweight:
8700 kg (19175 lb)

2. Remove the counterweight.

(See Counterweight section.)

: 36 mm
: 65 mm

SM6800
W2-3-2 EX455

MAIN FRAME

WARNING
Approx. weight of front attachment assembly:
8 900 kg (19 650 lb)

3. Remove front attachment assembly from the

upperstructure. (See Front Attachment section.)

: 19 mm, 30 mm, 36 mm, 41 mm

SM1140

4. Drain hydraulic oil from the hydraulic oil tank, and

disconnect hydraulic lines from the control valve to
the center joint on top of the center joint. Discon-
nect drain hose, and remove the fitting and stopper
from the center joint.

: 22 mm, 27 mm, 41 mm

SM6803
EX455 W2-3-3

MAIN FRAME

WARNING
Approximate weight of main frame:
7 840 kg (17 300 lb)

5. Attach wire ropes to the front and rear of main

frame. See wire ropes taut using a crane. Use chain
blocks for easy adjustment of wire rope lengths and
to level the frame.

IMPORTANT - Make sure rear slings do not touch

engine. SM6804

6. Put matching marks on swing bearing and main

frame. Remove bolts (14) from the swing bearing.

: 41 mm

14

SM6805

7. Lift main frame slightly from undercarriage.

Level main frame by adjusting the chain blocks.

Remove main frame.

SM1146
W2-3-4 EX455

MAIN FRAME

Installation

13
WARNING
Approximate weight of main frame:
7 840 kg (17 300 lb)

1. Fasten hoist to front and rear of main frame.

Level main frame by adjusting chain blocks (13)
and lower main frame onto undercarriage.
Align the matching mark on the swing bearing with
that on the main frame.

SM1146

2. Install bolts (14) on the swing bearing and tighten

temporary.
Install main frame and tighten bolts to specifica-
tion.
: 41 mm
Upperstructure side
: 1375 N m (140 kgf m)
14

SM6805

4 5 9
3. Connect hoses (8) and (10) to the center joint.
: 22 mm
: 69 N•m (7.0 kgf m, 51 lbf•ft)
: 27 mm
6 7
: 93 N•m (9.5 kgf m, 69 lbf•ft)

Connect lines (4 to 7).

: 41 mm, 27 mm, 36 mm
: 205 N•m (21 kgf•m, 152 lbf•ft)

Install stopper (9). 8

: 22 mm
: 135 N m (14 kgf m) 10
SM6803
EX455 W2-3-5

MAIN FRAME

WARNING
Approximate weight of cab: 250 kg (551 lb)

4. Install cab (2).

(See Cab in this section.)

2
: 24 mm
: 205 N•m (21 kgf•m, 159 lbf•ft)
: 17 mm
: 49 N•m (5 kgf•m, 36 lbf•ft)
: 13 mm
: 20 N•m (2 kgf•m, 14 lbf•ft)
: 8 mm SM1134

: 64 N•m (6.5 kgf•m, 47 lbf•ft)

WARNING
Approximate weight of counterweight:
8700 kg (19175 lb)

5. Install counterweight (1).

(See Counterweight in this section.)
: 36 mm
: 490 N•m (50 kgf•m, 362 lbf•ft)
: 65 mm
: 1962 N•m (200 kgf•m, 1447 lbf•ft)

WARNING SM6800
Approx. weight of front attachment assembly:
8900 kg (19650 lb)

6. Install front attachment assembly (3).

(See front Attachment in this section)
: 19 mm
: 29.5 N•m (3 kgf•m, 21.5 lbf•ft)
: 30 mm
: 540 N•m (55 kgf•m, 400 lbf•ft)
: 36 mm
: 137 N•m (14 kgf•m, 101 lbf•ft)
: 41 mm
: 205 N•m (21 kgf•m, 152 lbf•ft)
3 SM1140
W2-3-6 EX455

MAIN FRAME

7. Fill the hydraulic oil tank with hydraulic oil to the

specified level.
Run the engine at slow idle. Check hose connec-
tions for any oil leakage.

SM1147
EX455 W2-4-1

UPPERSTRUCTURE PUMP DEVICE

REMOVE AND INSTALL PUMP DEVICE

WARNING
Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by
relieving pressure before disconnecting hydraulic lines.
Hydraulic oil may be hot after operation and may spurt, possibly causing severe burns. Be sure to wait for oil
to cool before starting any repair work.
The hydraulic oil tank cap may fly off due to remaining pressure if removed quickly. Slowly loosen the cap to
release any remaining pressure completely.

Preparation

1. Park the machine on a level solid surface. Lower

the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining in
the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
SM1147
wrench to release the trapped air in the hydraulic oil
tank. Refer to Bleeding Air from Hydraulic System
on page W1-1-2.
: 4 mm
Cap

3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continuously to main-
tain negative pressure in the hydraulic oil tank.

NOTE - Run the vacuum pump continuously while

working on the hydraulic system.

SM5742
W2-4-2 EX455

UPPERSTRUCTURE PUMP DEVICE

Removal

IMPORTANT: Attach identification tags to discon-

nected hoses for reassembly.

1. Disconnect hoses (1 to 3), (10 to 12). Cap the

disconnected hoses.
: 19 mm, 27 mm, 36 mm, 41 mm

2. Remove socket bolts (15) (8 used) to disconnect

hoses (13) and (14).
: 10 mm

3. Remove socket bolts (5) (4 used) to remove suc-

tion pipe (4).
: 14 mm

4. Disconnect connectors of electrical cables.

SM5743

NOTE: Control proportional solenoid valves for pumps

1 and 2. Upside
Displacement angle sensor for pumps 1 and 2.
Delivery pressure sensor for pumps 1 and 2.

5. Remove the mounting bolt (7) of cable (6) to

remove the cable from the pump device.
: 17 mm

6. Remove bolts (8) (23 used) to remove covers (9) (5

used).
: 19 mm

WARNING
Pump device weight: 260 kg (580 lb) Eye Bolt
Position

7. Attach the wire rope to the eyebolts (2 used)

installated in the pump device. Then hoist to hold SM5744
the pump device by crane.

8. Remove the bolts (16) (12 used). Lift and remove

the pump device by crane.
: 19 mm

SM5745
EX455 W2-4-3

UPPERSTRUCTURE PUMP DEVICE

Installation

WARNING
Pump device weight: 260 kg (580 lb)

1. Lift the pump device by crane and install it with

bolts (16) (12 used).
: 19 mm
: 90 N•m (9.2 kgf•m, 67•Ibf ft)

2. Install covers (9) (5 used) with bolts (8) (23 used).

: 19 mm
: 90 N•m (9.2 kgf•m, 67 Ibf•ft)
SM5745

3. Connect all connectors on cable (6). Install the

cable onto the pump device with bolt (7).
: 17 mm
: 50 N•m (5.1 kgf•m, 37 Ibf•ft)

4. Install the O-ring onto the flange portion of suction

pipe (4). Install the suction pipe onto pump device
with socket bolts (5) (4 used).
: 14 mm
: 210 N•m (21 kgf•m, 152 Ibf•ft)

5. Connect hoses (13) and (14) onto the pump device

with socket bolts (15) (8 used).
: 10 mm
: 90 N•m (9.2 kgf•m, 67 Ibf•ft)

6. Connect hoses (1 to 3), (10 to 12) to the pump

device.
: 19 mm
: 29.5 N•m (3 kgf•m, 21.5 Ibf•ft)
: 27 mm
: 93 N•m (9.5 kgf•m, 69 Ibf•ft)
: 36 mm
SM5743
: 180 N•m (18 kgf•m, 130 Ibf•ft)
: 41 mm
: 210 N•m (21 kgf•m, 152 Ibf•ft)

IMPORTANT: Bleed air from the pump device. (Refer

to page W1-1-2).
After installation, check the oil level. Start the engine
and check for any oil leakage.
W2-4-4 EX455

UPPERSTRUCTURE PUMP DEVICE

DISASSEMBLE PUMP DEVICE

SM5746
EX455 W2-4-5

UPPERSTRUCTURE PUMP DEVICE

1 - Valve Cover 28 - Cylinder Spring 50 - Retaining Ring 77 - Driven Gear

2 - Nut (2 Used) (18 Used) (2 Used) 78 - Spacer
3 - Set Screw (2 Used) 29 - Spherical Bushing 51 - Backup Ring (2 Used) 79 - Retaining Ring
4 - Socket Bolt (2 Used) (2 Used) 52 - O-Ring (2 Used) 80 - Front Casing
5 - Booster 30 - Retainer (2 Used) 53 - Stopper R (2 Used) 81 - O-Ring
6 - O-Ring 31 - Shoe (18 Used) 54 - Servo Piston (2 Used) 82 - Oil Seal
7 - Booster Cover 32 - Plunger (18 Used) 55 - Stopper L (2 Used) 83 - Front Cover
8 - Socket Bolt (5 Used) 33 - Shoe Plate (2 Used) 56 - O-Ring (2 Used) 84 - Retaining Ring
9 - O-Ring 34 - Swash Plate (2 Used) 57 - Backup Ring (2 Used) 85 - Socket Bolt (11 Used)
10 - Cover 35 - Pin (2 Used) 58 - Pump Casing 86 - Sensor A
11 - Socket Bolt (2 Used) 36 - Tilt Bushing (2 Used) 59 - Eyebolt (2 Used) 87 - Angle Sensor
12 - Socket Bolt (2 Used) 37 - Tilt Pin (2 Used) 60 - Plug (20 Used) 88 - O-Ring
13 - Socket Bolt (9 Used) 38 - Feedback Pin (2 Used) 62 - O-Ring (5 Used) 89 - Socket Bolt (2 Used)
14 - ROH Plug (2 Used) 39 - Bolt (2 Used) 63 - O-Ring (2 Used) 90 - Washer (2 Used)
15 - O-Ring (6 Used) 40 - Feedback Lever 64 - Nameplate 91 - Cover
16 - Plug (14 Used) (2 Used) 65 - Rivet (2 Used) 92 - Leaf Spring
17 - Valve Plate Pin 41 - Pin (2 Used) 66 - Taper Screw with 93 - Socket Bolt (2 Used)
(2 Used) 42 - Swash Plate Support Orifice (4 Used) 94 - Oil Seal
18 - Seat Packing (2 Used) (2 Used) 67 - ROH Plug (3 Used) 95 - Retaining Ring
19 - Spring Pin (4 Used) 43 - Pin (2 Used) 68 - O-Ring (3 Used) 96 - Ball Bearing (2 Used)
20 - Stopper 1 (2 Used) 44 - Retaining Ring 69 - Socket Bolt (8 Used) 97 - Feedback Shaft
21 - Steel Ball (2 Used) (3 Used) 70 - Socket Bolt (8 Used) 98 - Spacer
22 - Seat (2 Used) 45 - Bearing Spacer. 71 - Servo Cover (2 Used) 99 - Retaining Ring
23 - Plug (2 Used) (3 Used) 72 - Nut (2 Used) 100 - O-Ring
24 - Needle Bearing (2 46 - Roller Bearing 73 - Set Screw (2 Used) 101 - Cover
Used) (2 Used) 74 - Retaining Ring 102 - Socket Bolt (2 Used)
25 - Valve Plate R 47 - Drive Shaft (2 Used)
26 - Valve Plate L 48 - Driven S heft 75 - Spacer (2 Used)
27 - Cylinder Block (2 Used) 49 - Bearing Spacer (2 Used) 76 - Drive Gear
W2-4-6 EX455

UPPERSTRUCTURE PUMP DEVICE

SM5747
EX455 W2-4-7

UPPERSTRUCTURE PUMP DEVICE

Disassemble Pump Device
• Be sure to read ail "Precautions for Disassembly
and Assembly" thoroughly on page W1-1-1 before
starting the disassembly work.
4. Remove the gear pump from booster cover (7).
Remove booster cover (7) and cover (10) from
valve cover (1).
: 8 mm

WARNING WARNING
Pump assembly weight: 260 kg (570 lb). Valve cover weight: 60 kg (130 lb).

5. Install bolts (M12, Pitch 1.75) into the mounting

IMPORTANT: Spread rubber sheet or cloth or etc. on
the work bench to prevent the parts from being dam-
aged.
1. Pump casing (58) should be secured horizontally
onto the work bench via the screw holes (M10,
Pitch 1.5, depth 16 mm) (2 places) in the lower part
of the pump casing.
Screw Hole
bolt hole in valve cover (1), attach a sling to the bolt
to lift the valve cover by crane.
IMPORTANT: Take care not to damage the matching
surface of valve cover (1) and pump casing (58).
IMPORTANT: There are valve plates (25) and (26),
check valves (22), (20) and (21), O-rings (62), (15) and
(63) and seat packing (18) on valve cover (1).
Take care as these parts have a tendency to drop off
while removing valve cover (1).

6. Remove socket bolts (13), (12) and (4) to remove

valve cover (1) by crane.
: 17 mm

NOTE: There are two spring assembling pins (19)

meshed tightly between valve cover (1) and pump
casing (58). Tap and remove valve cover (1) straightly
at right angle in the direction of drive shaft (47) and
driven shaft (48). (The aim is to prevent the rolling part
SM5748
of the needle bearing from being damaged.).

2. Remove plug (67) opposite to the mounting face of

the regulator) to drain the oil from pump casing (58).

NOTE: If plug (67) at the mounting face of sensor A

(86) for oil delivery port is removed, it will be easy to
drain the oil out.

IMPORTANT: The setting of the pressure flow rate for

the regulator of pump 1 (drive side) is different from
that for the regulator of pump 2 (driven side). There-
fore, marks should be made on the parts before
disassembling.

3. Remove the regulator from pump casing (58).

: 6 mm

NOTE: As for how to remove and disassemble the

regulator, refer to Regulator section.
W2-4-8 EX455

UPPERSTRUCTURE PUMP DEVICE

SM5749
EX455 W2-4-9

UPPERSTRUCTURE PUMP DEVICE

IMPORTANT: Do not loosen nuts (2) (2 used). Other-
wise the flow rate setting for the pump may change.
7. Remove valve plates (25) and (26) and discrimi-
nate between the removed valve plates by mak-
ing marks on the out race.
Remove needle bearing (24) from valve cover (1)
only when necessary.
NOTE: Do not remove needle bearing (24) unless its
service life is over.
IMPORTANT: Do not loosen nut (72) for servo cover
(71). Otherwise the flow rate setting of the pump may
change.
IMPORTANT: When removing tilt pin (37), take care
not to damage the head of the tilt pin.
12. If necessary, remove stopper L (55), stopper S
(53), servo piston (54), tilt pin (37), and servo
cover (71) from pump casing (58).
: 10 mm

IMPORTANT: Discriminate between the parts of drive
side and driven side by making marks.
IMPORTANT: Take care not to damage the sliding
surface of cylinder block (27), spherical bushing (29),
shoe (31) and swash plate (34).
8. Remove cylinder block (27) straightly out of pump
casing (58) in the direction of drive shaft (47) and
driven shaft (48). Meanwhile, remove plunger
assemblies (32 and 31), retainer (30), spherical
bushing (29) and cylinder spring (28), too.
9. Remove sensor A (86) from pump casing (58).
First, loosen socket bolt (89) to remove angle
sensor (87). Then, loosen socket bolt (93) to
remove sensor A (86).
When removing, take care not to drop O-ring (88)
and leaf spring (92).
NOTE: Bond (THREEBOND #1305N) was applied to
the matching portions of tilt pin (37) and servo piston
(54). Take care not to damage the servo piston.
IMPORTANT: As oil seal (82) is fit on front cover (83),
take care not to damage the lip section of oil seat (82)
when removing.
13. Remove retaining ring (84) from front casing (80)
to remove front cover (83).
NOTE: There is a notch in the outer groove of front
cover (83). Insert a screwdriver into the groove to pull
front cover (83) out straight along axis in the direction
of drive shaft (47).

10. Remove shoe plate (33) from swash plate (34)

with a screwdriver.

11. Remove swash plate (34) from pump casing (58).

W2-4-10 EX455

UPPERSTRUCTURE PUMP DEVICE

SM5750
EX455 W2-4-11

UPPERSTRUCTURE PUMP DEVICE

IMPORTANT: Since bond (THREEBOND #1305N)

WARNING was applied to socket bolt (69), heat it before remov-
Front casing weight: 32 kg (70 lb). ing.

19. Remove socket bolt (69) which is used to secure

swash plate support (42) to remove swash plate
IMPORTANT: When removing front casing (80), take support (42) from pump casing (58).
care not to damage the following items: : 6 mm
• Slide surface of oil seal for drive shaft (47).
• Seat packing (18).
• Matching face of front casing (80) and pump casing
(58).

14. Attach sling to the bolt hole in the engine mount-

ing section of front casing (80) and lift it by crane.
Remove socket bolts (85) (11 used) to lift and
remove front casing (80) from pump casing (58).
: 10 mm

NOTE: There are two spring pins (19) meshed tightly

between front casing (80) and pump casing (58). Tap
and remove front casing (80) straightly at right angle in
the direction of drive shaft (47).

15. Remove retaining rings (74, 79) from drive shaft

(47) and driven shaft (48) to remove bearing
spacers (75) and (78), drive gear (76) and driven
gear (77).

16. Remove retaining ring (50) and bearing spacer

(49) from pump casing (58).

17. Tap the rear ends of drive shaft (47) and driven
shaft (48) with plastic hammer to remove drive
shaft (47) and driven shaft (48) from pump casing
(58).

18. Remove retaining ring (44), bearing spacer (45),

roller bearing (46) from drive shaft (47) and driven
shaft (48) only when necessary. Do not remove
the roller bearing (46) unless its service life is
over. When removing, put a metal plate on the
outer race of roller bearing (46) and remove the
roller bearing by pressing out with a press. Roller
bearing (46) being pressed out can't be reused.
W2-4-12 EX455

UPPERSTRUCTURE PUMP DEVICE

ASSEMBLE PUMP DEVICE

Apply Bond (THREEBOND #1305N) Apply Bond (THREEBOND #1305N)

Section X-X

Apply Bond
(SEALAND L101)
to the Out Surface
of the Oil Seal

Valve Plate for Swing to Right

Section A-A
SM5751
EX455 W2-4-13

UPPERSTRUCTURE PUMP DEVICE

With the Matching Mark

facing the Opposite of
Lead Line

Apply Grease (CENTOPLEX2

Made by NOK) to the Mounting
Portion of the Leaf Spring

SM5752

1 - Valve Cover 25 - Valve Plate R 50 - Retaining Ring (2 Used) 76 - Drive Gear

2 - Nut (2 Used) 26 - Valve Plate L 51 - Backup Ring (2 Used) 77 - Driven Gear
3 - Set Screw (2 Used) 27 - Cylinder Block (2 Used) 52 - O-Ring (2 Used) 78 - Spacer
4 - Socket Bolt (2 Used) 28 - Cylinder Spring (18 Used) 53 - Stopper R (2 Used) 79 - Retaining Ring
5 - Booster 29 - Spherical Bushing (2 Used54 - Servo Piston (2 Used) 80 - Front Casing
6 - O-Ring 30 - Retainer (2 Used) 55 - Stopper L (2 Used) 81 - O-Ring
7 - Booster Cover 31 - Shoe (18 Used) 56 - O-Ring (2 Used) 82 - Oil Seal
8 - Socket Bolt (5 Used) 32 - Plunger (18 Used) 57 - Backup Ring (2 Used) 83 - Front Cover
9 - O-Ring 33 - Shoe Plate (2 Used) 58 - Pump Casing 84 - Retaining Ring
10 - Cover 34 - Swash Plate (2 Used) 59 - Eyebolt (2 Used) 85 - Socket Bolt (11 Used)
11 - Socket Bolt (2 Used) 35 - Pin (2 Used) 60 - Plug (20 Used) 86 - Sensor A
12 - Socket Bolt (2 Used) 36 - Tilt Bushing (2 Used) 62 - O-Ring (5 Used) 87 - Angle Sensor
13 - Socket Bolt (9 Used) 37 - Tilt Pin (2 Used) 63 - O-Ring (2 Used) 88 - O-Ring
14 - Plug (2 Used) 38 - Feedback Pin (2 Used) 64 - Nameplate 89 - Socket Bolt (2 Used)
15 - O-Ring (6 Used) 39 - Bolt (2 Used) 65 - Rivet (2 Used) 90 - Washer (2 Used)
16 - Plug (14 Used) 40 - Feedback Lever (2 Used) 66 - Taper Screw With 91 - Cover
17 - Valve Plate Pin (2 41 - Pin (2 Used) Orifice (4 Used) 92 - Leaf Spring
Used) 42 - Swash Plate Support 67 - Plug (3 Used) 93 - Socket Bolt (2 Used)
18 - Seat Packing (2 Used) (2 Used) 68 - O-Ring (3 Used) 94 - Oil Seal
19 - Spring Pin (4 Used) 43 - Pin (2 Used) 69 - Socket Bolt (8 Used) 95 - Retaining Ring
20 - Stopper 1 (2 Used) 44 - Retaining Ring (3 Used) 70 - Socket Bolt (8 Used) 96 - Ball Bearing (2 Used)
21 - Steel Ball (2 Used) 45 - Bearing Spacer (3 Used) 71 - Servo Cover (2 Used) 97 - Feedback Shaft
22 - Seat (2 Used) 46 - Roller Bearing (2 Used) 72 - Nut (2 Used) 98 - Spacer
23 - Plug (2 Used) 47 - Drive Shaft 73 - Set Screw (2 Used) 99 - Retaining Ring
24 - Needle Bearing (2 48 - Driven Shaft 74 - Retaining Ring (2 Used) 100 - O-Ring
Used) 49 - Bearing Spacer (2 Used) 75 - Spacer (2 Used) 101 - Cover
102 - Socket Bolt (2 Used)
W2-4-14 EX455

UPPERSTRUCTURE PUMP DEVICE

Apply Bond (THREEBOND #1305N)

Section X-X

Section A-A

SM5753
EX455 W2-4-15

UPPERSTRUCTURE PUMP DEVICE

Assemble Pump Device

• Be sure to read all "Precautions for Disassembly
and Assembly" thoroughly on page W 1-1-1 be-
fore starting the assembly work.
1. Secure pump casing (58) onto work bench hori-
zontlyviathescrewhole (M10, Pitch 1.5, depth 16
mm) (2 places) in the lower part of pump casing (58)
before starting the assembly work.
IMPORTANT: Do not tap drive shaft (47) and driven
shaft (48) with a plastic hammer.
5. Install drive shaft (47) and driven shaft (48) onto
pump casing (58), then install bearing spacer (49)
retaining ring (50) to secure them.
Tap and install the outer race of roller bearing (46)
with plastic hammer, then drive it to the end with a
bar.

Screw Hole 6. Install drive gear (76), driven gear (77) and bearing
spacers (75) and (78) into drive shaft (47) and
driven shaft (48), then secure them with retainings
(79) and (74).

NOTE: Check the direction to install drive gear (76)

and driven gear (77).
When installing retaining ring (79) and (74), their
upright edge at the outer race should face outside.

SM5748

IMPORTANT: Spread rubber sheet or cloth or etc. on WARNING

the work bench to prevent the parts from being dam- Front casing weight: 32 kg (70 lb).
aged.
7. Install the spring assembling pins (19) (2 used) into
2. Apply bond (THREEBOND #1305N) to the screw pump casing (58).
portion of socket bolt (69).
8. Install seat packing (18) for the applied grease on
mounting surface for pump casing (58).
IMPORTANT: Secure O-ring (62) on matching surface
of pump casing (58) with grease to prevent it from
coming off.

3. Install swash plate support (42) onto pump casing

(58), then tighten it with socket bolt (69).
: 6 mm
: 29.5 N•m (3.0 kgf•m, 21.5 Ibf•ft)

4. Install roller bearing (46), bearing spacer (45) and

retaining ring (44) onto drive shaft (47) and driven
shaft (48).

NOTE: When installing retaining ring (44) onto drive

shaft (47), the upright edge at outer race of retaining
ring (44) should face outside.
W2-4-16 EX455

UPPERSTRUCTURE PUMP DEVICE

Section X-X

Section A-A

SM5754
EX455 W2-4-17

UPPERSTRUCTURE PUMP DEVICE

9. Install front casing (82) onto pump casing (58),

IMPORTANT: When tightening servo piston (54) and
then tighten it with socket bolt (85).
tilt pin (37), take care not to damage the head of tilt pin
: 10 mm (37) and feedback pin (38).
: 98 N•m (10 kgf•m, 72 Ibf•ft)
13. Apply bond (THREEBOND #1305N) to the tilt pin
NOTE: As it will mesh lightly with spring (19), tap front mounting portion in servo piston (54).
casing (80) with a plastic hammer to install it vertically
in the direction of drive shaft (47). 14. Install servo piston (54), tilt pin (37), stopper L (55)
and stopper S (53) onto pump casing (58).
10. Apply a film of grease to the lip of the oil seal (82).
Then, install oil seal (82) onto front cover (83).

11. Install front cover (83) onto front casing (80) and
secure it with retaining ring (84).

NOTE: Take care not to damage the lip of oil seal (82)
when installing.
When installing retaining ring (84), its upright edge at
the outer race should face outside.

12. Apply bond (THREEBOND #1305N) to the screw

section of servo piston (54).
SM5755

15. Install servo cover (71) onto pump casing (58),

then secure it with socket bolt (70).
: 10 mm
: 98 N•m (10 kgf•m, 72 Ibf•ft)

IMPORTANT: Do not confuse the parts for drive

section with those for driven section.

16. Install tilt bushing (36) for swash plate (34) into tilt
pin (37). Install the swash plate (34) assembly
onto swash plate support (42) correctly. Then
confirm swash plate (34) can move smoothly or
not by fingers.

NOTE: When installation is finished, swash plate (34)

may come off from swash plate support (42). If grease
is applied to the sliding surface of swash plate support
(42), swash plate (34) is less prone to come off and its
operation is improved, too.
W2-4-18 EX455

UPPERSTRUCTURE PUMP DEVICE

Section X-X

Valve Plate for Swing to Left

Valve Plate for Swing to Right

Section A-A

SM5756
EX455
UPPERSTRUCTURE PUMP DEVICE
17. Before installing angle sensor (87), apply special
grease (CENTOPLEX2 made by NOK) leaf
spring (92).
18. Install sensor A (86) onto pump casing (58).
When installation, check the pin (41) for the edge
of swash plate (34), feedback lever (40) is in-
stalled into the groove of feedback shaft (97) on
sensor A (86).
: 5 mm
: 9.8 N•m (1.0 kgf•m, 7.2 Ibf•ft)
: 6 mm
: 29.4 N•m (3.0 kgf•m, 21.5 Ibf•ft)
With the Matching Mark
Facing the Opposite of
lead Line
Apply Grease (CENTOPLEX 2
Made by NOK) to the Mounting
Portion of the Leaf Spring
Sensor A (86)
IMPORTANT: Do not confuse the parts in drive sec-
tion with those in driven section.
19. Make sure that swash plate (34) is held together
with its support (42) and swash plate (34) is held
together with tilt pin (37).
Install cylinder block (27), plunger assemblies (32
and (31), retainer (30), spherical bushing (29) and
cylinder spring (28). (Plunger and cylinder assem-
bly)
W2-4-19
20. Install the assembly of plunger and cylinder
straightly, in the direction of drive shaft (47) and
driven shaft (48), into pump casing (58) with
spherical bushing (29) of the assembly aligning
with the spline matching position of cylinder block
(27).
IMPORTANT: Take care not to make mistakes when
handling the suction and delivery directions of valve
plates (25) and (26).
Drive section: Rotate to right, viewed from the shaft
end.
Driven section: Rotate to left, viewed from the shaft
end.
Notch Notch
For Swing to Left For Swing to Right
SM5758
The Difference between Valve Plates
21. Align valve plates (25) and (26) with valve plate
pin (17) while installing valve plates (25) and (26)
onto valve cover (1).
SM5757
NOTE: Valve plates (25 ) and (26) are prone to come
off. Applying grease to the matching surface of valve
cover (1), is helpful to operation.
22. Insert check valves (22), (21) and (20) to valve
cover (1) in right order.
NOTE: Check valves (22), (21) and (20) are prone to
come off. However, the performance may be improved
if grease is used to valve cover (1) at the portion being
inserted.
23. Install needle bearing (24) into valve cover (1).
24. Install O-rings (62), (15) and (63) and seat packing
(18) onto the mating surface of valve cover (1) on
pump casing (58).
NOTE: O-rings (62), (15) and (63) and seat packing
(18) are prone to come off. However, the performance
may be improved if grease is applied to their mounting
surface.
W2-4-20 EX455

UPPERSTRUCTURE PUMP DEVICE

Section X-X

Valve Plate for Swing to Left

Gear Pump

Valve Plate for Swing to Right

Section A-A

SM5759
EX455 W2-4-21

UPPERSTRUCTURE PUMP DEVICE

28. Install gear pump, booster cover (7), booster (5)

WARNING
Valve cover weight: 60 kg (130 lb).
25. Attach a special tool (a cover made of nylon and
resin, see figure bellow) to drive shaft (47) and
driven shaft (48) to prevent needle bearing (24)
from damaging.
and cover (10) with socket bolts (8), (11), etc.
: 8 mm
: 57 N•m (5.8 kgf•m, 42 Ibf•ft)
NOTE: Refer to Assemble Regulator in the regulator
section.

IMPORTANT: The settings of pressure and flow rate

for the regulator in pump 1 (drive section) are different
from those for the regulator in pump 2 (driven section).
Don't make mistakes when assembling.

29. Clamp the feedback pin (38) of tilt pin (37) onto
feedback lever (40) of the regulator. Install the
regulator onto pump casing (58), tight it with the
socket bolt.
: 6 mm
: 29.5 N•m (3.0 kgf•m, 21.5 Ibf•ft)

SM5760

IMPORTANT: Take care not to drop valve plates (25)

and (26), check valve (22), (20) and (21), O-rings (62),
(15) and (63) and seat packing (18).
Take care not to damage the mating surface of pump
casing (58) and valve cover (1).

26. There are two spring assembling pins (19) be-

tween valve cover (1) and pump casing (58). As
spring pins (19) are engaged tightly, a plastic
hammer should be used to tap valve cover (1) and
to install valve cover (1) vertically in the direction
of drive shaft (47) and driven shaft (48).

NOTE: Be sure to check whether swash plate (34) and

swash plate support (42) are held together and also
check swash plate (34) and tilt pin (37) for whether
being held together or not.

27. Tight the pump casing (58) onto valve cover (1)
with socket bolts (13), (12) and (4).
: 17 mm
: 630 N•m (64 kgf•m, 460 Ibf•ft)
W2-4-22 EX455

UPPERSTRUCTURE PUMP DEVICE

DISASSEMBLE REGULATOR

SM5761

1 - Regulator Casing 10 - Support Plug 20 - Pilot Piston 29 - Socket Bolt (2 Used)

2 - Spring Seat 11 - O-Ring (2 Used) 21 - Pf Sleeve 30 - O-Ring (2 Used)
3 - Pilot Spring 13 - Pin 22 - O-Ring 31 - Seat
4 - Adjusting Disc Q 14 - O-Ring (5 Used) 23 - Plug 32 - Steel Ball
5 - O-Ring (2 Used) 15 - O-Ring 24 - Socket Bolt (4 Used) 33 - Stopper
6 - Cover 16 - Pin 25 - Socket Bolt 34 - Socket Bolt (6 Used)
7 - Socket Bolt (4 Used) 17 - Feedback Lever 26 - Plug (9 Used)
8 - Nut 18 - Spool 27 - Valve Casing
9 - Adjusting Screw 19 - Sleeve 28 - Proportional Solenoid
Valve
EX455 W2-4-23

UPPERSTRUCTURE PUMP DEVICE

Disassemble Regulator 6. Remove spool (18) and sleeve (19) from the sleeve
hole in regulator casing (1).
• Be sure to read all "Precautions for Disassembly
and Assembly" thoroughly on page W1-1-1 before
7. Remove adjusting disc Q (4) from regulator casing
starting the disassembly work.
(1) to remove pilot spring (3) and spring seat (2)

IMPORTANT: Spread rubber sheet or cloth or etc. on

NOTE: When pulling adjusting disc Q (4), it is easier
the work bench to prevent the parts from being dam-
to finish the work if a bolt (M4) is used.
aged.
The settings of pressure and flow rate for the regulator
in pump 1 (drive section) are different from those for 8. Remove check valve (seat (31), steel ball (32), and
the regulator in pump 2 (driven section). Do not stopper (33)).
confuse them, make marks on the parts before disas-
sembling.

1. Remove socket bolt (34) to remove the regulator

from the pump casing.
Take care not to lose O-rings (15), (14), (5), (11).
: 5 mm

2. Remove socket bolts (24), (25) from valve casing

(27) to remove valve casing (27) in which propor-
tional solenoid valve (28) is assembled.
: 6 mm

IMPORTANT: On cover (6), adjusting screw (9) and

nut (8) are fitted there. However, don't loosen them. If
they are loosened, the setting value will change.

3. Remove socket bolt (7) from cover (6) to remove

cover (6).
: 5 mm

4. Remove Pf sleeve (21) and pilot piston (20) from

the regulator body.

5. Remove support plug (10) from regulator casing (1)

to remove feedback lever (17).
: 6 mm
W2-4-24 EX455

UPPERSTRUCTURE PUMP DEVICE

ASSEMBLE REGULATOR

Section A-A

SM5762
EX455 W2-4-25

UPPERSTRUCTURE PUMP DEVICE

1 - Regulator Casing 10 - Support Plug 20 - Pilot Piston 29 - Socket Bolt (2 Used)

2 - Spring Seat 11 - O-Ring (2 Used) 21 - Pf Sleeve 30 - O-Ring (2 Used)
3 - Pilot Spring 13 - Pin 22 - O-Ring 31 - Seat
4 - Adjusting Disc Q 14 - O-Ring (5 Used) 23 - Plug 32 - Steel Ball
5 - O-Ring (2 Used) 15 - O-Ring 24 - Socket Bolt (4 Used) 33 - Stopper
6 - Cover 16 - Pin 25 - Socket Bolt 34 - Socket Bolt (6 Used)
7 - Socket Bolt (4 Used) 17 - Feedback Lever 26 - Plug (9 Used)
8 - Nut 18 - Spool 27 - Valve Casing
9 - Adjusting Screw 19 - Sleeve 28 - Proportional Solenoid
Valve

Assemble Regulator 5. Assemble Pf sleeve (21), pilot piston (20), check

valve {seat (31), steel ball (32), stopper (33)} into
• Be sure to read all "Precautions for Disassembly
regulator casing (1) in correct order.
and Assembly" thoroughly on page W1-1-1 before
starting the assembly work.
6. Install valve casing (27), which with proportional
magnetic valve (28) already assembled in, into
IMPORTANT: Spread rubber sheet or cloth or etc. on regulator casing (1), then secure with socket bolts
the work bench to prevent the parts from damaging. (24) and (25).
: 5 mm
1. Assemble sleeve (19) and spool (18) into the : 11.5 N•m (1.2 kgf•m, 8.7 Ibf•ft)
sleeve hole in regulator casing (1).
Pay attention to the direction of spool (18).
Be sure to check that sleeve (19) and spool (18)
move smoothly in regulator casing (1) without any
resistance.

2. Insert feedback pin (16) of feedback lever (17) into

the pin hole in sleeve (19). Secure feedback lever
(17) by installing support plug (10). Operate feed-
back lever (17) to check if its play is too big or any
resistance is felt.
Tighten torque for support plug (10):
: 6 mm
: 36 N•m (3.7 kgf•m. 27.0 Ibf•ft)

3. Install spring seat (2), pilot spring (3) and adjusting

disc Q (4) into the sleeve hole in regulator casing
(1).

4. Install cover (6) onto regulator casing (1). Then

tighten cover (6) with socket bolt (7).
: 5 mm
: 11.5 N•m (1.2 kgf•m, 8.7 Ibf•ft)

NOTE: Adjusting screw (9) and nut (8) are assembled

to cover (6).
W2-4-26 EX455

UPPERSTRUCTURE PUMP DEVICE

DISASSEMBLE PILOT PUMP

SM6235

1 - Housing 5 - Seal (2 Used) 9 - O-Ring (2 Used) 13 - Bolt (4 Used)

2 - Flange 6 - Cover 10 - Gear 14 - Bushing (2 Used)
3 - Oil Seal 7 - Backup Ring (2 Used) 11 - Drive Gear 15 - Bushing (2 Used)
4 - Retaining Ring 8 - Key (2 Used) 12 - Washer (4 Used) 16 - Knock Pin (2 Used)
EX455 W2-4-27

UPPERSTRUCTURE PUMP DEVICE

Disassemble Pilot Pump

NOTE - (1) Clean the outside of the pilot pump

before disassembling.
(2) Make matching marks on cover (6),
housing (1) and flange (2) before disas-
sembling to aid reassembly.

1. Clamp pump flange (2) in vise with cover (6) up.

2. Remove four bolts (13).

: 17 mm

3. Remove cover (6) from housing (1).

4. Remove O-ring (9) from cover (6).

5. Take the pilot pump from vise and remove flange

(2) from housing (1).

6. Remove O-ring (9) from flange (2).

7. Remove retaining ring (4) from flange (2).

8. Remove oil seal (3) from flange (2).

9. Remove seal (5) and backup ring (7) from cover (6)
side bushings (14, 15).

NOTE - Be careful not to allow the key between the

bushings to fall off when removing them.

10. Lightly push drive gear (11) to remove cover (6)

side bushings (14, 15) from housing (1).

11. Remove seal (5) and backup ring (7) from flange
(2) side bushings (14, 15).

12. Remove flange (2) side bushings (14, 15). Re-

move gear (10) and drive gear (11) from housing
(1).
W2-4-28 EX455

UPPERSTRUCTURE PUMP DEVICE

ASSEMBLE PILOT PUMP

SM6235

1 - Housing 5 - Seal (2 Used) 9 - O-Ring (2 Used) 13 - Bolt (4 Used)

2 - Flange 6 - Cover 10 - Gear 14 - Bushing (2 Used)
3 - Oil Seal 7 - Backup Ring (2 Used) 11 - Drive Gear 15 - Bushing (2 Used)
4 - Retaining Ring 8 - Key (2 Used) 12 - Washer (4 Used) 16 - Knock Pin (2 Used)
EX455 W2-4-29

UPPERSTRUCTURE PUMP DEVICE

Assemble Pilot Pump

1. Tap oil seal (3) in flange (2) using a plastic hammer

and tool.

2. Install retaining ring (4) to flange (2).

NOTE - Position the bushings in the correct direction

when installing.

3. Install cover (6) side bushings (14, 15) in housing

(1) with the seal groove side down.

4. Install gear (10) and drive gear (11) in housing (1).

5. Install flange (2) side bushings (14, 15) in housing

(1) with the seal groove side up.

6. Install seal (5) and backup ring (7) into the seal
groove on bushings (14, 15).

7. Install O-ring (9) on flange (2).

8. Install flange (2) on housing (1).

NOTE - Be careful not to allow the bushings or gears

to fall off when rotating the assembly.

9. Rotate the housing and flange assembly 180° and

clamp flange (2) in vise. Install seal (5) and backup
ring (7) into the seal groove on the bushings.

10. Install O-ring (9) on cover (6).

11. Install cover (6) on housing (1).

12. Install washers (12) and bolts (13). Tighten bolts

(13).
: 17 mm
: 39 to 44 N⋅m
(4 to 4.5 kgf⋅m, 29 to 32.5 lbf⋅ft)
W2-4-30 EX455

UPPERSTRUCTURE PUMP DEVICE

MAINTENANCE STANDARDS

Allowable Limits for vulnerable Parts

1. Clearance between plunger (32) outer diameter (d)
and cylinder block (27) bore diameter (D).

D-d Unit: mm (in)

Standard Allowable Limit

SM5763

0.038 (0.001) 0.078 (0.003)

2. Free length (L) of spring (28).

L Unit: mm (in)

Standard Allowable Limit

40.9 (1.61) 40.1 (1.58)

3. Clearance (e) between plunger (32) and shoe (31)

and thickness (t) of shoe (31).
SM5764
e Unit: mm (in)

Standard Allowable Limit

0 to 0.1 (0 to 0.004) 0.35 (0.014)

t Unit: mm (in)

Standard Allowable Limit

5.4 (0.21) 5.0 (0.20)

SM5765

4. The difference between the face of cover plate (30)

to the top of spherical bushing (29).

H-h Unit: mm (in) Base

Standard Allowable Limit

13.5 (0.53) 12.5 (0.49)

SM5766

ALLOWABLE LIMITS FOR CYLINDER

The Repair Limits for Cylinder, Valve Plate and Swash Plate (Shoe Plate)

Roughness when repair is

Valve plate (slide portion) necessary 3 µm
Swash plate (shoe plate portion)
Cylinder (slide portion) Standard roughness (values Less than 0.4 µm (by lapping)
after being repaired)
EX455 W2-5-1

CONTROL VALVE

REMOVE AND INSTALL CONTROL VALVE

WARNING
Escaping pressure hydraulic oil can penetrate the skin or eyes, causing serious injury. Avoid this hazard by
relieving pressure before disconnecting hydraulic lines.
Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure
to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off due to internal pressure if turned quickly. Slowly turn the cap to release
internal pressure before completely removing the cap.
Preparation
1. Park the machine on a firm, level surface. 3. Remove the cap and connect a vacuum pump.
Lower the front attachment to the ground. Operate the vacuum pump constantly to maintain
2. Stop the engine. Move all control levers to release the negative pressure in the hydraulic oil tank.
any pressure remaining in the system. Slowly turn
the hydraulic oil tank cap approx. 30 degrees
counterclockwise to release any remaining pres- NOTE - Keep the vacuum pump running continu-ously
sure from the hydraulic oil tank. while working.

Removal

IMPORTANT - Attach identification tags to hoses to

aid reassembly.
Right Travel
Left Travel Front Bucket
1. Disconnect all hoses, pipes, and connectors from
Boom 1
the control valve. Auxiliary
: 19 mm Arm 2
: 34 N•m (3.5 kgf•m, 25 lbf•ft)
: 19 mm
Boom 2
: 88 N•m (9 kgf•m, 65 lbf•ft) Return Pipe
: 22 mm
: 49 N•m (5 kgf•m, 36 lbf•ft) Arm 1
: 36 mm
: 155 N•m (16 kgf•m, 108 lbf•ft)
: 41 mm
: 175 N•m (21 kgf•m, 152 lbf•ft) Swing
: 12 mm
: 175 N•m (18 kgf•m, 130 lbf•ft)
SM6824

WARNING Bucket Right Travel

Control valve weight: 380 kg (840 lb) Boom 1

Front
Arm 2
2. Remove control valve mounting bolts.
: 17 mm
: 390 N•m (40 kgf•m, 290 lbf•ft)

Installation

NOTE - Refer to "Removal" section for wrench sizes

and tightening torques.

1. Install the control valve. Tighten the bolts.

2. Connect all hoses, pipes, and connectors to the
control valve.
Left Travel
IMPORTANT - After installation, check the hydraulic
oil level. Run the engine and check for oil leaks. Auxiliary

Boom 2
Swing Arm 1
SM6825
W2-5-2 EX455

CONTROL VALVE

DISASSEMBLE CONTROL VALVE 1

SM6826
EX455 W2-5-3

CONTROL VALVE

1 - Overload Relief Valve (2 Used) 19 - Overload Relief Valve (2 Used) 37 - Spring (5 Used)
2 - O-Ring (7 Used) 20 - Sleeve 38 - Spool (Swing)
3 - Backup Ring (7 Used) 21 - Backup Ring (2 Used) 39 - Spool (Arm 1)
4 - O-Ring (7 Used) 22 - O-Ring 40 - Check Valve
5 - Sleeve (6 Used) 23 - Poppet 41 - Spring
6 - Poppet (6 Used) 24 - Spring 42 - Spacer
7 - Piston (6 Used) 25 - O-Ring 43 - O-Ring
8 - Spring (6 Used) 26 - Backup Ring 44 - Backup Ring
9 - Spring (6 Used) 27 - Cap 45 - Cap
10 - O-Ring (6 Used) 28 - Makeup Valve 46 - Spool (Boom 2)
11 - Backup Ring (12 Used) 29 - Overload Relief Valve 47 - Spool (Auxiliary)
12 - O-Ring (6 Used) 30 - Overload Relief Valve 48 - Spool (Left Travel)
13 - Seat (6 Used) 31 - O-Ring (10 Used) 49 - Cap (2 Used)
14 - Poppet (6 Used) 32 - Socket Bolt (20 Used) 50 - O-Ring (2 Used)
15 - Spring (6 Used) 33 - Cover 51 - O-Ring
16 - O-Ring (6 Used) 34 - Cap (5 Used) 52 - Pump Control Valve
17 - Adjusting Screw (6 Used) 35 - Guide (10 Used) 53 - Cover (5 Used)
18 - Lock Nut (6 Used) 36 - Sleeve (5 Used) 54 - Housing
W2-5-4 EX455

CONTROL VALVE

SM6826
EX455 W2-5-5

CONTROL VALVE

Disassemble Control Valve 1 Pump Control Valve

• Thoroughly read "Precaution for Disassembly and 10. Remove pump control valve (52) from housing
Assembly" on page W1-1-1 before starting repair (54).
work.
: 30 mm
5-Spool Section
Overload Relief Valve
WARNING
Control valve weight: 380 kg (840 lb) IMPORTANT - Do not disassemble the overload relief
valve unless necessary.

1. Install two eye bolts (M12, pitch 1.75) to the control 11. Remove overload relief valves (1) (2 used), (19) (2
valve. Lay two wooden blocks on a work bench. used), (29) and (30) from housing (54).
Place the control valve on the wooden blocks using
a crane. : 41 mm

2. Loosen socket bolts (32) (10 used) to remove cover 12. Remove lock nut (18) and seat (13) from sleeve
(33) from housing (54). (5).
: 10 mm
: 19 mm, 36 mm
3. While checking fitness between housing (54) and
spools (38), (39) and (46) to (48) (5 used), slowly 13. Remove adjusting screw (17), spring (15) and
pull the spools out of housing (54). poppet (14) from seat (13).

4. Remove O-rings (31) (5 used) from housing (54). : 6 mm

5. Loosen socket bolts (32) (10 used) on the control 14. Remove springs (9) and (8), poppet (6) and piston
valve bottom face to remove cover (53) (5 used) (7) from sleeve (5).
from housing (54).
: 10 mm Makeup Valve

6. Insert spool (38) into special tool (75301291) and 15. Remove makeup valve (28) from housing (54).
hold with a vise. Remove cap (34).
: 41 mm
: 10 mm
16. Loosen cap (27) to remove spring (24), poppet
7. Remove guide (35), sleeve (36), spring (37) and (23) from sleeve (20).
guide (35) from cap (34). : 36 mm

8. Disassemble spools (39) and (46) to (48) following

the same procedures as described in steps 6 and
7.

9. Remove cap (45), spacer (42), spring (41) and

check valve (40) from spool (39).
: 8 mm
W2-5-6 EX455

CONTROL VALVE

ASSEMBLE CONTROL VALVE 1

Pump Control Valve (52) Top Face of Control Valve

SM6827

Overload Relief Valve (1), (19), (29), (30) Makeup Valve (28)

SM6830

SM6828 SM6829

Bottom Face of Control Valve

SM6832

SM6831

Section A-A
EX455 W2-5-7

CONTROL VALVE

1 - Overload Relief Valve (2 Used) 19 - Overload Relief Valve (2 Used) 37 - Spring (5 Used)
2 - O-Ring (7 Used) 20 - Sleeve 38 - Spool (Swing)
3 - Backup Ring (7 Used) 21 - Backup Ring (2 Used) 39 - Spool (Arm 1)
4 - O-Ring (7 Used) 22 - O-Ring 40 - Check Valve
5 - Sleeve (6 Used) 23 - Poppet 41 - Spring
6 - Poppet (6 Used) 24 - Spring 42 - Spacer
7 - Piston (6 Used) 25 - O-Ring 43 - O-Ring
8 - Spring (6 Used) 26 - Backup Ring 44 - Backup Ring
9 - Spring (6 Used) 27 - Cap 45 - Cap
10 - O-Ring (6 Used) 28 - Makeup Valve 46 - Spool (Boom 2)
11 - Backup Ring (12 Used) 29 - Overload Relief Valve 47 - Spool (Auxiliary)
12 - O-Ring (6 Used) 30 - Overload Relief Valve 48 - Spool (Left Travel)
13 - Seat (6 Used) 31 - O-Ring (10 Used) 49 - Cap (2 Used)
14 - Poppet (6 Used) 32 - Socket Bolt (20 Used) 50 - O-Ring (2 Used)
15 - Spring (6 Used) 33 - Cover 51 - O-Ring
16 - O-Ring (6 Used) 34 - Cap (5 Used) 52 - Pump Control Valve
17 - Adjusting Screw (6 Used) 35 - Guide (10 Used) 53 - Cover (5 Used)
18 - Lock Nut (6 Used) 36 - Sleeve (5 Used) 54 - Housing
W2-5-8 EX455

CONTROL VALVE

Pump Control Valve (52) Top Face of Control Valve

SM6827

Overload Relief Valve (1), (19), (29), (30) Makeup Valve (28)

SM6830

SM6828 SM6829

Bottom Face of Control Valve

SM6832

SM6831
Section A-A
EX455 W2-5-9

CONTROL VALVE

Assemble Control Valve 1 9. After installing O-rings (4) and (2) and backup ring
(3) onto sleeve (20), install sleeve (20) into housing
1. With the manifold mounting face positioned down- (54).
ward, place housing (54) on a work bench.
: 41 mm
: 98 N•m (10 kgf•m, 72 lbf•ft)
NOTE - Lay soft material between housing (54) and the
work bench.
Pump Control Valve

10. After installing O-ring (51) onto pump control valve

Overload Relief Valve (52), install pump control valve (52) into housing
(54).
2. Install O-rings (10) and (12) and backup ring (11)
onto seat (13) and O-ring (16) into adjusting screw : 30 mm
(17). : 59 N•m (6 kgf•m, 43 lbf•ft)

3. Install poppet (14), spring (15), adjusting screw (17)
and lock nut (18) into seat (13).
: 19 mm
: 34 N•m (3.5 kgf•m, 25.5 lbf•ft)
: 6 mm
4. After installing piston (7), springs (8) and (9) into
poppet (6), install poppet (6) onto seat (13).
5. Install seat (13) into sleeve (5).
: 36 mm
: 98 N•m (10 kgf•m, 72 lbf•ft)
IMPORTANT - Install overload relief valves (1), (19),
(29) and (30) in the same positions where they were
previously located.
5-Spool Section
11. Install O-rings (31) (5 used) on the bottom face of
housing (54). Then, install covers (53) (5 used) to
housing (54) with socket bolts (32) (10 used).
: 10 mm
: 98 N•m (10 kgf•m, 72 lbf•ft)
12. Insert spool (38) into special tool (75301291) and
hold with a vise. After installing guide (35), sleeve
(36), spring (37) and guide (35) onto cap (34),
install cap (34) onto spool (38).
: 10 mm
: 98 N•m (10 kgf•m, 72 lbf•ft)
13. Assemble spools (39) and (46 to 48) in the same
procedure as described in step 12.

6. Install overload relief valves (1) (2 used), (19) (2

used), (29) and (30) to housing (54).

: 41 mm
: 98 N•m (10 kgf•m, 72 lbf•ft)

Makeup valve

7. Install O-ring (22) and backup ring (21) onto poppet

(23), and O-ring (25), backup ring (26) onto cap (27).

8. Install poppet (23), spring (24) and cap (27) into

sleeve (20).

: 36 mm
: 98 N•m (10 kgf•m, 72 lbf•ft)
W2-5-10 EX455

CONTROL VALVE

Pump Control Valve (52) Top Face of Control Valve

SM6827

Overload Relief Valve (1), (19), (29), (30) Makeup Valve (28)

SM6830

SM6828 SM6829

Bottom Face of Control Valve

SM6832

SM6831
Section A-A
EX455 W2-5-11

CONTROL VALVE

14. Install check valve (40), spring (41) and spacer

(42) into spool (39).

15. After installing O-ring (43) and backup ring (44)

onto cap (45), install cap (45) into spool (39).

: 8 mm
: 59 N•m (6 kgf•m, 43 lbf•ft)

16. Install O-rings (31) (5 used) on housing (54).

IMPORTANT - Install each spool (38), (39), (46), (47)

and (48) in the same position where it was previously
located.

17. Holding the spring section of each spool (38), (39),

(46), (47) and (48), insert the spool into housing
(54) while slowly rotating the spool.

18. Install cover (33) to housing (54) with socket bolts

(32) (10 used).

: 10 mm
: 98 N•m (10 kgf•m, 72 lbf•ft)
W2-5-12 EX455

CONTROL VALVE

DISASSEMBLE CONTROL VALVE 2

Orifice

Swing

Arm 1

Boom 2

Holding Valve (Arm)

Auxiliary

Left Travel

SM6833

1 - O-Ring (6 Used) 10 - Cap 18 - O-Ring (3 Used) 25 - Backup Ring

2 - Backup Ring (6 Used) 11 - Cap (2 Used) 19 - Backup Ring 26 - Ring
3 - Chip (6 Used) 12 - O-Ring (2 Used) 20 - Cover 27 - Spring
4 - Cap 13 - Spring 21 - Washer (4 Used) 28 - Poppet
5 - Check Valve (5 used) 14 - Poppet 22 - Socket Bolt (4 29 - Cap
6 - Spring (5 Used) 15 - Sleeve Used) 30 - Cap
7 - Cap 16 - Backup Ring 23 - Piston 31 - Housing
8 - Check Valve(4 Used) 17 - O-Ring 24 - O-Ring 32 - Socket Bolt (4 Used)
9 - Cap 33 - Washer (4 Used)
EX455 W2-5-13

CONTROL VALVE

Disassemble Control Valve 2

• Thoroughly read "Precaution for Disassembly and

Assembly" on page W1-1-1 before starting repair
work.

Holding Valve

1. Loosen socket bolts (22) (4 used) to remove

holding valve cover (20) from housing (31).

: 12 mm

2. Remove spring (27) and poppet (28) from housing

(31).

3. Loosen caps (11) (2 used) to remove spring (13),

poppet (14), sleeve (15) and piston (23) from cover
(20). Attach a round bar approx. 10 mm in diameter
to sleeve (15). While tapping the bar, remove
sleeve (15) taking care not to damage cover (20).

: 10 mm

Load Check Valve

(Except for swing)

4. Remove caps (9), (10), (29) and (30) from housing

(31).

: 14 mm

5. Remove check valves (8) (4 used), springs (6) (4

used) and check valves (5) (4 used) from housing
(31).

(Swing)

6. Remove cap (7) from housing (31).

: 14 mm

7. Remove spring (6) and check valve (5) from hous-

ing (31).
W2-5-14 EX455

CONTROL VALVE

ASSEMBLE CONTROL VALVE 2

Orifice Swing Arm 1

SM6834 SM6835
SM6836

Left Travel Auxiliary Boom 2 Holding Valve (Arm) Holding Valve (Arm)

Swing

Orifice

SM6837
SM6838
Arm 1

Left Travel Auxiliary Boom 2

SM6839 SM6840 SM6841

1 - O-Ring (6 Used) 10 - Cap 19 - Backup Ring 27 - Spring

2 - Backup Ring (6 Used) 11 - Cap (2 Used) 20 - Cover 28 - Poppet
3 - Chip (6 Used) 12 - O-Ring (2 Used) 21 - Washer (4 Used) 29 - Cap
4 - Cap 13 - Spring 22 - Socket Bolt 30 - Cap
5 - Check Valve (5 used) 14 - Poppet (4 Used) 31 - Housing
6 - Spring (5 Used) 15 - Sleeve 23 - Piston 32 - Socket Bolt (4 Used)
7 - Cap 16 - Backup Ring 24 - O-Ring 33 - Washer (4 Used)
8 - Check Valve(4 Used) 17 - O-Ring 25 - Backup Ring
9 - Cap 18 - O-Ring (3 Used) 26 - Ring
EX455 W2-5-15

CONTROL VALVE

Assemble Control Valve 2

Load Check Valve

(Swing)

1. Install check valve (5) and spring (6) into housing

(31).

2. Install O-ring (1) and backup ring (2) onto cap (7),
and install cap (7) to housing (31).

: 14 mm
: 345 N•m (35 kgf•m, 255 lbf•ft)

(Except for Swing)

3. Install check valve (5), spring (6) and check valve

(8) into housing (31).

4. Install O-rings (1) and backup rings (2) onto caps

(4), (9), (10), (29) and (30). Install caps (4), (9), (10),
(29) and (30) to housing (31).

: 14 mm
: 345 N•m (35 kgf•m, 255 lbf•ft)

Holding Valve

5. Install O-ring (26) and backup ring (25) onto poppet

(28). Install poppet (28) and spring (27) into housing
(31).

6. Install O-rings (17) and (18) and backup rings (16)

and (19) into sleeve (15).

7. Install piston (23), sleeve (15), poppet (14) and

spring (13) into cover (20).

8. After installing O-rings (12) onto caps (11) (2 used),

install caps (11) (2 used) into cover (20).

: 10 mm
: 49 N•m (5 kgf•m, 36 lbf•ft)

9. Install O-ring (24) on cover (20).

10. Install cover (20) on housing (31) with socket bolts

(22) (4 used).

: 12 mm
: 175 N•m (18 kgf•m, 130 lbf•ft)
W2-5-16 EX455

CONTROL VALVE

DISASSEMBLE CONTROL VALVE 3

Flow Combiner Valve

Shuttle Valve

SM6842
EX455 W2-5-17

CONTROL VALVE

1 - Makeup Valve (2 Used) 22 - Spring (4 Used) 43 - Seat 61 - Piston (4 Used)

2 - Cap (2 Used) 23 - Spool (Arm 2) 44 - Backup Ring 62 - Spring (4 Used)
3 - Backup Ring (2 Used) 24 - Cap 45 - O-Ring 63 - Poppet (4 Used)
4 - O-Ring (2 Used) 25 - Backup Ring 46 - Orifice 64 - Sleeve (4 Used)
5 - Spring (2 Used) 26 - O-Ring 47 - Spring 65 - Seat
6 - Poppet (2 Used) 27 - Spool (Boom 1) 48 - Poppet 66 - O-Ring
7 - O-Ring (2 Used) 28 - Spool (Bucket) 49 - Sleeve 67 - Ball
8 - Backup Ring (4 Used) 29 - Spool (Right Travel) 50 - Overload Relief Valve 68 - Cap
9 - Sleeve (2 Used) 30 - Main Relief Valve (4 Used) 69 - Backup Ring
10 - O-Ring (6 Used) 31 - Adjusting Screw 51 - Lock Nut (4 Used) 70 - O-Ring
11 - Backup Ring (6- Used) 32 - O-Ring 52 - Adjusting Screw 71 - Spring (2 Used)
12 - O-Ring (6 Used) 33 - Lock Nut (4 Used) 72 - Check Valve (2 Used)
13 - Housing 34 - Piston 53 - O-Ring (4 Used) 73 - Spool
14 - O-Ring 35 - Sleeve 54 - Spring (4 Used) 74 - Spacer
15 - Pump Control Valve 36 - O-Ring 55 - Poppet (4 Used) 75 - Spring
16 - O-Ring (8 Used) 37 - O-Ring 56 - Seat (4 Used) 76 - Cap
17 - Socket Bolt (16 Used) 38 - Lock Nut 57 - O-Ring (4 Used) 77 - Chip (2 Used)
18 - Cover 39 - Cap 58 - Backup Ring 78 - Backup Ring
19 - Cap (4 Used) 40 - O-Ring (8 Used) 79 - Cap
20 - Guide (8 Used) 41 - Spring 59 - O-Ring (4 Used) 80 - Cover
21 - Sleeve (4 Used) 42 - Poppet 60 - Spring (4 Used) 81 - Cover (3 Used)
W2-5-18 EX455

CONTROL VALVE

Flow Combiner Valve

Shuttle Valve

SM6842
EX455 W2-5-19

CONTROL VALVE

Disassemble Control Valve 3 Overload Relief Valve

• Thoroughly read "Precaution for Disassembly and

IMPORTANT - Do not disassemble the overload relief
Assembly" on page W1-1-1 before starting repair
valve unless necessary.
work.

9. Remove overload relief valves (50) (4 used) (two

4-Spool Section each located on top and bottom faces of the
housing) from housing (13).
1. Loosen socket bolts (17) (8 used) to remove cover : 41 mm
(18) from housing (13).
: 10 mm 10. Remove lock nut (51) and seat (56) from sleeve
(64).
2. While inspecting the fitness between housing (13) : 19 mm, 36 mm
and spools (23), (27), (28) and (29) (4 used), slowly
pull the spools out of the housing (13). 11. Remove adjusting screw (52), spring (54) and
poppet (55) from seat (56).
3. Remove O-rings (16) (4 used) from housing (13).
: 6 mm
4. Loosen socket bolts (17) (8 used) on the control
valve bottom side to remove covers (80) and (81) 12. Remove springs (62) and (60), poppet (63) and
(3 used) from housing (13). piston (61) from sleeve (64).

: 10 mm
Makeup Valve
5. Insert spool (23) into special tool (75301291) and
hold them with a vise. Remove cap (19). 13. Remove makeup valves (1) (2 used) (one each
located on top and bottom faces of the housing)
: 10 mm from housing (13).

6. Remove guide (20), sleeve (21), spring (22) and : 41 mm

guide (20) from cap (19).
14. Loosen cap (2) to remove spring (5), poppet (6)
7. Disassemble spools (27), (28) and (29) following from sleeve (9).
the same procedures as described in steps 5 and
6. : 36 mm

Pump Control Valve

8. Remove pump control valve (15) from housing (13).

: 30 mm
W2-5-20 EX455

CONTROL VALVE

Flow Combiner Valve

Shuttle Valve

SM6842
EX455 W2-5-21

CONTROL VALVE

Main Relief Valve

IMPORTANT - Do not disassemble the main relief

valve unless necessary.

15. Loosen and remove main relief valve (30) from

housing (13).

: 41 mm

16. Loosen lock nuts (33 and 38).

: 41 mm, 30 mm

17. Remove sleeve (35), spring (41) and poppet (42)

from cap (39).

18. Remove adjusting screw (31) and piston (34) from

sleeve (35).

19. Pull sleeve (49) out of seat (43) and remove orifice
(46), spring (47) and poppet (48) from sleeve (49).

Shuttle Valve

20. Loosen cap (68) to remove the shuttle valve from

housing (13).

: 41 mm

21. Remove spring (71) and check valve (72) from

housing (13).

22. Loosen seat (65) to remove ball (67) from cap (68).

: 27 mm

Flow Combiner Valve

23. Loosen cap (76) to remove spring (75), spacer (74)

and spool (73) from housing (13).

: 46 mm

Check Valve

24. Loosen cap (79) to remove spring (71) and check

valve (72) from housing (13).

: 14 mm
W2-5-22 EX455

CONTROL VALVE

ASSEMBLE CONTROL VALVE 3

Overload Relief Valve (50) Pump Control Valve (15)

Top Face of Control Valve

SM6827
SM6828
Main Relief Valve (30)

SM6830

Bottom Face of Control Valve SM6843

Shuttle Valve Flow Combiner Valve

SM6844 SM6845

SM6832

Makeup Valve Check Valve

SM6829 SM6835

Section A-A SM6846

EX455 W2-5-23

CONTROL VALVE

1 - Makeup Valve (2 Used) 22 - Spring (4 Used) 43 - Seat 61 - Piston (4 Used)

2 - Cap (2 Used) 23 - Spool (Arm 2) 44 - Backup Ring 62 - Spring (4 Used)
3 - Backup Ring (2 Used) 24 - Cap 45 - O-Ring 63 - Poppet (4 Used)
4 - O-Ring (2 Used) 25 - Backup Ring 46 - Orifice 64 - Sleeve (4 Used)
5 - Spring (2 Used) 26 - O-Ring 47 - Spring 65 - Seat
6 - Poppet (2 Used) 27 - Spool (Boom 1) 48 - Poppet 66 - O-Ring
7 - O-Ring (2 Used) 28 - Spool (Bucket) 49 - Sleeve 67 - Ball
8 - Backup Ring (4 Used) 29 - Spool (Right Travel) 50 - Overload Relief Valve 68 - Cap
9 - Sleeve (2 Used) 30 - Main Relief Valve (4 Used) 69 - Backup Ring
10 - O-Ring (6 Used) 31 - Adjusting Screw 51 - Lock Nut (4 Used) 70 - O-Ring
11 - Backup Ring (6- Used) 32 - O-Ring 52 - Adjusting Screw 71 - Spring (2 Used)
12 - O-Ring (6 Used) 33 - Lock Nut (4 Used) 72 - Check Valve (2 Used)
13 - Housing 34 - Piston 53 - O-Ring (4 Used) 73 - Spool
14 - O-Ring 35 - Sleeve 54 - Spring (4 Used) 74 - Spacer
15 - Pump Control Valve 36 - O-Ring 55 - Poppet (4 Used) 75 - Spring
16 - O-Ring (8 Used) 37 - O-Ring 56 - Seat (4 Used) 76 - Cap
17 - Socket Bolt (16 Used) 38 - Lock Nut 57 - O-Ring (4 Used) 77 - Chip (2 Used)
18 - Cover 39 - Cap 58 - Backup Ring 78 - Backup Ring
19 - Cap (4 Used) 40 - O-Ring (8 Used) 79 - Cap
20 - Guide (8 Used) 41 - Spring 59 - O-Ring (4 Used) 80 - Cover
21 - Sleeve (4 Used) 42 - Poppet 60 - Spring (4 Used) 81 - Cover (3 Used)
W2-5-24 EX455

CONTROL VALVE

Overload Relief Valve (50)

Top Face of Control Valve

Pump Control Valve (15)

SM6827

SM6828

Main Relief Valve (30)

SM6830

Bottom Face of Control Valve SM6843

Flow Combiner Valve

Shuttle Valve

SM6845
SM6844

SM6832

Makeup Valve

Check Valve

SM6835

SM6829

Section A-A
SM6846
EX455 W2-5-25

CONTROL VALVE

Assemble Control Valve 3 11. Install piston (61), springs (60) and (62) to poppet
(63). Then, install poppet (63) to seat (56).
1. With the manifold mounting face positioned down-
ward, place housing (13) on a work bench. 12. Install seat (56) into sleeve (64).

: 36 mm
NOTE - Lay soft material between housing (13) and the
work bench. : 98 N•m (10 kgf•m, 72 lbf•ft)

IMPORTANT - Install overload relief valves (50) in the

Main Relief Valve
2. Install lock nut (38), piston (34) and O-rings (36 and
37) to sleeve (35).
3. Install lock nut (33) and O-ring (32) to adjusting
screw (31). Then, install adjusting screw (31) to
sleeve (35).
same positions where they were previously located.
Be sure to adjust the overload relief set pressure.
(Refer to the "Overload Relief Valve Adjustment" in the
Operational Performance Test section in the Techni-
cal Manual.)
13. Install overload relief valves (50) (4 used) to
housing (13).

4. Install poppet (42), spring (41) and sleeve (35) to : 41 mm

cap (39).
: 98 N•m (10 kgf•m, 72 lbf•ft)
5. Install spring (47) and orifice (46) into sleeve (49).
Makeup Valve
6. Install O-ring (45) and backup ring (44) onto seat
(43).
14. Install O-ring (7) and backup ring (8) to poppet (6),
and O-ring (4) and backup ring (3) to cap (2).
7. Install sleeve (49) onto seat (43).
15. Install poppet (6), spring (5) and cap (2) into sleeve
IMPORTANT - Be sure to adjust the main relief set (9).
pressure. (Refer to the Main Relief Valve Adjustment
in the Operational Performance Test section in the : 36 mm
Technical Manual.) : 98 N•m (10 kgf•m, 72 lbf•ft)

16. Install O-rings (10) and (12) and backup ring (11)
8. Install main relief valve (30) to housing (13). onto sleeve (9). Then, install sleeve (9) to housing
(13).
: 41 mm
: 98 N•m (10 kgf•m, 72 lbf•ft) : 41 mm
: 98 N•m (10 kgf•m, 72 lbf•ft)

Overload Relief Valve

9. Install O-rings (57) and (59) and backup ring (58)

onto seat (56). Install O-ring (53) to adjusting screw
(52).

10. Install poppet (55), spring (54), adjusting screw

(52) and lock nut (51) to seat (56).

: 19 mm
: 34 N•m (3.5 kgf•m, 25.5 lbf•ft)
: 6 mm
W2-5-26 EX455

CONTROL VALVE

Top Face of Control Valve Pump Control Valve (15)

Overload Relief Valve (50)

SM6827
SM6828

Main Relief Valve (30)

SM6830

SM6843
Bottom Face of Control Valve

Shuttle Valve Flow Combiner Valve

SM6844 SM6845

SM6832

Check Valve

Makeup Valve

SM6829
SM6835

SM6846
Section A-A
EX455 W2-5-27

CONTROL VALVE

Pump Control Valve Shuttle Valve

17. Install O-ring (14) onto pump control valve (15).
Then, install pump control valve (15) to housing
(13).
: 30 mm
: 59 N•m (6 kgf•m, 43 lbf•ft)
24. Install O-rings (40) and (70) and backup ring (69)
onto cap (68), and O-ring (66) onto seat (65).
25. Install ball (67) and seat (65) into cap (68).
: 27 mm
: 59 N•m (6 kgf•m, 43 lbf•ft)

26. Install check valve (72), spring (71) and cap (68)
4-Spool Section
into housing (13).
18. Install O-rings (16) (4 used) on the bottom face of
: 41 mm
housing (13). Then, install covers (80) and (81) (3
used) to housing (13) with socket bolts (17) (8 : 175 N•m (18 kgf•m, 130 lbf•ft)
used).

Flow Combiner Valve

: 10 mm
: 98 N•m (10 kgf•m, 72 lbf•ft) 27. Install O-ring (40) onto cap (76).

19. Insert spool (23) into special tool (75301291) and 28. Install spool (73), spacer (74), spring (75) and cap
hold with a vise. After installing guide (20), sleeve (76) into housing (13).
(21), spring (22) and guide (20) onto cap (19),
install cap (19) onto spool (23). : 46 mm
: 175 N•m (18 kgf•m, 130 lbf•ft)
: 10 mm
: 98 N•m (10 kgf•m, 72 lbf•ft)
Check Valve
20. Assemble spools (27), (28) and (29) (3 used)
following the same procedure as described in step 29. Install O-ring (40) and backup ring (78) onto cap
19. (79).

21. Install O-rings (16) (4 used) on housing (13). 30. Install check valve (72), spring (71) and cap (79)
into housing (13).
IMPORTANT - Install each spool (23), (27), (28) or (29)
in the same position where it was previously located. : 14 mm
Install spool (27) so that lock plug for cover (80) enter : 345 N•m (35 kgf•m, 255 lbf•ft)
into the spool groove.

22. Holding the spring section of each spool (23), (27),

(28) or (29), insert the spool into housing (13) while
slowly rotating the spool.

23. Install cover (18) to housing (13) with socket bolts

(17) (8 used).

: 10 mm
: 98 N•m (10 kgf•m, 72 lbf•ft)
W2-5-28 EX455

CONTROL VALVE

DISASSEMBLE CONTROL VALVE 4

Center Bypass Valve

Arm 2

Boom 1
Bucket

Holding Valve (Boom)

SM6847

1 - Socket Bolt (7 Used) 10 - Sleeve 19 - O-Ring 28 - Cap (2 Used)

2 - Washer (7 Used) 11 - O-Ring 20 - Spring 29 - Cap
3 - Housing 12 - Backup Ring 21 - Poppet 30 - Check Valve
4 - Cap (2 Used) 13 - Cover 22 - Orifice 31 - Check Valve
5 - O-Ring (2 Used) 14 - Socket Bolt (4 Used) 23 - Check Valve (2 Used) 32 - Cap (3 Used)
6 - Spring 15 - Washer (4 Used) 24 - Spring (3 Used) 33 - Cap
7 - Poppet 16 - Piston 25 - O-Ring (7 Used) 34 - Spool
8 - Backup Ring 17 - O-Ring 26 - Backup Ring (7 Used) 35 - Spring
9 - O-Ring (4 Used) 18 - Backup Ring 27 - Chip (7 Used)
EX455 W2-5-29

CONTROL VALVE

Disassemble Control Valve 4 Center Bypass Valve

• Thoroughly read "Precaution for Disassembly and 8. Loosen and remove cap (33) from housing (3).
Assembly" on page W1-1-1 before starting to work.
: 46 mm

Holding Valve (Boom)
1. Loosen socket bolts (14) (4 used) to remove
holding valve cover (13) from housing (3).
: 12 mm
2. Remove spring (20) and poppet (21) from housing
(3).
3. Loosen caps (4) (2 used) to remove spring (6),
poppet (7), sleeve (10) and piston (16) from cover
(13). Attach a round bar approx. 10 mm in diam-
eter to sleeve (10). While tapping the bar, remove
sleeve (10) taking care not to damage cover (13).
: 10 mm
9. Remove spool (34) and spring (35) from housing
(3).
Orifice
10. Install special tool (75301292) of socket bolt (M5,
pitch: 1.0, length: 60 mm) into orifice (22).
11. While holding socket bolt (M5, pitch: 1.0, length:
60 mm) so that the bolt does not rotate, turn the
bolt head of special tool (75301292) counter-
clockwise to remove orifice (22) from housing (3).
: 4 mm
: 17 mm

Load Check Valve

(Arm 2)

4. Loosen and remove cap (29) from housing (3).

: 14 mm

5. Remove check valve (30), spring (24) and check

valve (31) from housing (3).

(Except for Arm 2)

6. Loosen and remove cap (28) from housing (3).

: 14 mm

7. Remove springs (24) (2 used) and check valve

(23) (2 used) from housing (3).
W2-5-30 EX455

CONTROL VALVE

ASSEMBLE CONTROL VALVE 4

Boom 1, Bucket
Center Bypass Valve Arm 2

SM6850
SM6848 SM6849

Arm 2 Boom 1 Bucket Holding Valve (Boom)

Center
Bypass
Valve

SM6852

Holding Valve (Boom)

SM6851

1 - Socket Bolt (7 Used) 10 - Sleeve 18 - Backup Ring 27 - Chip (7 Used)

2 - Washer (7 Used) 11 - O-Ring 19 - O-Ring 28 - Cap (2 Used)
3 - Housing 12 - Backup Ring 20 - Spring 29 - Cap
4 - Cap (2 Used) 13 - Cover 21 - Poppet 30 - Check Valve
5 - O-Ring (2 Used) 14 - Socket Bolt (4 22 - Orifice 31 - Check Valve
6 - Spring Used) 23 - Check Valve (2 Used) 32 - Cap (3 Used)
7 - Poppet 15 - Washer (4 Used) 24 - Spring (3 Used) 33 - Cap
8 - Backup Ring 16 - Piston 25 - O-Ring (7 Used) 34 - Spool
9 - O-Ring (4 Used) 17 - O-Ring 26 - Backup Ring (7 Used) 35 - Spring
EX455 W2-5-31

CONTROL VALVE

Assemble Control Valve 4 Holding Valve

Orifice 8. After installing O-ring (19) and backup ring (18)

1. Install socket bolt (M5, pitch: 1.0, length: 60 mm)
to orifice (22). Then, install orifice (22) into housing
(3) while tapping the bolt head.
onto poppet (21), install poppet (21) and spring (20)
into housing (3).
9. Install O-rings (9) and (11) and backup rings (12)
and (8) onto sleeve (10).

10. Install piston (16), sleeve (10), poppet (7) and

spring (6) into cover (13).
Load Check Valve
11. Install O-ring (17) on cover (13).
(Boom 1, Bucket)
12. After installing O-rings (5) onto caps (4) (2 used),
2. Install check valve (23) and spring (24) into housing install caps (4) (2 used) into cover (13).
(3).
: 110 mm
3. Install O-ring (25) and backup ring (26) onto cap
(28). Then, install cap (28) into housing (3). : 49 N•m (5 kgf•m, 36 lbf•ft)

13. Install cover (13) to housing (3) with socket bolts

: 14 mm
(14) (4 used).
: 345 N•m (35 kgf•m, 255 lbf•ft)
: 12 mm
(Arm 2)
: 175 N•m (18 kgf•m, 130 lbf•ft)
4. Install check valve (31), spring (24) and check
valve (30) into housing (3).

5. Install O-ring (25) and backup ring (26) onto cap

(29). Then, install cap (29) into housing (3).

: 14 mm
: 345 N•m (35 kgf•m, 255 lbf•ft)

Center Bypass Valve

6. Install O-ring (25) and backup ring (26) onto cap

(33).

7. Install spool (34), spring (35) and cap (33) into

housing (3).

: 46 mm
: 245 N•m (25 kgf•m, 180 lbf•ft)
W2-5-32 EX455

CONTROL VALVE

DISASSEMBLE CONTROL VALVE 5

Check Valve C

Check
Valve D

Check Valve B

Check
Valve A

Arm Regenerative Valve

SM6853

1 - Backup Ring 12 - O-Ring 23 - Chip (2 Used) 34 - Socket Bolt

2 - Backup Ring (3 Used) 13 - Cap 24 - Cap (2 Used) (14 Used)
3 - O-Ring (2 Used) 14 - Manifold 25 - Backup Ring (2 Used) 35 - Spool
4 - Spring (4 Used) 15 - Washer (21 Used) 26 - O-Ring (2 Used) 36 - Spring
5 - Check Valve (4 Used) 16 - Socket Bolt (7 Used) 27 - Spring Guide (2 Used) 37 - Spring Guide
6 - Backup Ring (4 Used) 17 - O-Ring (5 Used) 28 - Spring (2 Used) 38 - O-Ring (2 Used)
7 - O-Ring (2 Used) 18 - O-Ring (8 Used) 29 - Check Valve (2 Used) 39 - Cap
8 - O-Ring (2 Used) 19 - O-Ring 30 - O-Ring (2 Used) 40 - Sleeve
9 - Cap 20 - O-Ring (13 Used) 31 - Backup Ring (2 Used) 41 - Piston
10 - Check Valve 21 - O-Ring (3 Used) 32 - Seat (2 Used) 42 - O-Ring
11 - Spring 22 - O-Ring (2 Used) 33 - Backup Ring 43 - Sleeve
EX455 W2-5-33

CONTROL VALVE

Disassemble Control Valve 5 Check Valve B

• Thoroughly read "Precaution for Disassembly and 8. Loosen and remove caps (24) (2 used) from mani-
Assembly" on page W1-1-1 before starting repair fold (14).
work.
: 14 mm

Manifold 9. Remove springs (4) (2 used) and check valve (5)

from manifold (14).
NOTE - Before placing 4-spool or 5-spool housing and
manifold on a work bench, lay soft material on the work
bench to protect the housing or manifold mounting Check Valve C
surface from damaged.
10. Loosen and remove caps (9) from manifold (14).
1. Loosen socket bolts (16) (6 used) and the 4-spool
: 46 mm
side housing socket bolts (7 used) to remove the 4-
spool side housing from manifold (14).
11. Remove spring (4) and check valve (5) from
manifold (14).
: 14 mm
12. Loosen cap (13) to remove spring (11) and check
2. Remove O-rings (17) (2 used), (18) (4 used), (20) (6 valve (10) from cap (9).
used), (21) and (22) from manifold (14).
: 8 mm
3. Loosen socket bolts (16) (1 used), (34) (14 used)
and the 5-spool side housing socket bolts (4 used)
to remove the 5-spool side housing from manifold
Check Valve A, D
(14).
13. Using a copper bar, tap spring guide (27) from 5-
: 14 mm spool manifold (14) for the check valve A side and
4-spool manifold (14) for the check valve D side to
4. Remove O-rings (17) (3 used), (18) (4 used), (19) (1 remove seat (32), check valve (29), spring (28),
used), (20) (7 used), (21) (3 used) and (22) (1 used) and spring guide (27).
from manifold (14).

Arm Regenerative Valve

5. Loosen sleeve (40) to remove spring (36) and spool

(35) from manifold (14).

: 46 mm

6. Using a screw driver, push check valve (5) from the

5-spool housing side, remove sleeve (43), spring
(4) and check valve (5) from manifold (14).

7. Loosen cap (39) to remove spring guide (37) from

sleeve (40).

: 12 mm
W2-5-34 EX455

CONTROL VALVE

ASSEMBLE CONTROL VALVE 5

Check Valve A, D Check Valve B

SM6854 SM6855

Manifold (4-Spool Side) Manifold (Top Face) Manifold (5-Spool Side)

Check
Valve A

Check Check Valve D

Valve C

Check Check Valve C

Valve B
Check
Valve B

SM6856

Arm Regenerative Valve Check Valve C

SM6858
SM6857

1 - Backup Ring 12 - O-Ring 23 - Chip (2 Used) 34 - Socket Bolt

2 - Backup Ring (3 Used) 13 - Cap 24 - Cap (2 Used) (14 Used)
3 - O-Ring (2 Used) 14 - Manifold 25 - Backup Ring (2 Used) 35 - Spool
4 - Spring (4 Used) 15 - Washer (21 Used) 26 - O-Ring (2 Used) 36 - Spring
5 - Check Valve (4 Used) 16 - Socket Bolt (7 Used) 27 - Spring Guide (2 Used) 37 - Spring Guide
6 - Backup Ring (4 Used) 17 - O-Ring (5 Used) 28 - Spring (2 Used) 38 - O-Ring (2 Used)
7 - O-Ring (2 Used) 18 - O-Ring (8 Used) 29 - Check Valve (2 Used) 39 - Cap
8 - O-Ring (2 Used) 19 - O-Ring 30 - O-Ring (2 Used) 40 - Sleeve
9 - Cap 20 - O-Ring (13 Used) 31 - Backup Ring (2 Used) 41 - Piston
10 - Check Valve 21 - O-Ring (3 Used) 32 - Seat (2 Used) 42 - O-Ring
11 - Spring 22 - O-Ring (2 Used) 33 - Backup Ring 43 - Sleeve
EX455 W2-5-35

CONTROL VALVE

Assemble Control Valve 5 Arm Regenerative Valve

1. Place manifold (14) on a work bench with the 5-
spool housing mounting face positioned upwards.
NOTE - Before placing the manifold on a work bench,
lay soft material on the work bench to protect the
housing mounting surface from damaged.
Check Valve C
10. Install piston (41), O-rings (3) and (42), backup
rings (33) and (6) (2 used) to sleeve (43). Install
sleeve (43) into sleeve (40).
11. Install O-rings (7) and (8) and backup ring (2) onto
sleeve (40).
12. Install spool (35) into sleeve (40), and install check
valve (5) and spring (4) into sleeve (43) respec-
tively. Then, install sleeve (40) into manifold (14).

2. Install check valve (10) and spring (11) into cap (9).
3. Install O-ring (12) onto cap (13) and install cap (13)
into cap (9).
: 8 mm
: 39 N•m (4 kgf•m, 29 lbf•ft)
4. Install O-rings (3), (7), and (8), backup rings (1), (2)
(2 used) and (6) (2 used) onto cap (9).
5. Install check valve (5) and spring (4) into cap (9).
Install cap (9) into manifold (14).
: 46 mm
: 175 N•m (18 kgf•m, 130 lbf•ft)
: 46 mm
:175 N•m (18 kgf•m, 130 lbf•ft)
13. Install spring (36) and spring guide (37) into sleeve
(40).
14. Install O-ring (38) onto cap (39). Install cap(39) into
sleeve (40).
: 12 mm
: 98 N•m (10 kgf•m , 72 lbf•ft)
15. Install O-rings (17) (3 used), (18) (4 used), (19) (1
used), (20) (7 used), (21) (2 used) and (22) (1 used)
on manifold (14).
16. Install manifold (14) to the 5-spool housing.

Check Valve B 17. Tighten socket bolts (34) (14 used), (16) (1 used)
and the 5-spool housing socket bolts (4 used).
6. Install O-ring (26) (2 used) and backup ring (25) (2
used) onto cap (24). : 14 mm
: 245 N•m (25 kgf•m, 180 lbf•ft)
7. Install check valves (5) (2 used) and spring (4) (2
used) into cap (24) (2 used). Install cap (24) (2
used) into manifold (14).

: 14 mm
: 345 N•m (35 kgf•m, 255 lbf•ft)

Check Valve D

8. Install spring guide (27), spring (28), and check

valve (29) into manifold (14).

9. Install O-ring (30) and backup ring (31) onto seat

(32). Install seat (32) into manifold (14).
W2-5-36 EX455

CONTROL VALVE

Check Valve A, D Check Valve B

SM6854

SM6855

Manifold (4-Spool Side) Manifold (Top Face)

Manifold (5-Spool Side)

Check Valve D

SM6856

Arm Regenerative Valve Check Valve C

SM6858
SM6857
EX455 W2-5-37

CONTROL VALVE

Check Valve A

18. Install spring guide (27), spring (28), and check

valve (29) into manifold (14).

19. Install O-ring (30) and backup ring (31) onto seat
(32). Install seat (32) into manifold (14).

20. Install O-rings (17) (2 used), (18) (4 used), (20) (6

used), (21) (1 used) and (22) (1 used) on the 4-
spool housing mounting face of manifold (14).

21. Install the 4-spool housing to manifold (14).

22. Tighten socket bolts (16) (6 used) and the 4-spool

housing side socket bolts (7 used).

: 14 mm
: 245 N•m (25 kgf•m, 180 lbf•ft)
W2-5-38 EX455

CONTROL VALVE

NOTES
EX455 W2-6-1

SWING DEVICE

REMOVE AND INSTALL SWING DEVICE

WARNING
Escaping fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by
relieving pressure before disconnecting hydraulic lines.
Hot hydraulic oil may spout after operation, possibly causing severe burns. Wait for oil to cool before starting
any repair work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Thoroughly release any
remaining pressure before removing the cap.

Preparation
1. Park the machine on a firm, level surface.
Lower the front attachment to the ground.
2. Stop the engine. Move all control levers to release
pressure remaining in the system. Rotate the
hydraulic oil tank cap approx. 30° counterclock-
wise to release pressure remaining in the hydraulic
oil tank.
3. Remove the cap and connect a vacuum pump.
Operate the vacuum pump constantly to maintain
the negative pressure in the hydraulic oil tank.
NOTE - Keep the vacuum pump running continu-
ously while working.

Removal
1. Disconnect hoses (1 to 6) or (8 to 10) as necessary.
: 41 mm
: 205 N•m (21 kgf•m, 152 lbf•ft)
: 36 mm
: 167 N•m (16 kgf•m, 152 lbf•ft)
: 27 mm
: 93 N•m (9.5 kgf•m, 69 lbf•ft)
: 22 mm
: 39 N•m (4 kgf•m, 29 lbf•ft)

NOTE - Cap all disconnected hose ends.

2. Install eye bolts (M10, pitch 1.5) to two bolt holes on

the top of the swing motor to sling with a wire rope.
3. After removing bolts (7), remove the swing device
by slinging the swing device with a crane. SM6859

WARNING
Swing device assembly weight: 280 kg (620 lb)

: 32 mm
: 740 N•m (75 kgf•m, 540 lbf•ft) Eye Bolt Screw Holes

Installation

NOTE - Refer to "Removal" section for wrench sizes

and tightening torques.

1. After applying a fluid packing to the mating sur-

faces on the swing device and the frame, secure
the swing device with bolts (7).
2. Connect hoses (1 to 6) or (8 to 10).

IMPORTANT - Be sure to fill the swing motor with

hydraulic oil after installing it. Check the oil level.
SM6860
Check for any oil leaks after starting the engine
W2-6-2 EX455

SWING DEVICE

DISASSEMBLE SWING DEVICE

SM6861

1 - Motor 10 - First Stage Planetary 16 - Bearing 25 - O-Ring

2 - Socket Bolt (12 Used) Gear (3 Used) 17 - Retaining Ring 26 - Bearing
3 - Internal Gear 11 - Spring Pin (3 Used) 18 - Second Stage Carrier 27 - Cover
4 - Internal Gear 12 - Pin (3 Used) 19 - Thrust Plate 28 - Oil Seal
5 - First Stage Sun Gear 13 - Thrust Plate (6 Used) 20 - Second Stage Sun Gear 29 - Sleeve
6 - Thrust Plate 14 - Second Stage 21 - First Stage Carrier 30 - O-Ring
7 - Pin (3 Used) Planetary 22 - Bolt (8 Used) 31 - Shaft
8 - Thrust Plate (6 Used) Gear (3 Used) 23 - Pin (2 Used)
9 - Needle Bearing (3 Used) 15 - Spring Pin (3 Used) 24 - Housing
EX455 W2-6-3

SWING DEVICE

Disassemble Swing Device 7. Remove retaining ring (17) from shaft (31).

• Before starting any repair work, thoroughly read all

"Precautions for Disassembly and Assembly"
(W1-1-1).
WARNING
Housing (24), shaft (31) and other part
WARNING assembly weight: 145 kg (320 lb)
Swing motor weight: 60 kg (130 lb)

8. Turn housing (24) over.

1. Drain gear oil from the swing device. Put matching
marks at the mating sections of motor (1), internal 9. Loosen bolts (22) to remove cover (27). Remove O-
gears (3) and (4) and housing (24). Remove socket ring (25) from cover (27).
bolts (2). Remove motor (1) using a crane.
: 19 mm
: 14 mm

2. Remove first stage sun gear (5). Remove first WARNING

stage carrier (21) assembly from internal gear (3). Housing (24), shaft (31) and other parts
assembly weight: 140 kg (310 lb)
3. Remove second stage sun gear (20) from second
stage carrier (18).

10. Turn over housing (24).

WARNING 11. Push shaft (31) out of housing (24) using a press.
Internal gear (3) weight: 20 kg (44 lb)

4. Remove internal gear (3) from internal gear (4).

NOTE - Insert a screw driver between internal gears (3)

and (4) to pry internal gear (3) up for easy separation.

WARNING
Second stage carrier (18) assembly weight:
21 kg (46 lb)

5. Sling second stage carrier (18) with wires or belts.

Remove second stage carrier (18) using a crane.

WARNING
Internal gear (4) weight: 20 kg (44 lb)

6. Remove internal gear (4) from housing (24).

NOTE - Insert a screw driver between internal gear (4)

and housing (24) to pry internal gear (4) up for easy
separation.
W2-6-4 EX455

SWING DEVICE

SM6861
EX455 W2-6-5

SWING DEVICE

WARNING
Shaft (31), bearing (26) and other parts
assembly weight: approx. 58 kg (128 lb)

12. Pull bearing (26) out of shaft (31) using a press.

13. Remove sleeve (29) from shaft (31). Remove O-

ring (30) from sleeve (29).

14. Remove oil seal (28) from cover (27).

15. Remove bearing (16) from housing (24).

16. Drive spring pins (11) (used 3) out of first stage

carrier (21) using a round bar and a hammer.

(dia.: 5.0 mm, length: 50 mm or longer)

17. Remove three pins (7), three first stage planetary

gears (10), six thrust plates (8) and three needle
bearings (9) from first stage carrier (21).

18. Remove thrust plates (6) from first stage carrier

(21).

19. Disassemble second stage carrier (18) assembly

referring to steps 16 to 18 above.

NOTE - No needle bearings are used on second stage

planetary gear (14).
W2-6-6 EX455

SWING DEVICE

ASSEMBLE SWING DEVICE

SM6862

1 - Motor 10 - First Stage Planetary 16 - Bearing 25 - O-Ring

2 - Socket Bolt (12 Used) Gear (3 Used) 17 - Retaining Ring 26 - Bearing
3 - Internal Gear 11 - Spring Pin (3 Used) 18 - Second Stage Carrier 27 - Cover
4 - Internal Gear 12 - Pin (3 Used) 19 - Thrust Plate 28 - Oil Seal
5 - First Stage Sun Gear 13 - Thrust Plate (6 Used) 20 - Second Stage Sun Gear 29 - Sleeve
6 - Thrust Plate 14 - Second Stage 21 - First Stage Carrier 30 - O-Ring
7 - Pin (3 Used) Planetary 22 - Bolt (8 Used) 31 - Shaft
8 - Thrust Plate (6 Used) Gear (3 Used) 23 - Pin (2 Used)
9 - Needle Bearing (3 Used) 15 - Spring Pin (3 Used) 24 - Housing
EX455 W2-6-7

SWING DEVICE

Assemble Swing Device
IMPORTANT - Set thrust plate (6) so that the surface
having oil grooves faces upwards.
7. Install O-ring (30) on sleeve (29). Install sleeve (29)
onto shaft (31).
8. Press bearing (26) onto shaft (31).

1. Install thrust plate (6) in first stage carrier (21). WARNING

2. Install one needle bearing (9) in each first stage
planetary gear (10) (3 used).
IMPORTANT - Install thrust plates (8) with the
grooved side facing toward first stage planetary gear
(10).
3. Install three first stage planetary gears (10) and six
thrust plates (8) into first stage carrier (21).
Housing weight: 74 kg (163 lb)
9. Place housing (24) with the swing motor mounting
side facing downward on a press. Install shaft (31)
assembly into housing (24) using the press.
10. Install O-ring (25) in cover (27).
11. Install oil seal (28) on cover (27).

4. Aligning the hole on pin (7) (3 used) with the spring 12. Install cover (27) on housing (24). Secure cover
pin hole on first stage carrier (21), install pins (7) (27) with bolts (22) (8 used).
into first stage carrier (21).
: 19 mm
: 88 N•m (9 kgf•m, 65 lbf•ft)
5. Tap spring pins (11) (3 used) into first stage carrier
(21) and pin (7) using a hammer.
WARNING
Housing (24), shaft (31) and other parts
assembly weight: 140 kg (310 lb)
NOTE - When tapping spring pin (11) into first stage
carrier (21) and pin (7), face the slit of spring pin (11)
toward the end face of pin (7). 13. Press bearing (16) into housing (24) and onto shaft
(31).

Slit

SM6863

6. Assemble second stage carrier (18) referring to

steps 1 to 5 above.

NOTE - No needle bearings are used on second

stage carrier (18).
W2-6-8 EX455

SWING DEVICE

SM6862
EX455 W2-6-9

SWING DEVICE

14. Install retaining ring (17) on shaft (31). 21. Apply THREEBOND 1215 to internal gear (3)
mating face on internal gear (4).

WARNING WARNING

Second stage carrier (18) Internal gear (3) weight: 20 kg (44 lb)
assembly weight: 21 kg (46 lb)
22. Aligning the matching marks, put when disas-
15. Lift and install second stage carrier (18) assembly sembling, install internal gear (3) on internal gear
into housing (24) with a crane. (4).

16. Apply THREEBOND 1215 to internal gear (4)

mounting face on housing (24).
23. Fill with gear oil.

Gear Oil: 5.3 L (5.6 US qt)

WARNING
Internal gear (4) weight: 20 kg (44 lb)
WARNING

17. Aligning the matching marks, put when disas- Swing motor weight: 60 kg (130 lb)
sembling, install internal gear (4) on housing (24).

24. Lifting motor (1) with a crane, secure motor (1) on

18. Install second stage sun gear (20) into second the swing device with socket bolts (2).
stage carrier (18).
: 14 mm
19. Install first stage carrier (21) assembly on second
: 295 N•m (30 kgf•m, 215 lbf•ft)
stage carrier (18).

20. Install first stage sun gear (5) into first stage carrier
: 19 mm
(21).
: 88 N•m (9 kgf•m, 65 lbf•ft)
IMPORTANT - Install first stage sun gear (5) with the
stepped end face positioned downward.
W2-6-10 EX455

SWING DEVICE

DISASSEMBLE SWING MOTOR

SM6864

1 - Roller Bearing 12 - O-Ring 22 - Spacer 32 - Casing

2 - O-Ring 13 - Friction Plate (2 Used) 23 - Rotor 33 - Shaft
3 - Valve Casing 14 - Relief Valve (2 Used) 24 - Push Rod (12 Used) 34 - Retaining Ring
4 - Socket Bolt (4 Used) 15 - Pin (2 Used) 25 - Spacer 35 - Spacer (2 Used)
5 - Poppet (2 Used) 16 - Retaining Ring 26 - Holder 36 - Roller Bearing
6 - Spring (2 Used) 17 - O-Ring 27 - Retainer Plate 37 - Retaining Ring
7 - O-Ring (2 Used) 18 - Plate (3 Used) 28 - Plunger (9 Used) 38 - O-Ring
8 - Plug (2 Used) 19 - Retaining Ring 29 - Thrust Plate 39 - Oil Seal
9 - Valve Plate 20 - Spacer 30 - Plug 40 - Seal Cover
10 - Spring (16 Used) 21 - Spring 31 - O-Ring 41 - Retaining Ring
11 - Brake Piston
EX455 W2-6-11

SWING DEVICE

Disassemble Swing Motor 6. Remove valve casing (3) from casing (32).

• Before starting any repair work, thoroughly read all

NOTE - Valve plate (9) may come off together with
"Precautions for Disassembly and Assembly" (W1-
valve casing (3). Carefully remove valve casing (3) so
1-1).
that valve plate (9) does not drop.

WARNING 7. If valve plate (9) has not been removed in the

Swing motor assembly weight: approx. 60 kg (130 lb)
1. Remove plug (30) from swing motor casing (32) to
drain hydraulic oil.
previous step and remains on the rotor side, re-
move valve plate (9) from the rotor. Then, remove
the 16 pieces of springs (10). If a screw driver or
similar tool is used to separate valve plate (9) from
the rotor, take care not to damage the mating
surface.

: 19 mm 8. Install a bolt into screw hole (M8, pitch 1.25) on

brake piston (11). Then, remove brake piston (11)
from casing (32).
Relief Valve
9. Remove O-rings (12) and (17) from casing (32).
2. Remove two relief valves (14) from valve casing
(3).

IMPORTANT - Do not disassemble relief valve (14).

: 36 mm

Make-Up Valve

3. Remove two plugs (8).

: 14 mm

4. Remove two springs (6) and poppets (5).

5. Put a matching marks on the mating section

between valve casing (3) and casing (32). Loosen
and remove four socket bolts (4).

: 17 mm

NOTE - Note that valve casing (3) will be raised by

spring (10) force.
W2-6-12 EX455

SWING DEVICE

SM6864
EX455 W2-6-13

SWING DEVICE

10. Lay casing (32) and pull rotor (23) out of shaft
(33). WARNING
When removing retaining ring (19), be sure to
11. Remove three plates (18) and two friction plates
hold spacer (20) with a press or a similar tool.
(13) from casing (32).
Otherwise, retaining ring (19) and spacer (20)
will fly off, causing personal injury.
12. Remove retaining ring (41) and seal cover (40)
from casing (32).
21. Holding spacer (20) with a press, remove retaining
ring (19).
13. Remove shaft (33) from casing (32) by tapping
the end of shaft (33) with a plastic hammer.
22. Remove spacer (22) and spring (21).

14. Remove thrust plate (29).

15. Remove oil seal (39) from seal cover (40).

16. Using a puller, remove the outer race of roller

bearing (1) from valve casing (3). Remove O-ring
(2) and two pins (15).

17. Remove retaining ring (16) and the inner race of

roller bearing (1) from shaft (33).

18. Remove retaining rings (34) and (37) and two

spacers (35) from shaft (33).

19. Using a press, remove the inner race of roller

bearing (36) from shaft (33).

20. Remove nine plungers (28), retainer plate (27),

holder (26), spacer (25) and twelve push rods (24)
from rotor (23).
W2-6-14 EX455

SWING DEVICE

ASSEMBLE SWING MOTOR

SM6865

SM6866

31 - O-Ring
1 - Roller Bearing 11 - Brake Piston 21 - Spring 32 - Casing
2 - O-Ring 12 - O-Ring 22 - Spacer 33 - Shaft
3 - Valve Casing 13 - Friction Plate (2 Used) 23 - Rotor 34 - Retaining Ring
4 - Socket Bolt (4 Used) 14 - Relief Valve (2 Used) 24 - Push Rod (12 Used) 35 - Spacer (2 Used)
5 - Poppet (2 Used) 15 - Pin (2 Used) 25 - Spacer 36 - Roller Bearing
6 - Spring (2 Used) 16 - Retaining Ring 26 - Holder 37 - Retaining Ring
7 - O-Ring (2 Used) 17 - O-Ring 27 - Retainer Plate 38 - O-Ring
8 - Plug (2 Used) 18 - Plate (3 Used) 28 - Plunger (9 Used) 39 - Oil Seal
9 - Valve Plate 19 - Retaining Ring 29 - Thrust Plate 40 - Seal Cover
10 - Spring (16 Used) 20 - Spacer 30 - Plug 41 - Retaining Ring
EX455 W2-6-15

SWING DEVICE

Assemble Swing Motor
1. Install retaining ring (34) and one spacer (35) on
shaft (33). Press the inner race of roller bearing (36)
onto shaft (33).
12. After installing nine plungers (28) to retainer plate
(27), apply a film of hydraulic oil to the plunger
holes in rotor (23). Then, insert plungers (28) into
rotor (23).
13. Lay casing (32). Install rotor (23) assembly onto
shaft (33).

2. After installing another spacer (35) on shaft (33),

install retaining ring (37).
3. Press the inner race of roller bearing (1) onto shaft
(33). Install retaining ring (16).
IMPORTANT - Plate (18) has notches on the outer
diameter. Friction plate (13) has notches on the spline
teeth. Install plate (18) and friction plate (13) so that
notch positions on both parts align.

14. Stand casing (32) upright. Install three plates (18)

and two friction plates (13) one by one alternately.
4. Using a metal bar extension and a hammer, install
the outer race of roller bearing (36) into casing (32).

IMPORTANT - Install brake piston (11) so that the slits

on brake piston (11) are located as illustrated.
5. Install oil seal (39) into seal cover (40) using a
protection plate and a press.

6. Install O-ring (38) in casing (32).

7. Install shaft (33) and thrust plate (29) in casing (32). Slit

8. Apply a film of grease to the lip of oil seal (39).

Install seal cover (40) and retaining ring (41) into
casing (32).

9. Install spacer (22), spring (21), and spacer (20) into Brake Piston
SM6867
rotor (23), in that order.

10. Using a press, push spacer (20) until retaining ring

15. Install O-rings (17) and (12) in casing (32).
(19) is installed. Install retaining ring (19).

11. Install twelve push rods (24) in rotor (23). Install

spacer (25) and holder (26) in rotor (23), in that
order.
W2-6-16 EX455

SWING DEVICE

SM6865

SM6866
EX455 W2-6-17

SWING DEVICE

16. Install brake piston (11) into casing (32). If brake Relief Valve
piston (11) is hard to move into casing (32)
because of friction between O-rings (12 and 17), 22. Install two relief valves (14) to valve casing (3).
uniformly tap on the piston with a plastic hammer.
: 36 mm
: 175 N•m (18 kgf•m, 130 lbf•ft)

17. Install sixteen springs (10) in brake piston (11).

IMPORTANT - When installing roller bearing (1), tap

the side face on which the bearing type is marked with
a plastic hammer.

18. Drive the outer race of roller bearing (1) into valve
casing (3) with a plastic hammer.

19. Install O-ring (2), two pins (15), and valve plate (9)
(with the flat surface facing the valve casing) to
valve casing (3).

NOTE - Apply a film of grease to valve plate (9) to

prevent valve plate (9) from coming out of valve casing
(3).

IMPORTANT - while taking care not to allow valve

plate (9) to drop off, align the matching marks (put
during disassembly).

20. Secure valve casing (3) to casing (32) with four

socket bolts (4).

: 17 mm
: 430 N•m (44 kgf•m, 320 lbf•ft)

Makeup Valve

21. Install two poppets (5) and springs (6) in valve

casing (3). Tighten plugs (8) with O-rings (7).

: 14 mm
: 230 N•m (23 kgf•m, 165 lbf•ft)
W2-6-18 EX455

SWING DEVICE

MAINTENANCE STANDARD

Swing motor

1. Clearance between Plunger and Rotor Bore.(D-d)

Standard Clearance Allowable Limit d

0.028 mm (0.001 in) 0.058 mm (0.002 in)

NOTE - 1 mm = 0.03937 in.

SM6868

D D

SM6869

2. Clearance between Plunger Top and Shoe Bot-

δ)
tom (δ

Standard Clearance Allowable Limit

δ
0 0.3 mm (0.012 in)

SM6870

NOTE - 1 mm = 0.03937 in.

SM6871
EX455 W2-6-19

SWING DEVICE

3. Shoe Thickness (t)

Standard Clearance Allowable Limit

5.5 mm (0.217 in) 5.3 mm (0.209 in)

NOTE - 1 mm = 0.03937 in. t

SM6872

4. Friction Plate Thickness

Standard Clearance Allowable Limit

4.0 mm (0.157 in) 3.6 mm (0.142 in)

SM6873
NOTE - 1 mm = 0.03937 in.

5. Holder Height from Retainer Plate Bottom Face 2

(H - h) 1

Standard Clearance Allowable Limit

6.5 mm (0.256 in) 6.0 mm (0.236 in)

If dimension H - h is reduced to below 6 mm, replace

retainer plate (1) and holder (2). h H
SM6874

NOTE - 1 mm = 0.03937 in.

W2-6-20 EX455

SWING DEVICE

NOTE
EX455 W2-7-1

PILOT VALVE

REMOVE AND INSTALL RIGHT PILOT VALVE

WARNING
Escaping pressure hydraulic oil can penetrate the skin or eyes, causing serious injury. Avoid this hazard by
relieving pressurebefore disconnecting hydraulic lines.
Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure
to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off due to internal pressure if turned quickly. Slowly turn the cap to release
internal pressure before completely removing the cap.

Preparation

1. Park the machine on firm and level surface.
Lower the front attachment to the ground.
2. Stop the engine. Move all control levers to release
any pressure remaining in the system. Slowly turn
the hydraulic oil tank cap approx. 30 degrees
counterclockwise to release any remaining pres-
sure from the hydraulic oil tank.
3. Remove hydraulic oil tank cap. Connect a vacuum
(75298347) pump to maintain negative pressure in
the hydraulic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal 1 2 3
4
1. Loosen screws (6) (2 used), (1) (2 used) and (5) (2
used) to remove cover (7) and frame (2).
5
Loosen screws (4) (4 used) to dislocate boot (3).

7
SM1105

2. Confirm that the console is in the forefront position.

If not, position the console in the forefront position.
Loosen bolts (8) (2 used) to disconnect the joints.
Raise stand (9).
: 17 mm

8 9 SM1106

3. Remove screws (10) and (12). Dislocate cover (11)

to the right.
10

11

12 SM1107
W2-7-2 EX455

PILOT VALVE

4. Loosen screw joint (13) to remove the lever.

: 24 mm

IMPORTANT - Attach an identification tag on each 13 14

hose to aid in reassembly.

5. Disconnect hoses (15) to (20).

: 22 mm

15
NOTE - Attach a cap on each of disconnected hose
ends.
16

6. Loosen bolts (14) to remove the pilot valve. 17

: 13 mm
15 - Hose H : (To the bucket roll-out section in the
control valve)
16 - Hose P3: (From the pilot control shut-off valve)
17 - Hose A: (To the boom raise section in the con-
trol valve)
18 - Hose G: (To the bucket roll-in section in the
control valve)
19 - Hose T6: (To the hydraulic oil tank)
20 - Hose B: (To the boom lower section in the
20 19 18 SM1108
control valve)

Installation

1. Mount the pilot valve using bolts (14).

: 13 mm
: 9.8 N m (1.0 kgf m, 7.2 lbf ft)
13 14
2. Connect hoses (15) to (20).
: 22 mm
: 39 N m (4.0 kgf m, 29 lbf ft)

3. Attach the lever. Tighten screw joint (13) to secure

the lever.
15
: 24 mm
16
: 88 N m (9.0 kgf m, 65 lbf ft)
17
15 - Hose H : (To the bucket roll-out section in the
control valve)
16 - Hose P3: (From the pilot control shut-off valve)
17 - Hose A: (To the boom raise section in the con-
trol valve)
18 - Hose G: (To the bucket roll-in section in the
control valve)
19 - Hose T6: (To the hydraulic oil tank)
20 - Hose B: (To the boom lower section in the
control valve)
20 19 18 SM1108
EX455 W2-7-3

PILOT VALVE

4. Install cover (11) using screws (10) and (12).

10

11

12 SM1107

5. Secure stand (9) using bolts (8) (2 used).

: 17 mm
: 49 N m (5.0 kgf m, 36 lbf ft)

8 9 SM1106

6. Install frame (2) using screws (1) (2 used) and

screws (5) (2 used).
Install cover (7) using screws (6) (2 used). 1 2 3
Set the boot in position, and secure it using screws
(4) (4 used). 4

IMPORTANT - After completing installation:

Check hydraulic oil level. Add oil if necessary. Run the 6
engine. Check the components for any oil leakage.
7
SM1105
W2-7-4 EX455

PILOT VALVE

REMOVE AND INSTALL LEFT PILOT VALVE

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on firm and level surface.
Lower the front attachment to the ground.
2. Stop the engine. Move all control levers to release
any pressure remaining in the system. Slowly turn
the hydraulic oil tank cap approx. 30 degrees
counterclockwise to release any remaining pres-
sure from the hydraulic oil tank.
3. Remove hydraulic oil tank cap. Connect a vacuum
(75298347) pump to maintain negative pressure in
the hydraulic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal 4

1. Loosen screw (2) (2 used), to remove cover (1).

Loosen screws (4) (4 used) to dislocate boot (3).

2
1

SM5515

13 14

2. Remove pad (13).To remove pad, disengage the

➡
two latches while pressing and pushing pad (13) in 16 15
the direction indicated by arrow. Then, slide the pad
to the opposite of the direction indicated by arrow 16
to remove it.

3. Loosen screws (15) (2 used) and screws (16)

(2 used) to remove cover (14).
SM1109

4. Confirm that the console is in the forefront position.

If not, position the console in the forefront position.
Loosen bolts (8) (2 used) to disconnect the joints.
Raise stand (9).
: 17 mm
8 9 SM1106
EX455 W2-7-5

PILOT VALVE

5. Loosen screws (10) and (12) to dislocate cover (11) 13 14

to the right.

➡
16 15
6. Loosen screw joint (17) to remove the lever.
16
: 24 mm

IMPORTANT - Attach an identification tag on each

hose to aid in reassembly.
SM1109
7. Disconnect hoses (19) to (24).
: 22 mm 17 18

NOTE - Attach a cap on each of the disconnected hose

ends.
19
8. Loosen bolts (18) to remove the pilot valve.
: 13 mm 20

19 - Hose F : (To the right swing section in the control 21

valve)
20 - Hose P2 : (From the pilot control shut-off valve)
21 - Hose D : (To the arm roll-in section in the control
valve)
22 - Hose E : (To the left swing section in the control
valve)
23 - Hose T5 : (To the hydraulic oil tank)
24 - Hose C : (To the arm roll-out section in the control
valve)

SM1110

24 23 22

Installation

1. Mount the pilot valve using bolts (18).

: 13 mm 17 18
: 9.8 N m (1.0 kgf m, 7 lbf ft)

2. Connect hoses (19) to (24).

: 22 mm 19
: 39 N m (4.0 kgf m, 29 lbf ft)
20
3. Attach the lever. Tighten screw joint (17) to secure
21
the lever.
: 24 mm
: 88 N m (9.0 kgf m, 65 lbf ft)

19 - Hose F : (To the right swing section in the control

valve)
20 - Hose P2 : (From the pilot control shut-off valve)
21 - Hose D : (To the arm roll-in section in the control
valve)
22 - Hose E : (To the left swing section in the control
valve)
SM1110
23 - Hose T5 : (To the hydraulic oil tank)
24 - Hose C : (To the arm roll-out section in the control 24 23 22
valve)
W2-7-6 EX455

PILOT VALVE

4. Install cover (11) using screws (10) and (12).

10

11

12 SM1107

5. Secure stand (9) using bolts (8) (2 used).

: 17 mm
: 49 N m (5.0 kgf m, 36 lbf ft)

8 9 SM1106

6. Install cover (14) using screws (15) (2 used) and

screws (16) (2 used). 13 14

7. Install pad (13) on cover (14).

16 15

16

SM1109

8. Set boot (3) in position, and secure it using screws 3

(4) (4 used).
4

9. Install cover (1) using screws (2) (2 used).

2
IMPORTANT - After completing installation: 1
Check hydraulic oil level. Add oil if necessary. Run the
SM5515
engine. Check the components for any oil leakage.
EX455 W2-7-7

PILOT VALVE

REMOVE AND INSTALL TRAVEL PILOT VALVE

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a solid, level surface.
Lower the bucket attachment to ground.
2. Stop the engine. Move all control levers to release
any pressure remaining in the system. Rotate the
hydraulic oil tank cap approx. 30° coun-
terclockwise to release pressure remaining in the
hydraulic oil tank.
3. Remove hydraulic oil tank cap. Connect a vacuum
(75298347) pump to maintain negative pressure in
the hydraulic oil tank.
NOTE - Run the vacuum pump continuously while
working on the hydraulic system.

Removal

1. Loosen bolt (2) to remove pedal (1).
: 17 mm
IMPORTANT - Attach an identification tag on each
hose to aid in reassembly.
IMPORTANT - After completing installation:
Check hydraulic oil level. Add oil if necessary. Run the
engine. Check the components for any oil leakage.

2. Disconnect hoses (3) to (8).

: 22 mm
1
NOTE - Attach a cap on each of disconnected hose
ends.
2
3. Loosen bolts (9) to remove the pilot valve.
: 17 mm
3
Installation
8 4
1. Mount the pilot valve using bolts (9).
9
: 17 mm
7
: 49 Nm (5.0 kgf m, 36 lbf ft) 5
6
SM1111
2. Connect hoses (3) to (8).
: 22 mm
: 39 N m (4.0 kgf m, 29 lbf ft)
3 - Hose 12 : (To the right reverse travel section in the control
valve)
3. Mount pedal (1) using bolts (2). 4 - Hose 10 : (To the left reverse travel section in the control
valve)
: 17 mm 5 - Hose P1 : (From the pilot control shut-off valve)
6 - Hose 9 : (To the left forward section in the control valve)
: 49 N m (5.0 kgf m, 36 lbf ft) 7 - Hose 11 : (To the right forw. section in the control valve)
8 - Hose T4 : To the hydraulic oil tank
W2-7-8 EX455

PILOT VALVE

DISASSEMBLE RIGHT AND LEFT PILOT VALVE

1
25

23
24 2

22
21
21 3
20
20
19

19 4
18
18

5 5
17 6
6

7
12

11 8
16

10 9
15

14

13

SM1112

1 - Screw Joint 10 - Spring Guide B (2 Used) 19 - Spool (4 Used)

2 - Cam 11 - Pusher B (2 Used) 20 - Spacer (4 Used)
3 - Universal Joint 12 - Bushing B (2 Used) 21 - Shim (20 Used)
4 - Plate 13 - Socket Bolt 22 - Return Spring A (2 Used)
5 - Oil Seal (4 Used) 14 - Plate 23 - Balance Spring A (2 Used)
6 - O-Ring (4 Used) 15 - O-Ring 24 - Return Spring B (2 Used)
7 - Bushing A (2 Used) 16 - Seal Washer 25 - Balance Spring B (2 Used)
8 - Pusher A (2 Used) 17 - Casing
9 - Spring Guide A (2 Used) 18 - Piston (4 Used)
EX455 W2-7-9

PILOT VALVE

Disassemble Right and Left Pilot Valve

• Be sure to thoroughly read “Precautions for Disas- 10. Remove spools (19) (4 used) from casing (17).
sembly and Assembly” on page W1-1-1 before
starting the disassembly work. 11. Compress balance spring A (23) or B (25) to
• As casing (17) and spools (19) are precision parts remove spacers (20) from each spool (19).
specially made to fit each other, they must be Remove balance spring A (23) or B (25) and shims
replaced as a set. Do not attempt to replace these (21) from each spool (19).
parts individually.
• Note that return spring A (22) and balance spring 12. Remove spring guide A (9) or B (10), and return
A (23), which are used in ports 1 and 3, differ from spring A (22) or B (24) from each seat.
return spring B (24) and balance spring B (25),
which are used in ports 2 and 4.
• For this reason, be sure to indicate the port number
from which it is removed. Port numbers are
stamped on casing (17).

1. Remove screw joint (1) and cam (2).

: 19 mm, 32 mm

2. Temporarily tighten plate (4) using two bolts (M8,

Pitch 1.25). Loosen universal joint (3) to remove it
from casing (17).

3. Turn over casing (17) and place it in a vise.

Remove socket bolt (13).

: 10 mm

4. Pull out plate (14) using a pulling bolt (M16, Pitch

2). Remove O-ring (15) from the plate. Remove
seal washer (16) from casing (17).

5. Remove piston (18) from spool (19) in each port. 75301512

(Four pistons in total)

6. Turn over casing (17). Attach special tool

(75301512) to the universal joint connecting hole. 4
Tighten plate (4) using the special tool.
17
7. Remove the bolts (2 used) temporarily installed in
the step 2. Gradually loosen the special tool until
pushers A (8), B (11) and plate (4) are fully raised,
unloading spring compresssion. SM1113

8. Remove plate (4) and pushers A (8), B (11) from

casing (17).

9. Remove pusher A (8), O-ring (6), and oil seal (5)

from each bushing A (7). Remove pusher B (11),
O-ring (6), and oil seal (5) from each bushing B
(12).
W2-7-10 EX455

PILOT VALVE

ASSEMBLE RIGHT AND LEFT PILOT VALVE

1
11
2

8
12

4 7

20 6

10
9
25
23
24
22
21

19

17

18

13 14 16 15
SM5516

1 - Screw Joint 10 - Spring Guide B (2 Used) 19 - Spool (4 Used)

2 - Cam 11 - Pusher B (2 Used) 20 - Spacer (4 Used)
3 - Universal Joint 12 - Bushing B (2 Used) 21 - Shim (20 Used)
4 - Plate 13 - Socket Bolt 22 - Return Spring A (2 Used)
5 - Oil Seal (4 Used) 14 - Plate 23 - Balance Spring A (2 Used)
6 - O-Ring (4 Used) 15 - O-Ring 24 - Return Spring B (2 Used)
7 - Bushing A (2 Used) 16 - Seal Washer 25 - Balance Spring B (2 Used)
8 - Pusher A (2 Used) 17 - Casing
9 - Spring Guide A (2 Used) 18 - Piston (4 Used)
EX455 W2-7-11

PILOT VALVE

Assemble Right and Left Pilot Valve

1. Insert special tool (75301504) into each port on

casing (17). Be sure to insert the smaller end of the
special tool first.

IMPORTANT - The number of shims (21) has been

determined during the perfomance test at the factory.
Take care not lose them. Install spacer (20) with its
concave side facing the spring.

2. Install shims (21) (20 used) and balance spring A

(23) (2 used) or B (25) (2 used) onto each spool (19) SM1115
75301504
(4 used). While compressing balance spring A (23)
(2 used) or B (25) (2 used), insert spacer (20) (4
used) onto the neck part of each spool (19) (4
used).

IMPORTANT - Install spring guide A (9) or B (10) with

its concave side facing the spring.

3. Install spring guide A (9) (2 used) or B (10)

(2 used) and return spring A (22) (2 used) or B (24)
(2 used) onto each spool (19) (4 used).

IMPORTANT - Be sure to confirm the applicable port

number for each spool (19) before inserting.

4. Insert spools (19) into casing (17).

5. Install oil seal (5) (4 used) and O-ring (6) (4 used)

onto each bushing A (7) (2 used) or B (12)
(2 used). Insert pusher A (8) (2 used) or B (11)
(2 used) into each bushing A (7) or B (12),
respectively.

Oil Seal Driving Tool: 75301503 75301512

6. Put each of the pusher assemblies onto the

respective spool assembly.

7. Install plate (4) on bushings A (7) and B (12). Install

special tool (75301512) into the universal joint
connecting hole on casing (17).

8. Gradually tighten the special tool until the bottom

of bushings A (7) and B (12) is flush with the top
surface of casing (17). Remove special tool
(75301504) from each casing port.
SM1116
9. Temporarily secure plate (4) using two bolts (M8,
Pitch 1.25). Remove special tool (75301512).
W2-7-12 EX455

PILOT VALVE

1
11
2

19

17

18

13 14 16 15
SM1114
EX455 W2-7-13

PILOT VALVE

10. Insert piston (18) into each spool (19), with the
smaller end first.

11. Install seal washer (16) on casing (17).

Install O-ring (15) onto plate (14).

12. Secure plate (4) onto casing (17) using socket bolt
(13).
: 10 mm
: 49 N m (5 kgf m, 36 lbf ft)

13. Turn over casing (17). Apply LOCTITE 262 to

universal joint (3). Install universal joint (3) into
casing (17).
: 17 mm
: 24.5 N m (2.5 kg m, 18.1 lbf ft)

14. Sufficiently apply grease to the joint part of univer-

sal joint without giving any air gaps. Apply grease
to the top of pushers A (8) (2 used) and B (11) (2
used).

15. Install cam (2) onto universal joint (3).

16. Tighten screw joint (1) while keeping the clearance

between pushers A (8) and B (11) and cam (2) to
0 to 0.2 mm (0 to 0.008 in).
Remove the two temporarily installed bolts.

Filler Gauge
: 17 mm, 32 mm
: 69 to 88 N m
(7 to 9 kgf m, 50 to 65 lbf ft)
W2-7-14 EX455

PILOT VALVE

DISASSEMBLE TRAVEL PILOT VALVE

10 5
24
11
8
10 23

22

21

6 20
8
7 19

17

16
9
18

15

14

25

13

12

SM1117

1 - Cover 11 - Bushing (2 Used) 21 - Pusher (4 Used)

2 - Sems Bolt (2 Used) 12 - Plug 22 - Bushing (4 Used)
3 - Spring Pin (2 Used) 13 - O-Ring 23 - O-Ring (4 Used)
4 - Spring Pin (2 Used) 14 - Casing 24 - Oil seal (4 Used)
5 - Cam (2 Used) 15 - Spool (4 Used) 25 - Plate
6 - Socket Bolt (2 Used) 16 - Spacer (4 Used)
7 - Spring Washer (2 Used) 17 - Shim
8 - Pin (2 Used) 18 - Return Spring (4 Used)
9 - Holder 19 - Balance Spring (4 Used)
10 - Bushing (2 Used) 20 - Spring Guide (4 Used)
EX455 W2-7-15

PILOT VALVE

Disassemble Travel Pilot Valve

• Be sure to thoroughly read “Precautions for Disas-

sembly and Assembly” on page W1-1-1 before
starting the disassembly work.
• As casing (14) and spools (15) are precision parts
specially made to fit each other, they must be
replaced as a set. Do not attempt to replace these
parts individually.

1. Remove sems bolts (2) (2 used) to remove cover

(1) from holder (9).
: 10 mm

2. Turn over casing (14), and put it in a vise. Remove

plug (12) from casing (14). Remove O-ring (13) from
plug (12).
75301513
3. Turn over casing (16), and put it in a vise. Remove
one of two socket bolts (6). Install special tool
(75301513) into the bolt hole.
: 8 mm

4. Remove the other socket bolt (6). Install special

tool (75301513) into the bolt hole.
: 8 mm

5. Loosen (operate) both special tools (75301513) SM1118

evenly at the same time. Remove holder (9) from
casing (14).

6. Put holder (9) in a vise. Remove spring pins (3) (2

Used) and (4) (2 Used) using special tool
(75301487).

7. Remove pin (8) (2 Used) and cam (5) (2 Used) from

holder (9). Do not remove bushings (10) and (11)
unless they are damaged.

8. Remove the pusher assemblies (4 Used). Remove

pusher (21), O-ring (23), oil seal (24), from each
bushing (22).

9. Remove spools (15) (4 used) from casing (14).

10. Compress balance spring (19) to remove spring

guide (20) from each spool (15). Remove balance
spring (19), shims (17) and spacers (16) from
each spool (15). Remove return spring (18) from
each port.
W2-7-16 EX455

PILOT VALVE

ASSEMBLE TRAVEL PILOT VALVE

8 10 11 6-7 1 3-4 5 9

21

24

22

23
25
20
14
19

18

17

16

15

SM1119
12-13

1 - Cover (2 Used) 10 - Bushing (2 Used) 19 - Balance Spring (4 Used)

2 - Sems Bolt (2 Used) 11 - Bushing (2 Used) 20-Spring Guide (4 Used)
3 - Spring Pin (2 Used) 12 - Plug 21 - Pusher (4 Used)
4 - Spring Pin (2 Used) 13 - O-ring 22 - Bushing (4 Used)
5 - Cam (2 Used) 14 - Casing 23 - O-ring (4 Used)
6 - Socket Bolt (2 Used) 15 - Spool (4 Used) 24 - Oil seal (4 Used)
7 - Spring Washer (2 Used) 16 - Spacer (4 Used) 25 - Plate
8 - Pin (2 Used) 17 - Shim
9 - Holder 18 - Return Spring (4 Used)
EX455 W2-7-17

PILOT VALVE

Assemble Travel Pilot Valve

IMPORTANT - The number of shims (17) has been

determined during the perfomance test at the factory.
Take care not lose them. Install spring guide (20) with
its concave side facing the spring.

1. Attach shims (17) spacer (16) (4 used) and balance

spring (19) (4 used) onto each spool (15) (4 used).
While compressing balance spring (19), insert
spring guide (20) (4 used) onto the neck part of each
spool (15).

2. Turn over casing (14), and clamp with a vise.

3. Install O-ring (13) onto plug (12), and install plugs

(12) onto casing (14).
: 8 mm
: 34 N m (3,5 kgf m, 25 lbf ft)

4. Turn over casing (14) and clamp with a vise. Insert

return springs (18) (4 used) into casing (14).

IMPORTANT - Be sure to confirm the applicable port

number for each spool (15) before inserting.

5. Insert spool (15) (4 used) assemblies into casing

(14).

6. Install oil seal (24) and O-ring (23) onto each

bushing (22). Insert pusher (21) into of each bush-
ing (22) (4 used).

7. Put each of the pusher (21) assemblies onto the

respective spool (15) (4 used) assembly.
75301513
8. Install holder (9) on the pusher (21) (4 used)
assembly. Install special tools (75301513) (2 used)
into the bolt holes on casing (14).

9. Gradually tighten the special tools until the bottom

of bushings (22) is flush with the top surface of
casing (14).

SM1120
W2-7-18 EX455

PILOT VALVE

8 6-7 1 3-4 5 9

21

SM1119
EX455 W2-7-19

PILOT VALVE

10. Remove one of special tools (75301513). Tem-

porarily tighten spring washer (7) and socket bolt 75301513
(6).

11. Remove the other special tool (75301513). Tem-

porarily tighten the other spring washer (7) and
socket bolt (6). Tighten both socket bolts (6) (2
used) to specification.
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)

IMPORTANT - When inserting pin (8), the spring pin

hole nearer to the pin end must be facing outerwards. SM1121

12. Apply grease to the top of pushers (21) (4 used).

Place cam (5) (2 used) on holder (9), aligning the
pin holes. Insert pin (8) (2 used) into the pin hole.

IMPORTANT - Be sure to drive spring pins (3) and (4)

until they extrude approx. 3 mm (0.12 in) down from the
bottom of cam (5). Then, mushroom the spring pin
ends at the top of the cam to prevent them from coming
out.

13. Insert spring pins (3) and (4) using special tool
(75301487).

14. Install cover (1) onto holder (9) using sems bolts
(2) (2 used).
: 10 mm
: 2 N m (0.2 kgf m, 1.5 lbf ft)
W2-7-20 EX455

PILOT VALVE

SPECIAL TOOLS

Special Tools for Right and Left Pilot Valve

2
1

SM5519

ITEM Tools No. Tool Name Remarks

2 75301504 Guide for assembling plate For assembling spools and holder

1 75301512 Valve holder For disassembling and assembling plate

Special Tools for Travel Pilot Valve

SM1123
SM1124

ITEM Tools No. Tool Name Remarks

1 75301513 Valve holder assembly For disassembling and assembling valve

2 75301487 Spring pin driving guide For tapping in/out spring pin
EX455 W2-8-1

PILOT SHUT-OFF VALVE

REMOVE AND INSTALL PILOT SHUT-OFF VALVE

WARNING
Escaping fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by
relieving pressure before disconnecting hydraulic lines.
Hot hydraulic oil may spout after operation, possibly causing severe burns. Wait for oil to cool before starting
any repair work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Thoroughly release any
remaining pressure before removing the cap.

Preparation

1. Park the machine on a solid, level surface. 3. Remove the hydraulic oil tank cap. Connect a
Lower the bucket attachment to ground. vacuum pump and operate it continuously to main-
2. Stop the engine. Move all control levers to release tain negative pressure in the hydraulic oil tank.
any pressure remaining in the system. Rotate the
hydraulic oil tank cap approx. 30° coun-
NOTE - Run the vacuum pump continuously while
terclockwise to release pressure remaining in the
working on the hydraulic system.
hydraulic oil tank.

Removal

1. Remove the outer panel located under the driver's

compartment, by removing the six securing
screws.
: 17 mm

2. Remove ball joint (10).

: 13 mm

IMPORTANT - Attach identification tags to hoses to

aid reassembly.

3. Disconnect hoses (1 to 9).

: 22 mm
4. Remove bolt (11) to remove the pilot shut-off valve.
: 8 mm

Installation
1. Secure the pilot shut-off valve with bolt (11). SM6875

: 8 mm
: 64 Nžm (6.5 kgf•m, 47 lbf•ft)
2. Connect hoses (1 to 9). 1- Hose P2 : (To swing and arm pilot valve)
: 22 mm 2- Hose P1 : (To travel right and left pilot valves)
3- Hose P3 : (To boom and bucket pilot valve)
: 39 N•m (4 kgf•m, 29 lbf•ft)
4- Hose T4 : (From travel right and left pilot valves)
3. Install ball joint (10). 5- Hose T1 : (To hydraulic oil tank)
6- Hose PC : (From pilot check valve)
: 10 N•m (1 kgf•m, 7.3 lbf•ft)
7- Hose T5 : (From swing and arm pilot valve)
4. Install the outer panel. 8- Hose : (From boom 2 control valve)
9- Hose T6 : (From bucket and boom pilot valve)
: 17 mm
10- Ball Joint
: 49 Nm (5 kgf m) 11- Bolt
W2-8-2 EX455

PILOT SHUT-OFF VALVE

DISASSEMBLE PILOT SHUT-OFF VALVE

SM6876

1 - Retaining Ring 5 - O-Ring 9 - Spring Pin 13 - Steel Ball

2 - Washer 6 - Backup Ring 10 - Lever 14 - Body
3 - Backup Ring 7 - Washer 11 - Spool
4 - O-Ring 8 - Retaining Ring 12 - Socket Bolt
EX455 W2-8-3

PILOT SHUT-OFF VALVE

Disassemble Pilot Shut-Off Valve

• Before disassembling, be sure to read and under-

stand all the "Precautions for Disassembly and
Assembly" on page W1-1-1.

1. Remove retaining ring (1) and washer (2) and

pull out spool (11).

NOTE - Mark spool (11) and lever (10) for alignment

when installing.

2. Pull out spring pin (9) from spool (11), and

remove lever (10).

3. Remove washer (7) and retaining ring (8) from

spool (11).

4. Remove backup ring (3), (6) and O-ring (4), (5)

from body (14).

5. Loosen socket bolt (12) from body (14).

: 6 mm
W2-8-4 EX455

PILOT SHUT-OFF VALVE

ASSEMBLE PILOT SHUT-OFF VALVE

SM6877

1 - Retaining Ring 5 - O-Ring 9 - Spring Pin 13 - Steel Ball

2 - Washer 6 - Backup Ring 10 - Lever 14 - Body
3 - Backup Ring 7 - Washer 11 - Spool
4 - O-Ring 8 - Retaining Ring 12 - Socket Bolt
EX455 W2-8-5

PILOT SHUT-OFF VALVE

Assemble Pilot Shut-Off Valve

IMPORTANT - Apply a film of grease to O-rings (4) and

(5), and backup rings (3) and (6).

1. Install O-rings (4) and (5), backup rings (3) and (6)
to body (14).

2. Install washer (7) and retaining ring (8) to spool (11).

3. Drive spring pin (9) alignmenting spool (11) and

lever (10). (Alignment marks made when disas-
sembling.)

IMPORTANT - Be sure to apply a film of hydraulic oil

to spool (11).

4. Install spool (11) to body (14).

5. Install washer (2) and retaining ring (1) to spool (11).

6. Install and tighten socket bolt (12).

: 6 mm
: 44 N m (4.5 kgf m, 33 lbf ft)
W2-8-6 EX455

PILOT SHUT-OFF VALVE

NOTES
EX455 W2-9-1

SHOCKLESS VALVE

REMOVE AND INSTALL FRONT ATTACHMENT SHOCKLESS VALVE

WARNING
Escaping fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by
relieving pressure before disconnecting hydraulic lines.
Hot hydraulic oil may spout after operation, possibly causing severe burns. Wait for oil to cool before starting
any repair work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Thoroughly release any
remaining pressure before removing the cap.

Preparation

1. Park the machine on a solid level surface. Lower
the bucket to ground.
2. Stop the engine. Move all control levers to release
pressure remaining in the system. Rotate the
hydraulic oil tank cap approx. 30° counterclock-
wise to release pressure remaining in the hydraulic
oil tank.
3. Remove the hydraulic oil tank cap. Connect a
vacuum pump and operate it continuously to main-
tain negative pressure in the hydraulic oil tank.
NOTE - Run the vacuum pump continuously while
working on the hydraulic system.

Removal

IMPORTANT - Attach identification tags to hoses to

aid re-assembly.

1. Disconnect hoses (2 to 6) and (8 to 13).

: 19 mm, 22 mm

2. Remove pressure switches (1) and (7).

: 14 mm

3. Remove two bolts (located on the bottom face of

the shockless valve) to remove the shockless
valve.
: 13 mm
SM6878
Installation

1. Install the shockless valve with two bolts.

: 13 mm 1- Pressure Switch (Boom Raise)
: 20 Nžm (2 kgf•m, 14.5 lbf•ft) 2- Hose A : (From boom raise pilot valve)
3- Hose B : (From boom lower pilot valve)
2. Connect hoses (2 to 6) and (8 to 13). 4- Hose C : (From arm roll-out pilot valve)
5- Hose D : (From arm roll-In pilot valve)
: 19 mm 6- Hose SJ : (To swing shuttle valve)
: 29 N•m (3 kgf•m, 22 lbf•ft) 7- Pressure Switch (Arm Roll-In)
: 22 mm 8- Hose H3 : (To hydraulic oil tank)
9- Hose 4 : (To arm roll-in control valve)
: 39 N•m (4 kgf•m, 29 lbf•ft) 10 - Hose 3 : (To arm roll-out control valve)
11 - Hose 2 : (To boom lower control valve)
3. Install pressure switches (1) and (7). 12 - Hose 1 : (To boom raise control valve)
13 - Hose H1 : (From pilot relief valve)
: 14 mm
: 20 N•m (2 kgf•m, 14.5 lbf•ft)
W2-9-2 EX455

SHOCKLESS VALVE

DISASSEMBLE AND ASSEMBLE FRONT

ATTACHMENT SHOCKLESS VALVE

SM6879
EX455 W2-9-3

SHOCKLESS VALVE

Section Z-Z

Section X-X Section Y-Y

SM6880
W2-9-4 EX455

SHOCKLESS VALVE

Item Part Name Q.ty Wrench Size Tightening Torque Remarks

No. (mm) Nm
• kgf•m lbf•ft

1 Plug 9 :5 14.5 1.5 11

2 O-ring 13
3 O-ring 1
4 Guide 1
5 Steel Ball 1
6 Plug 4 :6 19.5 2 14.5
7 Spring 4
8 Steel Ball 4
9 Body 1
10 Plunger 2
11 Spring 4
12 O-Ring 4
13 Nipple 2 : 22 39 4 29
14 Spool 4
15 Spring 4
16 Nipple 2 : 22 39 4 29
17 Plunger 1
EX455 W2-9-5

SHOCKLESS VALVE

REMOVE AND INSTALL TRAVEL SHOCKLESS VALVE

WARNING
Escaping fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by
relieving pressure before disconnecting hydraulic lines.
Hot hydraulic oil may spout after operation, possibly causing severe burns. Wait for oil to cool before starting
any repair work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Thoroughly release any
remaining pressure before removing the cap.

Preparation

1. Park the machine on a solid level surface. Lower 3. Remove the hydraulic oil tank cap. Connect a
the bucket to ground. vacuum pump and operate it continuously to main-
2. Stop the engine. Move all control levers to re-lease tain negative pressure in the hydraulic oil tank.
pressure remaining in the system. Rotate the
hydraulic oil tank cap approx. 30° counter-clock-
NOTE - Run the vacuum pump continuously while
wise to release pressure remaining in the hydraulic
working on the hydraulic system.
oil tank.

Removal

IMPORTANT - Attach identification tags to hoses to

aid reassembly.

1. Disconnect hoses (1 to 4) and (6 to 11).

: 19 mm, 22 mm

2. Remove bolts (5) to remove the shockless valve.

: 17 mm

Installation

1. Apply LOCTITE to bolts (5) and secure the

shockless valve.
: 17 mm
: 49 N•m (5 kgf•m, 36 lbf•ft)
SM6881
2. Connect hoses (1 to 4) and (6 to 11).
: 19 mm
: 29 N•m (3 kgf•m, 21.5 lbf•ft)
: 22 mm 1- Hose 9 : (From left forward travel pilot valve)
2- Hose 10 : (From left reverse travel pilot valve)
: 39 N•m (4 kgf•m, 29 lbf•ft)
3- Hose 11 : (From right forward travel pilot valve)
4- Hose 12 : (From right reverse travel pilot valve)
5- Bolt
6- Hose H4 : (To hydraulic oil tank)
7- Hose 12B : (To right reverse travel control valve)
8- Hose 11B : (To right forward travel control valve)
9- Hose 10B : (To left reverse travel control valve)
10 - Hose 9B : (To left forward travel control valve)
11 - Hose H2 : (From pilot relief valve)
W2-9-6 EX455

SHOCKLESS VALVE

DISASSEMBLE AND ASSEMBLE TRAVEL

SHOCKLESS VALVE

SM6882
EX455 W2-9-7

SHOCKLESS VALVE

SM6883

Section X-X
W2-9-8 EX455

SHOCKLESS VALVE

Item Part Name Q.ty Wrench Size Tightening Torque Remarks

No. (mm) Nm
• kgf•m lbf•ft

1 Plug 8 :8 39 4 29
2 O-ring 8
3 Steel Ball 8
4 O-ring 4
5 Filter Assembly 4A
5A Filter 4
5B Sleeve 4
6 Spring 4
7 O-ring 4
8 Plug 4 :6 19.5 2 14.5
9 Plug 4 :8 39 4 29
10 Plunger 8
11 Plunger Assembly 4A
11A Plunger 4
11B Ring 4
11C Orifice 4
12 Body 1
EX455 W2-10-1

SOLENOID VALVE UNIT

REMOVE AND INSTALL THREE-SPOOL SOLENOID VALVE

WARNING
Escaping fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by
relieving pressure before disconnecting hydraulic lines.
Hot hydraulic oil may spout after operation, possibly causing severe burns. Wait for oil to cool before starting
any repair work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Thoroughly release any
remaining pressure before removing the cap.

Preparation

1. Park the machine on a solid level surface. Lower
the bucket to ground.
2. Stop the engine. Move all control levers to release
pressure remaining in the system. Rotate
the hydraulic oil tank cap approx. 30°
counterclockwise to release pressure remaining in
the hydraulic oil tank.
3. Remove the hydraulic oil tank cap. Connect a
vacuum pump and operate it continuously to main-
tain negative pressure in the hydraulic oil tank.
NOTE - Run the vacuum pump continuously while
working on the hydraulic system.

Removal

1. Disconnect all wire harnesses from the solenoid

valve.

2. Disconnect pilot pipes (1 to 3) and (5 to 9).

: 19 mm, 22 mm, 27 mm

3. Remove bolt (4) to remove the three-spool sole-

noid valve.
: 17 mm

Installation

1. Secure the three-spool solenoid valve with bolt

(4).
: 17 mm
: 49 Nžm (5 kgf•m, 36 lbf•ft)

2. Connect pilot pipes (1 to 3) and (5 to 9).

: 19 mm SM6884

: 29 N•m (3 kgf•m, 21.5 lbf•ft)

: 22 mm
1 - Hose SC : (To swing motor)
: 39 N•m (4 kgf•m, 29 lbf•ft) 2 - Hose SB : (To Travel motor)
3 - Hose SA : (To main relief valve)
: 27 mm 4 - Bolt
: 60 N•m (6 kgf•m, 43 lbf•ft) 5 - Hose PD : (To pilot check valve)
6 - Hose H2 : (To shockless valve)
3. Connect all wire harnesses to the solenoid valve. 7 - Hose H5 : (To hydraulic oil tank)
8 - Hose T3 : (To hydraulic oil tank)
9 - Hose PB : (From pilot pump)
W2-10-2 EX455

SOLENOID VALVE UNIT

DISASSEMBLE AND ASSEMBLE THREE-SPOOL SOLENOID VALVE

SM6585

Wrench Tightening Torque Wrench Tightening Torque

Item Part Name Quantity Size Item Part Name Quantity Size
No. (mm) N•m kgf•m lbf•ft No. (mm) N•m kgf•m lbf•ft

1 Plug 1 22 49 5 36 13 Spool 1
Assembly

2 Shim 1 14 Rod 3

3 Spring 1 15 O-Ring 3

4 O-Ring 1 16 Stopper 3

5 Valve 1 17 Plunger 3
Assembly

6 Gasket 1 18 Screw 3 32 29.5 3 22

7 Casing 1 19 Coil 3
Assembly

8 Spool 2 20 Spring 3
Assembly

9 Spring 3 21 Spring Seat 3

10 O-Ring 3 22 Pipe 3

11 O-Ring 3 23 Housing 3

12 O-Ring 3 24 Spacer 3
SECTION 3
UNDERCARRIAGE
CONTENTS
Group 1 - Swing Bearing
Remove and Install
Swing Bearing ...................................... W3-1-1
Group 2 - Travel Device
Remove and Install
Travel Device ...................................... W3-2-1
Disassemble Travel Device ................... W3-2-4
Assemble Travel Device ........................ W3-2-8
Disassemble Travel Motor ................... W3-2-14
Assemble Travel Motor ........................ W3-2-18
Disassemble Brake Valve ................... W3-2-22
Assemble Brake Valve ........................ W3-2-24
Maintenance Standard ........................ W3-2-26
Group 3 - Center Joint
Remove and Install Center Joint ........... W3-3-1
Disassemble Center Joint ..................... W3-3-2
Assemble Center Joint .......................... W3-3-4
Maintenance Standard .......................... W3-3-6
Group 4 - Track Adjuster
Remove and Install
Track Adjuster ...................................... W3-4-1
Disassemble Track Adjuster .................. W3-4-2
Assemble Track Adjuster ...................... W3-4-4
EX455
Group 5 - Front Idler
Remove and Install Front Idler .............. W3-5-1
Disassemble and Assemble
Front Idler ............................................. W3-5-2
Maintenance Standard .......................... W3-5-4
Group 6 - Upper and Lower Roller
Remove and Install
Upper Roller ...................................... W3-6-1
Remove and Install
Lower Roller ...................................... W3-6-4
Disassemble Upper Roller ..................... W3-6-8
Assemble Upper Roller ....................... W3-6-10
Disassemble Lower Roller ................... W3-6-12
Assemble Lower Roller ....................... W3-6-14
Maintenance Standard ........................ W3-6-16
Group 7 - Tracks
Remove and Install Tracks .................... W3-7-1
Maintenance Standard .......................... W3-7-7
EX455 W3-1-1

SWING BEARING

REMOVE AND INSTALL SWING BEARING

Removal Matching Mark

1. Put matching marks on swing bearing inner race (1)

and track frame (2).

2. Remove the front attachment, the counterweight

and the cab from the main frame.

3. Remove the main frame mounting bolts (36 used)

and knock pins (2 used) to remove the main frame. SM6886

: 41 mm

4. Disconnect all grease pipes to the swing bearing.

: 17 mm

5. Remove swing bearing inner race mounting bolts

(3) (36 used).

: 41 mm

SM6887

WARNING
Swing bearing weight: 655 kg (1450 lb)

6. Attach lifting tool to hoist and remove swing bear-

ing (4).

SM6888
W3-1-2 EX455

SWING BEARING

Installation

Clean the track frame and the swing bearing mating

surfaces.

1. Coat THREEBOND 1102 to the swing bearing

mounting surface on the track frame.

WARNING
Swing bearing weight: 655 kg (1450 lb)

SM6888

IMPORTANT - Be sure to align the matching marks.

Otherwise, the inner race soft zone will be in the
incorrect position.

2. Hoist swing bearing (4).

Align the swing bearing with the track frame using
the matching marks put during disassembly.

Plug Position
Soft Zone
Position
Soft Zone Position
(Outer Race)
(Inner Race)
Greasing Hole
Positions
(3 places)

SM6889

3. Apply LOCTITE 262 to swing bearing mounting

bolts (3) (36 used) and tighten to specification.

: 41 mm
: 1375 N•m (140 kgf•m, 1010 lbf•ft)

4. Reconnect all grease pipes to the swing bearing.

: 17 mm
: 49 N•m (5 kgf•m, 36 lbf•ft)

5. Mount the main frame. Drive in knock pins with a

hammer. Secure the frame with mounting bolts (3).

: 41 mm
: 1375 N•m (140 kgf•m, 1010 lbf•ft)
SM6887

6. Mount the front attachment, the counterweight and

the cab on the main frame.
EX455 W3-2-1

TRAVEL DEVICE

REMOVE AND INSTALL TRAVEL DEVICE

WARNING
Escaping pressure hydraulic oil can penetrate the skin or eyes, causing serious injury. Avoid this hazard by
relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure
to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off due to internal pressure if turned quickly. Slowly turn the cap to release
internal pressure before completely removing the cap.

Preparation
1. Park the machine on firm and level surface. Lower
the front attachment to the ground.
2. Stop the engine. Move all control levers to release
any pressure remaining in the system. Slowly turn
the hydraulic oil tank cap approx. 30 degrees
counterclockwise to release any remaining pres-
sure from the hydraulic oil tank.
3. Remove hydraulic oil tank cap. Connect a vacuum
(75298347) pump to maintain negative pressure in
the hydraulic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal
The procedure starts on the premise that the track link
has already been removed. Refer to page W3-7-1 for
track removal.

1. Remove piping cover and clamps and disconnect

hydraulic hoses and pipes.

: 19 mm
: 22 mm
: 27 mm
: 10 mm SM6890

NOTE - Cap the disconnected hose and pipe ends.

2. Remove counterbalance valve (1).

: 10 mm

WARNING
Travel device assembly weight: 500 kg (1129 lb)
SM6891

3. Attach a hoist to travel device (3) and hold it.

4. Loosen mounting bolts (2) to remove travel device

(3) from track frame (4).

: 32 mm

SM6892
W3-2-2 EX455

TRAVEL DEVICE

Installation

WARNING
Travel device assembly weight: 500 kg (1129 lb)

1. Install travel device (3) with mounting bolts (2).

: 32 mm
: 740 N•m (75 kgf•m, 540 lbf•ft)

SM6893

2. Install counterbalance valve (1).

: 10 mm
: 108 N•m (11 kgf•m, 80 lbf•ft)

SM6890

3. Remove the plug (5) (drain port) and (6) (travel

speed change port).
Fill-up inside of the travel motor casing with hydrau-
lic oil in both ports using a oil filler clean with new
oil.
(About 1.2 liter for each motor).

4. Connect the drain and travel speed change piping

to the travel motor ports (5) and (6) without tighten
the adapter on the travel device.
- Fill up the hydraulic oil tank to proper level.
- Confirm that oil come out from the adapters.
- Tighten the adapters.

SM6890
EX455 W3-2-3

TRAVEL DEVICE

5. Connect the delivery hoses (5), (6), (7) and (8) and
install piping cover and clamps.

: 19 mm
: 88 N•m (9.0 kgf•m, 65 lbf•ft)
: 22 mm
: 69 N•m (7.0 kgf•m, 50 lbf•ft)
: 27 mm
: 93 N•m (9.5 kgf•m, 69 lbf•ft)
: 10 mm
: 108 N•m (11 kgf•m, 80 lbf•ft)

6. Install the track link (refer to page W3-7-1).

Check and/or fill the hydraulic oil tank to proper
level.
SM6890

IMPORTANT - After installation, check that no oil

leakage appears on the joints.
After installing the travel motor or travel device, do
following break-in operation to prevent a seizure.
1. Engine control dial: slow idle
2. Travel speed change switch: Slow
3. Travel at forward position for 5 min. continuously
(Continuous travel motion in same direction to release
air in the pipings).

NOTE - When move the travel lever to forward the

movement should be apply very slowly.
- Do not move the lever to forward or reverse quickly.
- Even after the break-in operation, do not operate the
travel motor at high speed and P mode immediately.
- During inspection for travel performance, carry on a
SM6894
warm up step by step of travel device, moving the
travel speed change switch from "Slow" to "Fast" and
from E-SE-P-SP mode accordingly.
W3-2-4 EX455

TRAVEL DEVICE

DISASSEMBLE TRAVEL DEVICE

SM6895

1 - Motor 13 - Pin (3 Used) 26 - Thrust Plate (8 Used) 36 -

First Stage Carrier
2 - Bolt (4 Used) 14 - Needle Bearing (3 Used) 27 - Needle Bearing (8 Used) 37 -
Plug (3 Used)
3 - Spring Washer (4 Used) 15 - Second Stage Sun Gear 28 - Pin (4 Used) 38 -
Bolt (16 Used)
4 - O-Ring 16 - Spacer (2 Used) 29 - Spring Pin (4 Used) 39 -
Cover
5 - Housing 17 - Second Stage Carrier 30 - Third Stage Planetary 40 -
Bearing
6 - Floating Seal 18 - Third Stage Sun Gear Gear (4 Used) 41 -
Stopper Pin
7 - Roller Bearing (2 Used) 19 - Third Stage Carrier 31 - Thrust Plate (6 Used) 42 -
Retaining Ring
8 - Drum 20 - Bolt (24 Used) 32 - Needle Bearing 43 -
Socket Bolt
9 - O-Ring 21 - Spring Washer (24 Used) (3 Used) (30 Used)
10 - Thrust Plate (6 Used) 22 - Bearing Nut 33 - Pin (3 Used) 44 - Ring Gear
11 - Spring Pin (3 Used) 23 - Lock Plate 34 - Second Stage Planetary 45 - Propeller Shaft
12 - First Stage Planetary 24 - Bolt (2 Used) Gear (3 Used)
Gear (3 Used) 25 - Sprocket 35 - Spring Pin (3 Used)
EX455
TRAVEL DEVICE
Disassemble Travel Device
• Be sure to thoroughly read "Precautions for Dis-
assembly and Assembly" on page W1-1-1 before
starting any repair work.
WARNING
Pressure may remain in the travel device. Slowly
loosen the air bleed plug to completely release
the residual pressure. Then, remove the drain
plug and drain the gear oil into a container. If the
air bleed plug is loosened quickly, the plug may
fly off and/or gear oil may spout. Position your
face and body away from the plug.
WARNING
Travel device weight: 500 kg (1100 lb)
1. After loosening plug (37-B) 2 to 3 turns, remove
plug (37-A) to drain gear oil from the travel device.
Lay the travel device on a work bench with motor
(1) positioned upward.
: 14 mm
SM6896
WARNING
Motor (1) weight: 125 kg (280 lb)
2. Loosen bolts (2) (4 used). Hoist and remove motor
(1) by crane. Remove O-ring (4) from motor (1).
: 27 mm
WARNING
Travel device weight (Excluding motor):
375 kg (830 lb)
W3-2-5
3. Turn over the travel device using a crane.
WARNING
Cover (39) weight: 22 kg (49 lb)
4. Loosen bolts (38) (16 used). Install eye bolts (PT
3/4) to cover (39). Using a crane, remove cover
(39).
: 22 mm
5. Remove socket bolts (43) (30 used).
: 27 mm
WARNING
Ring gear (44) weight: 70 kg (155 lb)
6. Install eye bolts (M14, pitch 2) to ring gear (44).
Using a crane, remove ring gear (44).
7. Remove propeller shaft (45).
8. Remove first stage carrier (36) assembly from
second stage carrier (17) assembly.
9. Remove second stage sun gear (15) from second
stage carrier (17).
WARNING
Second stage carrier (17) assembly weight:
approx. 25 kg (55 lb)
10. Attach a wire rope or belt to second stage carrier
(17) assembly. Using a crane, remove second
stage carrier (17) assembly.
11. Remove third stage sun gear (18) from third stage
carrier (19).
WARNING
Third stage carrier (19) assembly weight:
approx. 75 kg (165 lb)
12. Attach a wire rope or belt to third stage carrier (19)
assembly. Using a crane, remove third stage
carrier (19) assembly.
13. Remove O-ring (9) from drum (8).
W3-2-6 EX455

TRAVEL DEVICE

SM6895
EX455 W3-2-7

TRAVEL DEVICE

14. Remove bolts (24) (2 used) to remove lock plate

(23). WARNING
Drum (8) and other part assembly weight:
:19 mm approx.100 kg (220 lb)
15. Install special tool (75298541) to bearing nut (22)
to remove bearing nut (22). 21. Turn drum (8) over. Remove the outer race of roller
bearing (7) from drum (8).

Special Tool : 75298541 22. If necessary, cut the inner race of roller bearing (7)
using a torch to remove it from housing (5). Take
care not to damage housing (5) at this time.
75298541
23. Using a round steel bar, remove spring pins (29) (4
used) from third stage carrier (19).

24. Remove pins (28) (4 used), third stage planetary

gears (30) (4 used) and thrust plates (26) (8 used)
from third stage carrier (19).

25. Remove needle bearings (27) (8 used) from third

stage planetary gear (30).

26. Disassemble first stage carrier (36) and second

stage carrier (17) assemblies following the same
SM6897
procedures in steps 23 to 25.

27. Remove spacers (16) from first stage carrier (36)

WARNING and second stage carrier (17).
Drum (8), sprocket (25) and other part
assembly weight: approx.180 kg (400 lb)

16. Install eye bolts (M18, pitch 2.5) to drum (8). Using
a crane, remove drum (8) assembly together with
one bearing (7) from housing (5). Remove roller
bearing (7) inner race.

17. Remove one half of floating seal (6) from housing

(5).

18. Remove one half of floating seal (6) from drum (8).

19. Remove roller bearing (7) outer race from drum (8).

WARNING
Sprocket (25) weight: 85 kg (190 lb)

20. Loosen bolts (20) (24 used) to remove sprocket

(25) from drum (8).
:32 mm
W3-2-8 EX455

TRAVEL DEVICE

ASSEMBLE TRAVEL DEVICE

1 4 5 6 7 8 25 21 20 22 9

43 19 18 44 16 17 15

37

36

16
45
40
41
39
42
12
13
11
10
14

2 3
26 29 33 31 32 34 31 35 10 38

SM6597

28 23 24 27 26 30

1 - Motor 13 - Pin (3 Used) 26 - Thrust Plate (8 Used) 36 -

First Stage Carrier
2 - Bolt (4 Used) 14 - Needle Bearing (3 Used) 27 - Needle Bearing (8 Used) 37 -
Plug (3 Used)
3 - Spring Washer (4 Used) 15 - Second Stage Sun Gear 28 - Pin (4 Used) 38 -
Bolt (16 Used)
4 - O-Ring 16 - Spacer (2 Used) 29 - Spring Pin (4 Used) 39 -
Cover
5 - Housing 17 - Second Stage Carrier 30 - Third Stage Planetary 40 -
Bearing
6 - Floating Seal 18 - Third Stage Sun Gear Gear (4 Used) 41 -
Stopper Pin
7 - Roller Bearing (2 Used) 19 - Third Stage Carrier 31 - Thrust Plate (6 Used) 42 -
Retaining Ring
8 - Drum 20 - Bolt (24 Used) 32 - Needle Bearing 43 -
Socket Bolt
9 - O-Ring 21 - Spring Washer (24 Used) (3 Used) (30 Used)
10 - Thrust Plate (6 Used) 22 - Bearing Nut 33 - Pin (3 Used) 44 - Ring Gear
11 - Spring Pin (3 Used) 23 - Lock Plate 34 - Second Stage Planetary 45 - Propeller Shaft
12 - First Stage Planetary 24 - Bolt (2 Used) Gear (3 Used)
Gear (3 Used) 25 - Sprocket 35 - Spring Pin (3 Used)
EX455 W3-2-9

TRAVEL DEVICE

Assemble Travel Device

WARNING
1. Install one half of floating seal (6) on housing (5) Drum (8) and sprocket (25)
using a wooden spatula or similar tool to guide the assembly weight: approx.180 kg (400 lb)
seal along the periphery.

IMPORTANT - For handling of floating seal (6), refer to

the section "Precautions for floating seal handling" on 8. Install eye bolts (M18, pitch 2.5) to drum (8).
page W1-1-3. Install drum (8) onto housing (5) using a crane.

2. In case motor side roller bearing (7) inner race was 9. Press ring gear side roller bearing (7) inner race
removed from housing (5), install roller bearing (7) onto housing (5).
inner race onto housing (5).

10. Tighten bearing nut (22) to housing (5) by hand.

3. Install roller bearing (7) outer race into motor (1)
mounting side bore of drum (8). 11. Attach special tool (75298541) to bearing nut (22).
Tighten bearing nut (22) to specification using a
torque wrench.
4. Install one half of floating seal (6) to drum (8) using
a wooden spatula or similar to guide the seal along
the periphery. Tool: 75298541

: 41 mm
IMPORTANT - For handling of floating seal (6), refer
to the section "Floating Seal Precautions" on page : 785 N•m (80 kgf•m, 580 lbf•ft)
W1-1-3.

CAUTION
75298541
Drum (8) weight: 100 kg (220 lb)

5. After turning drum (8) over, install roller bearing (7)

outer race into drum (8).

CAUTION
Sprocket (25) weight: 85 kg (190 lb)

SM6897
6. Install sprocket (25) on drum (8).
7. Apply LOCTITE 262 to bolts (20) (24 used) and
tighten the bolts with spring washers (21).
12. After tightening bearing nut (22) tap the end face
: 32 mm of drum (8) with a plastic hammer to secure
: 740 N•m (75 kgf•m, 540 lbf•ft) appropriate play. Then, rotate drum (8) three turns
in both directions.
W3-2-10 EX455

TRAVEL DEVICE

5 8 22 9

19 18 16 17 15

36

16

12
13
11
10
14

2 3
26 29 33 31 32 34 31 35 10

SM6597

28 23 24 27 26 30
EX455 W3-2-11

TRAVEL DEVICE

13. Repeat step 11. Then, tighten bearing nut (22) to 22. Install pins (13) (3 used) into first stage carrier (36),
specification. Align bolt holes on housing (5) and aligning the spring pin holes.
lock plate (23).
: 785 N•m (80 kgf•m, 580 lbf•ft)
23. Drive spring pins (11) (3 used) into first stage
carrier (36) and pins (13) (3 used).
14. Apply LOCTITE 262 to bolts (24) (2 used). Secure
lock plate (23) to housing (5) with bolts (24).
: 19 mm
: 88 N•m (9 kgf•m, 65 lbf•ft) NOTE - Be sure that the slit part of spring pin (11) faces
the end face of pin (13).
15. Install needle bearings (27) (8 used) into third stage
planetary gears (30) (4 used).

16. Putting thrust plates (26) (8 used) on both ends of

each third stage planetary gears (30) (4 used),
install them into third stage carrier (19).
13

17. Install pins (28) (4 used) into third stage carrier (19), Slit
aligning the spring pin holes. 11

18. Drive spring pin (29) into third stage carrier (19) and
pins (28). 24. Assemble second stage carrier (17) following the
same procedures in steps 19 to 23.

25. Install O-ring (9) to drum (8).

NOTE - Be sure that the slit part of spring pin (29) faces
the end face of pin (28). WARNING
Third stage carrier (19) assembly weight:
approx. 75 kg (165 lb)

28 26. Attach a wire rope or belt to third stage carrier (19)

Slit assembly. Using a crane, install third stage carrier
29
(19) assembly into housing (5).

27. With the lower tooth height side upward, install

19. Install spacer (16) to first stage carrier (36). third stage sun gear (18) into third stage carrier
(19).
20. Install needle bearings (14) (3 used) into first stage
planetary gears (12) (3 used).
Top Side
21. Putting thrust plates (10) on both ends of each first
stage planetary gears (12), install them into first
stage carrier (36).

SM6898
W3-2-12 EX455

TRAVEL DEVICE

1 4 5 8

43 19 44 17 15

37

36

45
40
41
39
42
12

2 3
38

SM6597
EX455
TRAVEL DEVICE
WARNING
Second stage carrier (17) assembly weight:
approx. 25 kg (55 lb)
28. Attach a wire rope or belt to second stage carrier
(17) assembly. Using a crane, install second
stage carrier (17) assembly onto third stage carrier
(19).
29. With the lower tooth height side upward, install
second stage sun gear (15) into second stage
carrier (17).
Top Side
SM6898
15
30. Install first stage carrier (36) onto second stage
carrier (17).
31. Insert propeller shaft (45) into the carrier center so
that the propeller shaft gear meshes with first
stage planetary gear (12).
WARNING
Ring gear (44) weight: 70 kg (155 lb)
32. Install eye bolts (M14, pitch 2) to ring gear (44).
Install ring gear (44) onto drum (8) using a crane.
33. Apply LOCTITE 262 to bolts (43) (30 used).
Secure ring gear (44) to drum (8) by tightening the
bolts.
: 27 mm
: 390 N•m (40 kgf•m, 290 lbf•ft)
34. In case bearing (40) and stopper pin (41) were
removed, install bearing (40) and stopper pin (41)
on cover (39).
35. Install retaining ring (42) to cover (39).
W3-2-13
36. Coat THREEBOND 1389 to cover (39) mounting
face on ring gear (44).
WARNING
Cover (39) weight: 22 kg (49 lb)
37. Install eye bolts (PT 3/4) to cover (39). Install
cover (39) on ring gear (44) using a crane.
38. Apply LOCTITE 262 to bolts (38) (16 used).
Secure cover (39) to ring gear (44) by tightening
the bolts.
: 22 mm
: 155 N•m (16 kgf•m, 115 lbf•ft)
39. Wrap seal tape around plugs (37) (3 used). Install
the plugs to cover (39).
: 14 mm
: 69 N•m (7 kgf•m, 50 lbf•ft)
WARNING
Travel device weight (Excluding motor):
375 kg (830 lb)
40. Turn the travel device over.
41. Add gear oil into the travel device.
Gear oil: 12 L (12.7 US qt)
42. Install O-ring (4) to motor (1).
WARNING
Travel motor (1) weight: 125 kg (280 lb)
43. Hoist motor (1) by crane. While aligning spline
teeth on propeller shaft (45) and motor (1), install
motor (1) on housing (5).
44. Secure motor (1) to housing (5) with spring wash-
ers (3) and bolts (2) (4 used each).
: 27 mm
: 295 N•m (30 kgf•m, 215 lbf•ft)
W3-2-14 EX455

TRAVEL DEVICE

DISASSEMBLE TRAVEL MOTOR

1
2 Travel Speed Shift Valve
3
4

5 27
6
4
3 26
2 25
1 24
22

15 23 7
8
31 30 28
9 29
10 32
33
11 34
55 35
12 36
13 37
21 38
39
20
14 41 54
19 43
54 40
42
18 44
17 45
16 46
47
48
49
50
52 51
53
SM6899

1 - Plug (2 Used) 15 - Overload Relief Valve 28 - Plate (6 Used) 42 - Plug (2 Used)

2 - O-ring (2 Used) (2 Used) 29 - Plug (6 Used) 43 - O-Ring (2 Used)
3 - Spring (2 Used) 16 - O-Ring (2 Used) 30 - Casing 44 - Retaining Ring
4 - Valve (2 Used) 17 - O-Ring (2 Used) 31 - Plug (2 Used) 45 - Case
5 - Body 18 - Cover 32 - Spring (4 Used) 46 - O-Ring
6 - Socket Bolt (6 Used) 19 - O-Ring (3 Used) 33 - Piston (4 Used) 47 - Oil Seal
7 - O-ring 20 - Plug (3 Used) 34 - Swash Plate 48 - Washer
8 - Collar 21 - Socket Bolt (8 Used) 35 - Plunger (9 Used) 49 - Retaining Ring
9 - Needle Bearing 22 - O-Ring (7 Used) 36 - Retaining Plate 50 - Bearing
10 - Pin 23 - Spring (12 Used) 37 - Holder 51 - Shaft
11 - Plug (2 Used) 24 - O-Ring 38 - Rotor 52 - Inner Race
12 - O-Ring (2 Used) 25 - Brake Piston 39 - Valve Plate 53 - Retaining Ring
13 - Plug (2 Used) 26 - O-Ring 40 - Spring (9 Used) 54 - O-Ring (4 Used)
14 - O-Ring (2 Used) 27 - Friction Plate (6 Used) 41 - Ball (2 Used) 55 - O-Ring (2 Used)
EX455 W3-2-15

TRAVEL DEVICE

Disassemble Travel Motor

WARNING
• Be sure to thoroughly read "Precautions for Disas- Rotor (38) assembly weight: 21 kg (46 lb)
sembly and Assembly" on page W1-1-1 before
starting any repair work.
8. Lay casing (30) on its side. Pull out rotor (38)
assembly from shaft (51).

WARNING 9. Remove plungers (35) (9 used), retainer plate (36)

Cover (18) weight: 30 kg (66 lb) from rotor (38).

10. Remove holder (37) and springs (40) (9 used) from

1. Loosen socket bolts (6) (6 used), and remove body rotor (38).
(5) from cover (18).
11. Remove plates (28) (6 used) and friction plates
(27) (6 used) from casing (30).
: 6 mm
12. Attach bolt (M8, pitch 1.25) to swash plate (34).
2. Loosen socket bolts (21) (8 used). Using a crane, Remove swash plate (34) from casing (30).
remove cover (18) from casing (30).
13. Remove balls (41) (2 used), pistons (33) (4 used)
: 14 mm and springs (32) (4 used) from casing (30).

3. Turn cover (18) over.

Remove spring (23) (12 used), valve plate (39), O-
ring (7), (16) (2 used), (17) (2 used), (22) (7 used)
and (54).

NOTE - If valve plate (39) and springs (23) have not

been removed in the previous step, remove them.

4. Remove collar (8) and needle bearing (9) from

cover (18).

5. Remove O-rings (54) (3 used) from casing (30).

WARNING
Be sure to reduce air pressure to 98 to 196 kPa
(1 to 2 kgf/cm2, 14 to 28 psi) when using
compressed air. Cover brake piston (25) with
cloth when removing the piston using
compressed air to avoid piston flying out.

6. Attach bolts (M8, pitch 1.25) (2 used) to the brake

piston (25).
Remove brake piston (25) from casing (30) while
2
supplying 98 to 196 kPa (1 to 2 kgf/cm , 14 to 28
psi) air pressure to the brake releasing hydraulic
circuit using an air pump.

7. Remove O-rings (24), (26) from brake piston (25).

W3-2-16 EX455

TRAVEL DEVICE

1
3
4

4
3
1
22

15 23

30

18
44
45
46
47
48
49
50
52 51
53
SM6899
EX455 W3-2-17

TRAVEL DEVICE

14. Remove retaining ring (44) from casing (30).

Remove case (45) from casing (30).

15. Remove shaft (51) using a plastic hammer.

16. Remove retaining ring (49) and washer (48) from

shaft (51).

17. Press bearing (50) using a press to remove bear-

ing (50) from shaft (51).

18. Remove oil seal (47) and O-ring (46) from case
(45).

19. Remove retaining ring (53) and inner race (52) from
shaft (51).

NOTE - Inner race (52) does not need to be removed

as long as the machine hourmeter is within the 8000
hours and no scratches or fraking are found on it.

20. Hold body (5) with a vice and remove plugs (1) (2
used).
: 32 mm

21. Remove springs (3) (2 used) and valves (4) (2

used) from body (5).

22. Remove overload relief valves (15) (2 used) from

cover (18).
: 36 mm
W3-2-18 EX455

TRAVEL DEVICE

ASSEMBLE TRAVEL MOTOR

16 17
23 7 24 25 26 27 28 40 36 34 30 41 50
48
6 5 4 3 2 1
49

44
18
10 Travel Speed
Shit Valve
54
8
45
9 11
12
51 13
52
14
53

20 47
19
46
39
32
29 42
43

22 54 31 38 35 37 33 21 55 15
SM6900

1 - Plug (2 Used) 15 - Overload Relief Valve 28 - Plate (6 Used) 42 - Plug (2 Used)

2 - O-ring (2 Used) (2 Used) 29 - Pug (6 Used) 43 - O-Ring(2 Used)
3 - Spring (2 Used) 16 - O-Ring (2 Used) 30 - Casing 44 - Retaining Ring
4 - Valve (2 Used) 17 - O-Ring (2 Used) 31 - Plug (2 Used) 45 - Case
5 - Body 18 - Cover 32 - Spring (4 Used) 46 - O-Ring
6 - Socket Bolt (6 Used) 19 - O-Ring (3 Used) 33 - Piston (4 Used) 47 - Oil Seal
7 - O-ring 20 - Plug (3 Used) 34 - Swash Plate 48 - Washer
8 - Collar 21 - Socket Bolt (8 Used) 35 - Plunger (9 Used) 49 - Retaining Ring
9 - Needle Bearing 22 - O-Ring (7 Used) 36 - Retaining Plate 50 - Bearing
10 - Pin 23 - Spring (12 Used) 37 - Holder 51 - Shaft
11 - Plug (2 Used) 24 - O-Ring 38 - Rotor 52 - Inner Race
12 - O-Ring (2 Used) 25 - Brake Piston 39 - Valve Plate 53 - Retaining Ring
13 - Plug (2 Used) 26 - O-Ring 40 - Spring (9 Used) 54 - O-Ring (4 Used)
14 - O-Ring (2 Used) 27 - Friction Plate (6 Used) 41 - Ball (2 Used) 55 - O-Ring (2 Used)
EX455 W3-2-19

TRAVEL DEVICE

Assemble Travel Motor
1. Install valves (4) (2 used) and springs (3) (2 used)
into body (5).
2. Attach O-rings (2) (2 used) to plugs (1) (2
used).Install plugs (1) (2 used) to body (5).
: 32 mm
: 83 N•m (8.5 kgf•m, 62 lbf•ft)
3. Install bearing (50) onto shaft (51) using a press.
10. Insert needle bearing (9) into cover (18) using a
press.
11. Install O-rings (7), (16) (2 used), (17) (2 used), (22)
(7 used), and (54) on cover (18).
12. Install collar (8) and springs (23) (12 used) into
cover (18).
IMPORTANT - Be sure to apply grease to the contact
surface of valve plate (39) so as to prevent it from
dropping when installing cover (18) onto casing (30).

4. Install washer (48) and retaining ring (49) onto shaft 13. Install valve plate (39) on cover (18).
(51).
14. Install shaft (51) into casing (30) using a press.

15. Install case (45) and retaining ring (44) into casing
5. Install inner race (52) onto shaft (51) using a press.
(30).
6. Install retaining ring (53) onto shaft (51).

16. Install springs (32) (4 used), pistons (33) (4 used)

and balls (41) (2 used) into casing (30).
7. Install oil seal (47) and O-ring (46) on case (45).
17. Install swash plate (34) into casing (30) using a
8. Install springs (40) (9 used) into rotor (38). Install
bolt (M8, pitch 1.25).
holder (37) onto rotor (38).

IMPORTANT - Be sure that the flange part of plungers

(35) securely fit in retainer plate (36) bores. B e
sure to apply a film of hydraulic oil on the rotor (38) bore
surface before inserting plungers (35).

9. Attach plungers (35) (9 used) on retainer plate (36).

Insert plungers (35) into rotor (38).

IMPORTANT - Be sure that the model stamped end of

needle bearing faces on the rotor (38) when installing
the needle bearing.
W3-2-20 EX455

TRAVEL DEVICE

23 24 25 26 27 28 30

6 5

18

54

51

39

54 38 21 55 15
SM6900
EX455 W3-2-21

TRAVEL DEVICE

18. Lay casing (30) on its side. Insert rotor (38)

assembly onto shaft (51).

19. Install friction plates (27) (6 used) in casing (30)

and plates (28) (6 used) onto rotor (38) one by one
alternately.

20. Attach O-rings (54) (3 used) on casing (30).

21. Attach O-rings (24) and (26) on brake piston (25).

Install brake piston (25) into casing (30).

WARNING
Cover (18) weight: Approx. 20 kg (44 lb)

IMPORTANT - Take care not to drop valve plate (39)

and springs (23).

22. Install cover (18) on casing (30).

23. Tighten socket bolts (21) (8 used).

: 14 mm
: 275 N•m (28 kgf•m, 203 lbf•ft)

24. Install body (5) and tighten socket bolts (6) (6

used).

: 6 mm
: 34 N•m (3,5 kgf•m, 25.5 lbf•ft)

25. Attach O-rings (55) (2 used) on overload relief

valves (15) (2 used). Install overload relief valves
(15) on cover (18).

: 36 mm
: 415 N•m (42 kgf•m, 305 lbf•ft)
W3-2-22 EX455

TRAVEL DEVICE

DISASSEMBLE BRAKE VALVE

SM6901

1 - Plug (2 Used) 7 - Backup Ring (2 Used) 12 - Plunger 17 - O-Ring (2 Used)

2 - O-Ring (4 Used) 8 - Plug (2 Used) 13 - Body 18 - Plug (2 Used)
3 - Spring (2 Used) 9 - Socket Bolt (8 Used) 14 - Socket Bolt (8 Used) 19 - Spring Seat (2 Used)
4 - Ball (2 Used) 10 - Plug (2 Used) 15 - Check Valve (2 Used) 20 - Spring (2 Used)
5 - Cap (2 Used) 11 - O-Ring (2 Used) 16 - Spring (2 Used) 21 - Spring Seat (2 Used)
6 - O-Ring (2 Used)
EX455 W3-2-23

TRAVEL DEVICE

Disassemble Brake Valve

• Be sure to thoroughly read all "Precautions for

Disassembly/Assembly" work on page W1-1-1
before disassembling.

1. Remove socket bolts (9).

: 10 mm

2. Remove caps (5) from body (13).

3. Remove O-rings (6) (2 used) and backup rings (7)

(2 used) from cap (5).

4. Remove plugs (1) (2 used), springs (3) (2 used) and

balls (4) (2 used) from cap (5).

: 14 mm

5. Remove spring seats (21) and (19) and springs (20)

from cap (5).

6. Remove plunger (12) from body (13).

7. Remove plugs (18) (2 used).

: 14 mm

8. Remove springs (16) and check valves (15) from

body (13).

IMPORTANT - Place soft protectors, such as cloth,

between the vise and plunger (12) so as not to damage
plunger (12).

9. Insert a metal bar into the hole provided on the

stepped part of plunger (12).
Note that the metal bar is used to prevent plunger
(12) from turning when removing plugs (10) (2
used). Put plunger (12) in a vise.

10. Remove plugs (10) (2 used) from plunger (12).

: 19 mm
W3-2-24 EX455

TRAVEL DEVICE

ASSEMBLE BRAKE VALVE

SM6902

1 - Plug (2 Used) 7 - Backup Ring (2 Used) 12 - Plunger 17 - O-Ring (2 Used)

2 - O-Ring (4 Used) 8 - Plug (2 Used) 13 - Body 18 - Plug (2 Used)
3 - Spring (2 Used) 9 - Socket Bolt (8 Used) 14 - Socket Bolt (8 Used) 19 - Spring Seat (2 Used)
4 - Ball (2 Used) 10 - Plug (2 Used) 15 - Check Valve (2 Used) 20 - Spring (2 Used)
5 - Cap (2 Used) 11 - O-Ring (2 Used) 16 - Spring (2 Used) 21 - Spring Seat (2 Used)
6 - O-Ring (2 Used)
EX455 W3-2-25

TRAVEL DEVICE

Assemble Brake Valve

IMPORTANT - Place soft protectors, such as cloth,

betw een the vise and plunger (12) so as not to damage
plunger (12).

1. Insert a metal bar into the hole provided on the

stepped part of plunger (12).
Note that the metal bar is used to prevent plunger
(12) from turning. Put plunger (12) in a vise.

2. Install O-rings (11) (2 used) to plugs (10). Install

plugs (10) into plunger (12).

: 19 mm
: 88 N•m (9 kgf•m, 65 lbf•ft)

3. Install check valves (15) and springs (16) into body

(13).

4. Install O-rings (17) (2 used) to plugs (18) (2 used).

Install plugs (18) into body (13).

: 14 mm
: 365 N•m (37 kgf•m, 268 lbf•ft)

5. Insert plunger (12) into body (13).

6. Install spring seats (19), springs (20) and spring

seats (21) onto plunger (12) in that order.

7. After installing O-ring (6), backup ring (7) to cap (5),

install caps (5) to body (13).

8. Tighten socket bolts (9) (8 used).

: 10 mm
: 108 N•m (11 kgf•m, 80 lbf•ft)

9. Install ball (4) and spring (3) into cap (5).

10. Install O-ring (2) to plug (1). Tighten plug (1).

: 14 mm
: 15 N•m (1.6 kgf•m, 11.5 lbf•ft)
W3-2-26 EX455

TRAVEL DEVICE

MAINTENANCE STANDARD

1. Move the plunger up and down to measure the

clearance between the plunger and shoe.
Unit : mm (in)

Standard Allowable Limit

0.15 (0.006) 0.4 (0.016)

SM6903

2. Clearance between plunger and rotor.

Measure the plunger outer diameter and the rotor
inner diameter to check the clearance.
Unit : mm (in)

Standard Allowable Limit

0.045 (0.0018) 0.06 (0.0024)

If a scratch is found on the plunger, replace with

SM6904
a new one.

SM6905

3. Measure the piston outer diameter and the casing

piston bore to check the clearance.
Unit : mm (in)

Standard Allowable Limit

0.018 (0.00071) 0.04 (0.0016)

If a scratch is found on the piston, replace with a

new one.

SM6906
EX455 W3-2-27

TRAVEL DEVICE

4. Move the piston up and down to measure the

clearance between the piston and the shoe.
Unit : mm (in)

Standard Allowable Limit

0.5 (0.020) 0.7 (0.028)

SM6907

5. Selector Valve Check. 2

Measure the clearance between valve (2) and body

(1).
Unit : mm (in)

Standard Allowable Limit

0.018 (0.00071) 0.04 (0.0016)

1
SM6908
W3-2-28 EX455

TRAVEL DEVICE

Sprocket

SM6909

Standard Allowable Limit

mm in mm in Remedy

A 92 3.62 82 3.23

B 728.2 28.67 718 28.27

After cladding by
C 800.2 31.50 – – welding, finish manually.

D 820 32.28 810 31.89

E 215.9 8.50 – –
EX455 W3-3-1

CENTER JOINT

REMOVE AND INSTALL CENTER JOINT

WARNING
Escaping pressure hydraulic oil can penetrate the skin or eyes, causing serious injury. Avoid this hazard by
relieving pressure before disconnecting hydraulic lines.
Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure
to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off due to internal pressure if turned quickly. Slowly turn the cap to release
internal pressure before completely removing the cap.

Preparation
1. Park the machine on firm, level surface. Lower the
front attachment to the ground.
2. Stop the engine. Move all control levers to release
any pressure remaining in the system. Slowly turn
the hydraulic oil tank cap approx. 30 degrees
counterclockwise to release any remaining pres-
sure from the hydraulic oil tank.
3. Remove hydraulic oil tank cap. Connect a vacuum
(75298347) pump to maintain negative pressure
in the hydraulic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal
1. Attach tags to all hoses connected to the center
joint to aid re-connection. Disconnect hoses (1, 2,
4 to 15) and remove adapters.
: 22 mm
: 69 N•m (7.0 kgf•m, 51 lbf•ft)
: 27 mm
: 93 N•m (9.5 kgf•m, 69 lbf•ft)
: 41 mm
: 205 N•m (21 kgf•m, 152 lbf•ft)

NOTE - Cap all disconnected hose and pipe ends.

2. Remove lock plate (3).

: 22 mm SM6910
: 135 N•m (14 kgf•m, 101 lbf•ft)

3. Install eye bolt (PF 1) to the center joint to lift the

center joint with a wire rope.

WARNING
Center joint weight: 77 kg (170 lb)

4. Remove bolts (16). Then, remove the center joint

assembly while holding the center joint with a
crane.
: 24 mm
: 205 N•m (21 kgf•m, 152 lbf•ft)

Installation

NOTE - Refer to "Removal" section above for wrench

sizes and tightening torque.

1. Install the center joint with bolts (16).

2. Connect hoses (1, 2, and 4 to 15) and adapters.
SM6911
3. Install lock plate (3) with bolts.
W3-3-2 EX455

CENTER JOINT

DISASSEMBLE CENTER JOINT

SM6912

1 - Spindle 6 - Ball (26 Used) 11 - Spring Washer (4 Used) 15 - Backup Ring

2 - O-Ring 7 - Seal 12 - Ring 16 - O-Ring
3 - Cover 8 - Seal (5 Used) 13 - Retaining Ring 17 - Cover
4 - Dust Seal 9 - Body 14 - O-Ring 18 - Bolt (6 Used)
5 - O-Ring 10 - Bolt (4 Used)
EX455 W3-3-3

CENTER JOINT

Disassemble Center Joint

• Be sure to thoroughly read all "Precautions for

Disassembly and Assembly" work on page W1-1-1
before disassembling.

WARNING
Center joint weight: 77 kg (170 Ib)

1. Install eye bolt (M12, pitch 1.75) to cover (17).

Lift the center joint and set it on a work bench.
SM6913

2. Loosen bolts (18) to remove cover (17).

: 19 mm

IMPORTANT - Put a matching mark on body (9) and

spindle (1).
Matching
Mark
3. Remove O-ring (14) from cover (17), retaining ring
(13) and ring (12) from spindle (1).

4. Using bolt (18), install center joint removal special SM6914

tool (75301505) to body (9).
: 19 mm

5. Pull out body (9) from spindle (1)upward approx. 50

75301505
mm.
After checking that balls (6) are on cover (3), take
out balls (6) (26 used). Then, remove body (9)
upward.

IMPORTANT - Take care not to damage the seal slide

surface on spindle (1). Use two pins to easily remove
seal (8).
Take care not to damage the seal groove with the pin. SM6915

6. Remove seal (8) (6 used) from body (9).

7. Remove dust seal (4) and O-ring (5) from body (9).

SM6916
W3-3-4 EX455

CENTER JOINT

ASSEMBLE CENTER JOINT

SM6917

1 - Spindle 5 - O-Ring 9 - Body 15 - Backup Ring

2 - O-Ring 6 - Ball (26 Used) 12 - Ring 16 - O-Ring
3 - Cover 7 - Seal 13 - Retaining Ring 17 - Cover
4 - Dust Seal 8 - Seal (5 Used) 14 - O-Ring 18 - Bolt (6 Used)
EX455 W3-3-5

CENTER JOINT

Assemble Center Joint

1. Install O-ring (5) and dust seal (4) into body (9).

2. Install seals (7) and (8) (5 used) into body (9).

3. Place spindle (1) on a work bench. Aligning the

matching marks put when disassembling, install
body (9) on spindle (1).

IMPORTANT - Be sure to slowly push body. Failure to

do so may damage seals. The clearance between
body (9) and spindle (1) is approx. 0.05 mm (0.004 in)
so that body (9) and spindle (1) center must be aligned
during installation. SM6918

4. Tap body (9) with a plastic hammer, until the

distance between cover (3) and dust seal (4) is 30
mm (1.2 in). Then, place balls (6) (26 used) on
cover (3) and insert body (9) further until the top end
face is flush with the top end of spindle (1).

IMPORTANT - Install ring (12) with the chamfered

edge facing downward.

5. Install ring (12) to body (9).

IMPORTANT - Install retaining ring (13) with the

chamfered edge facing ring (12). SM6919

6. Install retaining ring (13) onto spindle (1).

7. Install O-rings (14) and (16) and backup ring (15) to

cover (17).
Secure cover (17) to body (9) with bolts (18) (6
used).

: 19 mm
: 88 N•m (9 kgf•m, 65 lbf•ft)

IMPORTANT - Check for oil leaks while applying oil

pressure of 0.5 Mpa (5 kgf/cm2, 71 psi) to the main and
drain ports, respectively.

SM6920
W3-3-6 EX455

CENTER JOINT

MAINTENANCE STANDARD

Part Name and Location Allowable Limit (basis of judgment) Remedy

Body, Spindle Sliding Surfaces Heavily damaged one by seizure Replace.

with Seals or foreign matter.

Sliding Surfaces 1. Excessively worn one by seizure Replace.

between Body and or foreign matter, or one having the
Spindle other than score of 0.1 mm (0.004 in) or more.
Sliding Surfaces
with Seals 2. One having the score of less than Repair the surface
0.1 mm (0.004 in). smoothly with an oil
stone.

Sliding Surfaces 1) One that has worn 0.5 mm (0.02 in) Replace.
with Ring or more, or excessively worn.

2) One that has worn 0.5 mm Repair the surface

(0.02 in) or less. smooth.

3) One that has scores due to Repair the surface

seizure or foreign matter but the smooth.
damage is less than the allowable
wear limit 0.5 mm (0.02 in) and
is repairable.

Cover Sliding surfaces 1) One that has worn 0.5 mm (0.02 in) Replace.
with ring or more.

2) One that has worn less than Repair the surface

0.5 mm (0.02 in). smooth.

3) One that has scores due to seizure Repair the surface

or foreign matter but the damage is smooth.
less than the allowable wear limit
0.5 mm (0.02 in) and is repairable.
EX455 W3-4-1

TRACK ADJUSTER

REMOVE AND INSTALL TRACK AD-

JUSTER AND FRONT IDLER

Before removing the track adjuster and front idler, the

tracks must be removed first. For removal and instal-
lation of the tracks, refer to applicable removal/instal-
lation sections. In this section, the procedure starts on
the premise that the tracks has already been removed.

Removal

WARNING
Track adjuster and front idler assembly
weight: 532 kg (1173 lb)

1. Swing superstructure 90° across of longitudinal

machine axis for easier access to track compo- 1
nents.

WARNING
Be sure cables are anchored and the anchor
point is strong enough to handle the expected
load. Keep exposed personnel clear of anchor
point and cables or chain.
SM1801

2. Using a special tool (1) as shown, remove the front

idler with track adjuster.

Installation

WARNING
Track adjuster and front idler assembly
1
weight: 532 kg (1173 lb)

WARNING
Be sure cables are anchored and the anchor
point is strong enough to handle the expected
load. Keep exposed personnel clear of anchor
point and cables or chain.

SM1802

1. Using a special tool (1) as shown, install the front

idler with track adjuster.
 W3-4-2 EX455

TRACK ADJUSTER

DISASSEMBLE TRACK ADJUSTER

12
11

5
14

18
15

11 7

16

21

27A

27
27B
27C

SM6924

1 - Front idler wheel 8 - Shaft 15 - Plate 27 - Valve assembly

2 - Cylinder 11 - Support 16 - Spring 27A - Relief valve
5 - Spacer 12 - Spring pin 18 - Nut 27B - Extension
6 - Yoke 14 - Plug 21 - Piston 27C - Grease fitting
7 - Bolt
EX455 W3-4-3

TRACK ADJUSTER

Disassemble Track Adjuster

• Be sure to thoroughly read "Precautions for Disas-
sembly and Assembly" on page W1-1-1 before
starting the disassembly work.
WARNING
• Idler wheel with support weight: 263 kg (580 lb)
• Track adjuster weight: 218 kg (480 lb)
• Yoke weight: 30.5 kg (67 lb)
WARNING
Piston weight: 28.5 Kg (63 lb)
2. To remove piston (21) from release control cylinder
(2) simply inject some grease throught the hydrau-
lic adjuster valve until the piston is ejected.
NOTE - Check that surface piston does not show deep
scoring mark; check seals for satisfactory condition.

1. Remove 4 screws (7) and separate the front idler

assy (w/supports) from track adjuster. Remove the
screws (3) securing the yoke to spring support and WARNING
take out the yoke.
Track adjuster is assembled into machine with
: 30 mm high compressive load. Follow procedures rec-
ommended in Service Manual when assenbling
11 or disassembling this part.
1 12
10

NOTE - To disassemble/assemble the track adjuster

3 4 requires the use of portable hydraulic press 75297580
6 complete with its tool kit.
5
19 3. Identify the tool kit components prepare according
18
4
15
to the arrangement as shown.
7

WARNING
Plate weight: 16.5 kg (36 lb)
SM6922
Spring weight: 122 kg (269 lb)
Cylinder weight: 49.8 kg (110 lb)

WARNING
4. Activate the press to relieve nut (18) of the spring
Do not attempt to eject the piston from cylinder
load.
using compressed air.
5. Remove the spring pin (19) and unscrew the nut
and gradually reduce press action until spring load
is fully relieved.

SM6923

I - Track release spring E - Punch 75298551 H - Adaptor 75301294

G - Frame 75295567 A - Cylinder 75297580 L - Adaptor 75297574
W3-4-4 EX455

TRACK ADJUSTER

ASSEMBLE TRACK ADJUSTER

1
27B
11

12

27A

14
7 27C

5
18 27

15

16

21

27
SM6921

1 - Front idler wheel 8 - Shaft 15 - Plate 27 - Valve assembly

2 - Cylinder 11 - Support 16 - Spring 27A - Relief valve
5 - Spacer 12 - Spring pin 18 - Nut 27B - Extension
6 - Yoke 14 - Plug 21 - Piston 27C - Grease
7 - Bolt
EX455 W3-4-5

TRACK ADJUSTER

Assemble Track Adjuster

1. Use the tool Kit components and arrangement as shown.

SM6923

I - Track release spring E - Punch 75298551 H - Adaptor 75301294

G - Frame 75295567 A - Cylinder 75297580 L - Adaptor 75297574

WARNING
Plate weight: 16.5 kg (36 lb)
Spring weight: 122 kg (269 lb) 15
Cylinder weight: 49.8 kg (110 lb)

2. Prepare plate (15), spring (16) and cylinder (2) and 16

install in the tool arragment.
.
WARNING 2
Track adjuster is assemble into machine
with hight compressive load.

3. Activate the press until the spring reaches an

assembled length of 600 mm under a load of
20200 kg.
SM6925
W3-4-6 EX455

TRACK ADJUSTER

18 27A

7 27
SM6926

SECTION THROUGH RELEASE MECHANISM

7 - Screws securing the idler support

18 - Spring retaining nut
27 - Adjuster valve
27A - Pressure relief valve.
X = 600 mm under a load of 20200 Kg (44533 lb)

4. Lock the spring in position tighten the retaining nut

(18) and insert the spring pin (19) then neutralize
the press.

5. Fix the spacer (5) and yoke (6) to the plate (15) with
four screws (3).

: 30 mm
: 403 to 473 N•m
(41.1 to 48.3 kgf•m, 297 to 349 lbt•ft)

SM6927
EX455 W3-4-7

TRACK ADJUSTER

NOTE - Thoroughly clean the cylinder and piston

surface before assemble.

6. Check piston (21) and cylinder (2) surface are

without scoring marks.

7. As a general rule, replace the seals.

Install seals (17), (20) in the piston (21).
Apply a film of grease on seals. Insert piston (21)
in the cylinder (2). Apply grease to the grease
fitting.
Check the function of adjuster valve.

8. Fix the track adjuster on front idler wheel supports

(1) with four bolts (7).

: 30 mm
: 403 to 473 N•m
(41.1 to 48.3 kgf•m, 297 to 349 lbt•ft)
SM6928

3
4

5
19
14 18

4 15
7

SM6929
W3-4-8 EX455

TRACK ADJUSTER

NOTES
EX455 W3-5-1

FRONT IDLER

REMOVE AND INSTALL TRACK AD-

JUSTER AND FRONT IDLER

Before removing the track adjuster and the front idler,

the tracks must be removed first. For removal and
installation of the tracks, refer to applicable removal/
installation sections. In this section, the procedure
starts on the premise that the tracks has already been
removed.

Removal
WARNING
Track adjuster and front idler assembly
weight: 532 kg (1173 lb)

1. Swing superstructure 90° across of longitudinal

machine axis for easier access to track compo- 1
nents.

WARNING
Be sure cables are anchored and the anchor
point is strong enough to handle the expected
load. Keep exposed personnel clear of anchor
point and cables or chain.
SM1801

2. Using a special tool (1) as shown, remove the front

idler with track adjuster.

Installation

WARNING
Track adjuster and front idler assembly 1
weight: 532 kg (1173 lb)

WARNING
Be sure cables are anchored and the anchor
point is strong enough to handle the expected
load. Keep exposed personnel clear of anchor
point and cables or chain.

SM1802

1. Using a special tool (1) as shown, install the front

idler with track adjuster.
W3-5-2 EX455

FRONT IDLER

DISASSEMBLE AND ASSEMBLE

FRONT IDLE

SM6930

1 - Idler 7 - Bolt (4 used) 11 - Support (2 used)

3 - Bolt (4 used) 8 - Shaft 12 - Spring pin (2 used)
4 - Spring washer (8 used) 9 - Floating seal (2 used) 13 - Bushing (2 used)
6 - Yoke 10 - O-ring (2 used) 14 - Plug
EX455 W3-5-3

FRONT IDLER

Disassemble Front Idler Assemble Front Idler

• Be sure to thoroughly read "Precautions for Disas- 1. With a suitable tool install bushings on the wheel.
sembly and Assembly" on page W1-1-1 before
starting the disassembly work. 2. With necessary cautions reinstall the rotary lip
seals and O-ring.
• In this section, the procedure starts on the premise
that the track adjuster has already been removed.

1. Drain out oil through plug (14).

WARNING
Idler wheel weight: 188.6 kg (416 lb)
WARNING
Wheel support: 20.8 kg (46 lb)
Be sure to wear goggles or safety glasses
before performing any service work in which
flying pieces of metal or debris are anticipated,
especially before removing/installing pins. 3. Reinstall supports (11) to wheel on the shaft (8).
Insert roll pins (12).

4. Fix supports (11) to yoke (6) with bolts (7).

2. Remove roll pin (12) and, using a bridge type puller,
Tightening torque: 40.3 to 47.3 daNm
take wheel supports of the shaft (8).
(41.1 to 48.3 kgm)

5. Supply oil to the idler wheel through the plug hole.

WARNING Install plug.
Idler wheel weight: 188.6 kg (416 lb) Oil quantity: 0.450 kg
Wheel support: 20.8 kg (46 lb)

3. Pickup the rotary lip seals keeping their halves

paired to prevent mixups at reassembly.
Using a suitable drift, remove the bushings.

IMPORTANT - Only remove bushings if replacement

if necessary.
W3-5-4 EX455

FRONT IDLER

MAINTENANCE STANDARD

Front Idler

C D

A
B
SM6931

Unit: mm (in)

Standard Allowable Remedy

Limit

A 101 (3.98) 92 (3.62)

B 203 (7.99) - Cladding

by welding and finish
C 630 (24.80) 620 (24.41) or replace

D 674 (26.54) -

E 22 (0.87) -

Axle and Bushing

Unit: mm (in)

Standard Allowable Limit Remedy

Axle Outside Dia. 110 (4.33) 109.2 (4.30)

Replace
Bushing Inside Dia. 110 (4.33) 111 (4.37)
EX455 W3-6-1

UPPER AND LOWER ROLLER

REMOVE AND INSTALL UPPER ROLLER

Removal

WARNING
Do not loosen valve (1) quickly or loosen it too
much as high-pressure grease in the adjusting
cylinder may spout out. Loosen carefully, keeping
body parts and face away from valve (1).
Never loosen grease fitting (2).

SM1228

IMPORTANT - When gravel or mud is packed between

sprockets and tracks, remove it before loosening.

1. Loosen valve (1) to drain grease.

: 50 mm

SM6932

WARNING
Use a nonskid cloth between track frame (5) and oil 3
jack to prevent slipping.

2. Jack up tracks (3) heigh enough to permit upper

roller (4) removal.

SM1230
5 4

3. Insert wooden blocks between tracks (3) and track

frame (5).
3

5
SM1231
W3-6-2 EX455

UPPER AND LOWER ROLLER

4. Remove bolts (2) from upper roller (1).

: 27 mm

SM1232

WARNING
Upper roller weight: 32.5 kg (72 lb)

5. Remove upper roller (1) from track frame (3). 1

SM1233
3

Installation

WARNING
Upper roller weight: 32.5 kg (72 lb)

1. Install upper roller (1) and bolts (2).

1
: 27 mm
: 340 N m (34.7 kgf m, 250 lbf ft) 2

SM1233

2. Remove the wooden blocks and jack.

SM1230
EX455 W3-6-3

UPPER AND LOWER ROLLER

3. Supply grease to valve (1) to adjust tracks tension.

: 50 mm

SM6932

Check the track tension measuring the track sag (A)

as indicated in the TRACKS section.

Track sag specifications (A): 390 to 440 mm

(15.4 to 17.3 in)

NOTE - Check track sag after thoroughly removing soil

stuck on the track area by washing.

SM1234
W3-6-4 EX455

UPPER AND LOWER ROLLER

REMOVE AND INSTALL LOWER ROLLER

Removal

1. Remove the roller guard and loosen bolts (5).

5
: 32 mm

SM1236

2. Lift the one side of the track frame high enough to

remove the lower roller.
Insert wooden blocks under track frame (2).

SM1237

WARNING
Do not loosen valve (3) quickly or loosen it too much
as high-pressure grease in the adjusting cylinder
may spout out. Loosen carefully, keeping body
parts and face away from valve (3).
Never loosen grease fitting (4).

SM1228

3. Loosen valve (3) to drain grease enough to permit

the roller removal.

: 50 mm

SM6932
EX455 W3-6-5

UPPER AND LOWER ROLLER

WARNING
Lower roller weight: 74 kg (163 lb)

4. Securely hold the lower roller using a fork lift.

Remove lower roller (1).

1 SM1238

Installation
2 1
WARNING
Lower roller weight: 74 kg (163 lb)

1. Securely hold the lower roller using a fork lift.

Put lower rollers (1) on the tracks as illustration.

SM1239

2. Lower track frame (2) enough to allow bolts (4) to be

installed into track frame (2).
2 4

SM1240

3. Align tapped holes in track frame (2).

Tighten bolt (4).
: 32 mm
: 550 N m (56 kgf m, 405 lbf ft)

SM1236
W3-6-6 EX455

UPPER AND LOWER ROLLER

4. Supply grease to valve (3) to adjust tracks tension.

: 50 mm

SM6932

Check the track tension measuring the track sag (A)

as indicated in the TRACKs section.

Track sag specifications (A):

390 to 440 mm (15.4 to 17.3 in)

NOTE - Check track sag after thoroughly removing soil

stuck on the track area by washing.

SM1234
EX455 W3-6-7

UPPER AND LOWER ROLLER

NOTES
W3-6-8 EX455

UPPER AND LOWER ROLLER

DISASSEMBLE UPPER ROLLER

3
4
6 2

12
7

5 8

10

11

7
SM6933

1 - Socket Bolt (3 Used) 4 - O-Ring 7 - Roller 10 - Axle

2 - Plug 5 - Thrust Plate 8 - Bushing 11 - Bracket
3 - Cover 6 - Bushing 9 - Floating Seal 12 - Bolt (2 Used)
EX455 W3-6-9

UPPER AND LOWER ROLLER

Disassemble Upper Roller

• Be sure to thoroughly read "Precautions for Dis-

assembly and Assembly" on page W1-1-1 before
starting disassembly.

WARNING
Upper roller weight: 32.5 kg (72 lb)

1. Remove plug (2) to drain oil.

: 6 mm

2. Remove socket bolts (1) (3 used) and cover (3).

: 8 mm

3. Remove bolt (12) (2 used) and thrust plate (5).

: 17 mm

4. Remove axle (10) from roller (7).

5. Remove floating seal (9) from roller (7) and bracket

(11).

NOTE - Floating seal (9) can be reused if it is not worn.

Keep the floating seal in a matched set and put
cardboard between seals to protect the sealing face.

6. When replacing bushings (6) and (8), remove the

bushing from the roller by using a press and special
tool.
Bushings can also be removed by cladding four
SM6934
weld beads on the inside of bushing at 90° inter-
vals.
Bushing will shrink enough to permit removal using
a hammer.
W3-6-10 EX455

UPPER AND LOWER ROLLER

ASSEMBLE UPPER ROLLER

3 4 5 7 6 2 8 9 11 10

12
SM6935

1 - Socket Bolt (3 Used) 4 - O-Ring 7 - Roller 10 - Axle

2 - Plug 5 - Thrust Plate 8 - Bushing 11 - Bracket
3 - Cover 6 - Bushing 9 - Floating Seal 12 - Bolt (2 Used)
EX455 W3-6-11

UPPER AND LOWER ROLLER

Assemble Upper Roller

Before assembling:
• Clean all parts.
• Remove all scratches and roughness on the parts
using an oil stone.
• Replace all O-rings and seals with new ones.

IMPORTANT - Required pressing force to install

bushings (6) and (8) into roller (7) is 3 tons (6610 lb).

1. Install bushings (6) and (8) into roller (7) using a

press.

IMPORTANT - Apply a coat of grease to the O-ring part

of floating seal (9) and a film of hydraulic oil to the steel
ring part.
For handling of floating seal (9), refer to the section
"Floating Seal Precautions" on page W1-1-3.

2. Install floating seal (9) to roller (7) and to bracket

(11).

3. Insert axle (10) into roller (7).

4. Install thrust plate (5) to axle (10), tighten bolt (12)

(2 used).

: 17 mm
: 51.9 to 61.7 N•m
(5.3 to 6.3 kgf•m, 38.3 to 45.5 lbf•ft)

5. Apply grease to O-ring (4) and install it to cover (3).

6. Install cover (3) to roller (7), and tighten bolts (1) (3

used).

: 8 mm
: 51.9 to 61.7 N•m
(5.3 to 6.3 kgf•m, 38.3 to 45.5 lbf•ft)

7. Add oil via plug (2) hole on roller (7).

3
Oil quantity : 200 cm (0.21 US qt)

8. Apply sealant (LOCTITE 503 or equivalent) to plug

(2). Tighten plug (2) to roller (7).

: 6 mm
: 29 N•m (3 kgf•m, 22 lbf•ft)
W3-6-12 EX455

UPPER AND LOWER ROLLER

DISASSEMBLE LOWER ROLLER

1
2
8
4
5

6 2

7
6 SM6936

1 - Plug 4 - O-ring (2 Used) 7 - Roller

2 - Collar ( 2 Used) 5 - Floating Seal (2 Used) 8 - Axle
3 - Elastic pin (2 Used) 6 - Bushing (2 Used)
EX455 W3-6-13

UPPER AND LOWER ROLLER

Disassemble Lower Roller

2 5 7 5
Be sure to thoroughly read “Precautions for Disassem-
bly and Assembly” on page W1-1-1 before starting the
disassembly work.
5 2
1. Remove plug (1) from roller (7) and drain oil.
: 6 mm
2. Remove elastic pins (3) from collars (2).
SM1243
: 24 mm

3. Press down axle (8) until O-ring (4) comes out of

collar (2). 2
4
Remove collar (2) from axle (8).

4. Remove O-ring (4) from axle (8).

8
5. Remove floating seal (5) from roller (7) and collar
(2).

6. Press out axle (8) from roller (7), and remove collar SM1244

(2) and O-ring (4) from axle (8).

7. In case of replacing bushings (6), remove the

bushings using a press and the special tool. Spe-
cial Tool: (75301509). 75301509

SM1245
W3-6-14 EX455

UPPER AND LOWER ROLLER

ASSEMBLE LOWER ROLLER

7 8 1 6 5

4 3
2

3
SM6937

1 - Plug 4 - O-ring (2 Used) 7 - Roller

2 - Collar ( 2 Used) 5 - Floating Seal (2 Used) 8 - Axle
3 - Elastic pin (2 Used) 6 - Bushing (2 Used)
EX455 W3-6-15

UPPER AND LOWER ROLLER

Assemble Lower Roller

8 3
1. Install bushings (6) (2 used) onto roller (7) using a
press. Take care not to dent the flange surface of
bushings (6). Apply a coat of grease to O-ring (4)
and install onto axle (8).

2. Install collar (2) onto axle (8), aligning the pin holes.
Secure them using elastic pin (3). Take care not to 2 4 SM1247
damage O-ring (4).

7 5
IMPORTANT - The elastic pin has to be fitted with the
slit oriented to the internal side of the roller.

5 2
IMPORTANT - For handling of floating seal (5), refer to
the section “Floating Seal Precautions” on page W1-1-3.

3. Install floating seal (5) to roller (7) and to collar (2). SM1248

4. Insert axle (8) into roller (7). Install the other floating
seal (5) to roller (7) and to collar (2). Install O-ring 2 5 8 7
(4) and other collar (2). Secure them using elastic
pin (3).

IMPORTANT - The elastic pin has to be fitted with the

slit oriented to the internal side of the roller.
SM1249
4

5. Add oil via plug (1) hole. Apply sealant (LOCTITE

503 or equivalent) to plug (1). Tighten plug (1).
3 7
SAE 40 oil quantity: 555 cm3 (0.59 US qt)
: 6 mm
1
: 9,8 ÷ 19,6 N m (1 ÷ 2 kgf m)

SM1250
2
W3-6-16 EX455

UPPER AND LOWER ROLLER

MAINTENANCE STANDARD

Upper Roller

SM6938

Unit: mm (in)

Standard Allowable Remedy

Limit

A 103 (4.06) –
Cladding
B 190 (7.48) – by welding and finish
or replace
C 160 (6.30) 150 (5.91)

Axle and Bushing

Unit: mm (in)

Standard Allowable Limit Remedy

Axle Outside Dia. 60 (2.37) 59.2 (2.33)

Inside Dia. 60 (2.37) 61 (2.40) Replace

Bushing
Flange Thickness 4.5 (0.18) 3.7 (0.15)
EX455 W3-6-17

UPPER AND LOWER ROLLER

Lower Roller

SM6939

Unit: mm (in)

Standard Allowable Remedy

Limit

A 208 (8.19) –
Cladding
B 270 (10.63) – by welding and finish
or replace
C 31 (1.22) –

D 200 (7.87) 190 (7.48)

Axle and Bushing

Unit: mm (in)

Standard Allowable Limit Remedy

Axle Outside Dia. 85 (3.35) 84.2 (3.32)

Inside Dia. 85 (3.35) 86.0 (3.39) Replace

Bushing
Flange Thickness 6 (0.24) 5.2 (0.20)
W3-6-18 EX455

UPPER AND LOWER ROLLER

NOTES
EX455 W3-7-1

TRACKS

REMOVE AND INSTALL TRACKS 5

Removal

1. Move the tracks so that master pin (3) is positioned 4

over front idler (4).
Put a wooden block under track shoes (5), as
shown.
3

WARNING
Do not loosen valve (1) quickly on loosen too much
since high-pressure grease in the adjusting cylinder SM1254
may spout out.
Loosen carefully, keeping body parts and face away
from valve (1).
Never loosen grease fitting (2).

SM1253

2. To loosen the track tension, slowly turn valve (1)

counterclockwise one turn; grease will escape
from grease outlet.

: 50 mm

SM6940

Grease outlet 1
SM6941
W3-7-2 EX455

TRACKS

WARNING
The front idler may jump out of position due to strong
spring force when the tracks is disconnected. Espe-
cially, the strong spring force is always applied to
the bolt part of the rod. If the rod and/or the bolt are
damaged, metal fragments may fly off when the
tracks is disconnected.

SM1256

Spacer
3. Remove master pin (3) by using a special tool.

Bushing
3

A: 75294946 SM1257
B: 75295630
C: 75294975
D: 75294977
E: 75295759 D C 3 E
G: 75297580
3: MASTER PIN

G B A
SM1258

4. Slowly drive the machine in reverse until the whole

length of the removing track comes on the ground.

SM1259

5. Rotate the upperstructure 90 degrees toward the

removing track side, perpendicular to the tracks.
Operate the boom and arm so that the angle
between them is 90 to 110 degrees. Lower the
boom with the bucket rolled-in to jack up the
machine as illustrated. 90° ÷ 110°
Put wooden blocks under the track frame to safely
support the raised machine.

SM1260
EX455 W3-7-3

TRACKS

Installation

1. Jack up the machine and put the track under the

lower roller. Idler side Sprocket
Be sure to position the track in correct direction, as side
illustrated.

SM1261

2. Lift the track, and place it on sprocket (1).

SM1262

3. Slowly turn the sprocket in forward direction.

SM1263

3
4. Turn sprocket (1) until end of track (4) comes on
front idler (3).
Lower the machine and put a wooden block as
illustrated.

SM1264
W3-7-4 EX455

TRACKS

IMPORTANT - Hole surfaces, link holes and

counterbore surfaces, bushing ends, shall be free from Spacer
dust and rust.

5. Install master pin (5), using a hammer and special

Bushing
tool.
5

A: 75294946 SM1257

B: 75295630
C: 75294975
D: 75294977 D C 5 E
E: 75295759
G: 75297580
5: MASTER PIN

IMPORTANT - Inject rust preventive protective (ex. G B A

TECTYL165 G) between pin and bushing clearance. SM1258

IMPORTANT - If any links have been removed from

the track, be sure to charge the grease (es. AMBRA
MG2) into the clearance between the pin and bushing
when reconnecting the links. Also, apply a coat of
grease to the ends of the bushing.
Grease Charging Method:
- Stand the bushing on a flat plate.
- Fill the bushing bore with the grease.
- Insert the pin into the bushing while pushing the
bushing onto the plate (so that the bushing end stays
on the plate).
- Wipe off excess grease.

6. Supply grease to the cylinder through the grease

fitting to adjust the track tension.

: 50 mm

Check the track tension measuring the track sag (A)

as indicated in the pages to follow.

SM1265
EX455 W3-7-5

TRACKS

Checking track sag

• Turn the upperstructure 90° and lower the bucket to

raise one track off the ground as shown. 90° ÷ 110°

• Keep the angle between boom and arm 90° to 110°

and rest the bucket round side (outer) onto the
ground.
SM1260
• Place blocks under the frame to support the ma-
chine.

• Rotate the raised track in reverse two full rotations,

then forward two full rotations.

• Measure track sag (A) at the middle of the frame and

from the bottom of the track frame to the back face
of the track shoe. Distance (A) should be 390 to 440
mm.

NOTE: check track sag after thoroughly removing dirt

stuck on the track by pressure-washing.

Precautions for adjusting track sag

• If track sag is not within specification, loosen or

tighten the track following the procedures detailed
below.

• When adjusting track sag, lower the bucket to the

ground to raise one track off the ground. Repeat this
procedure to raise the other track. Place blocks
under the frame on the side of the raised track to SM1234

support the machine.

• After adjusting track sag of both tracks, move the

machine back and forth several times. Check track
sag again. If, after settling, this is not within
specifications repeat the above procedures until
correct sag is obtained.
W3-7-6 EX455

TRACKS

Loosening the track

WARNING
- Do not loosen the valve (1) quickly or too much as
grease pressure inside the cylinder might dan-
gerously eject it off its seat.
- Loosen the valve with care, keeping the body
parts and face away from the valve (1).
- Never loosen the grease fitting (2).

SM6940

IMPORTANT: remove any matter such as mud or

gravel possibly stuck between sprockets and track
links before loosening.

• To loosen the track, slowly turn valve (1) anticlock-

wise using a 50 mm long socket. The grease will
escape from the valve base.

• 1 to 1.5 turns of the valve (1) are sufficient to loosen

the track.
Grease Outlet 1
• If grease does not come out evenly, slowly rotate the
raised track. SM6941

• When proper track sag is obtained, turn valve (1)

clockwise and tighten it.

Tightening the track

WARNING
It is abnormal if the trac remains tight after turning
valve (1) anticlockwise or if the track is still loose
after charging grease through the grease fitting (2).
In such cases NEVER ATTEMPT TO DISASSEM-
BLE the track or the track adjuster due to danger-
ous high-pressure grease inside the track adjuster.
Contact your authorised FIAT KOBELCO Dealer
immediately.

• To tighten the track, inject grease from a grease gun

into fitting (2) until sag is within specification.
EX455 W3-7-7

TRACKS

MAINTENANCE STANDARD

Link Pin and Track Bushing

• Measure the length of four links, as illustrated, with

the tension on the track.
• Do not measure the master-pin included part of the
track.

SM1266
A

Unit: mm (in)

Standard Allowable Remedy

Limit

Buildup weld
A 864 (34) 882 (34.7) and finishing
or replace

IMPORTANT - Consult FIAT KOBELCO for any inqueries concerning welding procedures.

Master Pin

SM1269

Unit: mm (in)

Standard Allowable Remedy

Limit

A 242 (9.53) - Replace

B 44.4 (1.75) 41.7 (1.64) Replace

W3-7-8 EX455

TRACKS

Master Bushing

SM1267

Unit: mm (in)

Standard Allowable Remedy

Limit

A 148.3 (5.84) -

B 47.93 (1.89) 50.9 (2.00) Replace

C 71.4 (2.81) 66.4 (2.61)

Grouser Shoe

SM1268

Unit: mm (in)

Standard Allowable Remedy

Limit

A 253 (9.96) -

B 16.5 (0.65) - Replace

C 30 (1.18) 15 (0.59)
SECTION 4 EX455

FRONT ATTACHMENT

CONTENTS

Group 1 - Front attachment Group 2 - Cylinders

Hydraulic Circuit Pressure Remove and install cylinders ................. W4-2-1

Release Procedure ................................ W4-1-1
Remove and install front attachment ..... W4-1-3
Maintenance Standard .......................... W4-1-7
Bucket teeth ......................................... W4-1-9
Standard dimensions for arm and
bucket connection ............................... W4-1-10
Disassemble cylinders ......................... W4-2-12
Assemble cylinders .............................. W4-2-16
Maintenance Standard ......................... W4-2-20
Special Tools ........................................ W4-2-21
EX455 W4-1-1

FRONT ATTACHMENT

HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE

In case it is necessary to disconnect parts of the front attachment hydraulic system as result of a sudden stop of
the engine, due to some failure, it is required, prior to proceeding with any operation, to release the residual pressure
trapped in the cylinders.

WARNING
Pressure not released could cause serious injuries to the operator that would proceed in a
careless manner in the removal of connections or piping, being pressurised oil capable of penetrating the skin.

Check that the cylinders are at stroke end (the only position ensuring that there is no residual pressure) otherwise
proceed as follows:

1. Position all cylinders, as far as possible, at stroke

end, actuating the pilot valve levers, using the pilot
pressure made available by the accumulator equip-
ping the machine.

WARNING
Protect the body and face when loosening the
breather plug. Move carefully to eliminate
gradually the pressure inside.

2. Insert the wrench as shown and turn the wrench

clockwise and hold the wrench.

3. Turn cap counterclockwise about 30°, at which

point stop cap to release the air.

4. Turn cap further and remove cap.

SM6942

5. Identify the cylinder section from which it is neces-

sary to drain the oil to bring it to stroke end. Identify,
also, referring to the figure in the page that follows,
the relevant spool on the control valve.

6. Disconnect the pilot piping and the relevant con-

nection from the control valve port.

7. Screw slowly tool 75298783 on the control valve

port until the relevant cylinder is at stroke end.
Repeat the operation for the other cylinders requir-
ing it.

WARNING
Since it is not possible to have a direct control of
the movements of the arms from the position on
the machine where it is necessary to operate on
the control valve, the intervention of an assistant
is required.

8. Reconnect the components of the control valve

previously removed and proceed with the interven- SM6943
tions required on the front attachment.
W4-1-2 EX455

FRONT ATTACHMENT
NOTE - To release the residual pressure in the front or rear sleeve of an hydraulic cylinder, screw the tool in the
port of the control valve identified by the same number. Example: if pressure must be released from the rear sleeve
of the dipper stick cylinder identified by number (1), screw the tool in the control valve port identified as number
(1) in the figure below.

2
4

2
Front

Rear

Rear 1
5
MANIFOLD
6 (5-Spool Side View)
CONTROL VALVE CROSS Front
SECTION (5-Spool)

Rear
Rear

4 CONTROL VALVE
CROSS
MANIFOLD SECTION (4-Spool)
(4-Spool Side View) 3
SM6944
EX455 W4-1-3

FRONT ATTACHMENT

REMOVE AND INSTALL FRONT

ATTACHMENT

Preparation

Position the machin on flat ground.

Lower the bucket to the ground. SM1317

Stop the engine.

Move all control levers to release any pressure remain-
ing in the system.
Loosen the breather cover and bleed the air from the
oil reservoir (see W4-1-1).

Removal

1. Disconnect the lubrication hoses from the adaptors

on the end of the boom cylinder rods.

: 19 mm

SM6945

Ring
2. Remove the screws of the stop plate and the ring
of the pin connecting the rod eye and the boom
cylinder.

: 30 mm

Stop plate
WARNING
SM6946
Boom cylinder weight: 387 kg (853 lb)

3. Secure a cable to the boom cylinder.

WARNING
Prevent personal injury. Metal fragments may fly
off when a hammer is used to remove pins. Be sure
to wear necessary protection, such as goggles,
hardhat, etc. SM6947

4. Push-out the pin using a hammer so as to free the

cylinder rod.

5. Lower the right boom cylinder resting it on a stand.

Secure a cable to the other cylinder (left side) of the
boom.
Push the pin toward the opposite direction to
remove the left cylinder.
Lower the left cylinder.
SM6948
W4-1-4 EX455

FRONT ATTACHMENT

6. Loosen and remove the flange screws.

Disconnect the four hoses from the cylinder of the
arm and the bucket cylinder.

: 12 mm

7. Plug all openings to avoid the entry of dirt.

SM6949

8. Remove the two screws, the two spring washers

and the lock plate of the pin at the base of the boom.

: 30 mm

SM6950

9. Secure a lifting cable to the front attachment.

WARNING
Front Assembly weight: 8900 kg (19650 lb)

SM6951

10. Pull-out the pin at the base of the boom, using a

punch and hammer.

11. Remove the front attachment.

SM6952
EX455 W4-1-5

FRONT ATTACHMENT

Installation

WARNING
Front Assembly weight: 8900 kg (19650 lb)

1. Secure a lifting cable to the front attachment and

install the dust seals at the base of the boom.
SM6952
Align the boss of the base of the boom with the
boss on the main frame.

2. Install the pin at the base of the boom with a

hammer.
Install the lock plate with the screws and spring
washers.

: 30 mm
: 390 N•m (40 kgf•m, 290 lbf•ft)

SM6953

3. Remove the plugs used to avoid the entry of dirt.

Replace the O-rings and connect the hydraulic
hoses.

: 12 mm
: 108 N•m (11 kgf•m, 80 lbf•ft)

SM6949

WARNING
Boom cylinder weight: 387 kg (853 lb)

4. Lift the cylinders using a hoist.

Bring them near the pivoting point with the boom.

SM6954

5. Start the engine.

Align the holes on the side of the boom cylinders
with the hole in the center of the boom itself,
actuating the pilot valves to extend or retract the
rods.

SM6947
W4-1-6 EX455

FRONT ATTACHMENT

6. Install the pin from the left side with a hammer.

SM6955

7. Install the rings, lock plates and tighten the screws Ring
on both sides.

: 30 mm
: 490 N•m (50 kgf•m, 362 lbf•ft)

Stop plate
SM6956

8 Connect the lubrication hoses at the ends of the

boom cylinder rods.

: 19 mm
: 34 N•m (3.5 kgf•m, 25.5 lbf•ft)

SM6945
EX455 W4-1-7

FRONT ATTACHMENT

MAINTENANCE STANDARD

Pins and bushes

SM6957

Unit: mm

Pin Bush
Index Parts to be measured Remedy
ND WL ND WL

A Base of boom 120 119 120 121.5

B Boom cylinder head side 110 109 110 111.5

C Boom cylinder rod side 120 119 120 121.5

D Boom tip 120 119 120 121.5

E Arm cylinder rod side 110 109 110 111.5

Replace
F Arm cylinder head side 110 109 110 111.5

G Bucket cylinder head side 100 99 100 101.5

H Bucket cylinder rod side 110 109 110 111.5

I Tie rod "B" arm side 100 99 100 101.5

J Tie rod "A" arm side 110 109 110 111.5

K Arm bucket side 110 109 110 111.5

ND: Nominal Dimension WL : Wear Limit

W4-1-8 EX455

FRONT ATTACHMENT

Clearance between pins and bushes

SM6957

Unit: mm

Clearance between pin and bush

Index Parts to be measured Remedy
ND WL

A Base of boom 0.195 ~ 0.473 3.0

B Boom cylinder head side 0.150 ~ 0.450 3.0

C Boom cylinder rod side 0.150 ~ 0.450 3.0

D Boom tip 0.195 ~ 0.473 3.0

E Arm cylinder rod side 0.150 ~ 0.450 3.0

Replace
F Arm cylinder head side 0.150 ~ 0.450 3.0

G Bucket cylinder head side 0.150 ~ 0.450 3.0

H Bucket cylinder rod side 0.150 ~ 0.450 3.0

I Tie rod "B" arm side 0.195 ~ 0.480 3.0

J Tie rod "A" arm side 0.170 ~ 0.450 3.0

K Arm bucket side 0.159 ~ 0.435 3.0

ND: Nominal Dimension WL : Wear Limit

EX455 W4-1-9

FRONT ATTACHMENT

BUCKET TEETH

Replacement

WARNING
Keep people not involved in the maintenance work
outside the working area.
Wear adequate personal clothes and glasses with
side shields as a protection against flying debris.

• Ensure the machine is parked on a level surface. 1 2 3

5
• Rest the bucket to the ground.

• Switch off the auto-idle, fully turn the engine speed

manual control anticlockwise, stop the engine,
remove the ignition key and move the safety lever in
the locked position (LOCK).

• Using a hammer (3) and a drift (2), as shown, drive

the lock pin (1) from its seat and remove the tooth.

4 SM1329

NOTE: Hit the lock pin (1) with the drift (2) on the pin
tapered portion to drive it out of its seat.

• Clean shank (5) surface and install a new tooth (4)

onto the shank.

• Install the lock pin (1) into its seat and drive it in using
a drift (2) and a hammer (3) until it is fully seated.
W4-1-10 EX455

FRONT ATTACHMENT

STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION

d
e
f c
b
a

j
o p
k
i n

h m
g l
q

Section A Section B
SM1330

Unit: mm (in)

EX455 FH450.3

a (*) 530 (20.9) ←

b (*) 15 (0.59) ←

c 750 (29.5) ←

d 710 (28) ←

e 572 (22.5) ←

f 1869 (73.6) 1885 (74.2)

g 643 (25.3) ←

h 497 (19.6) 471 (18.5)

i 110 (4.33) ←

j 561 (22) ←

k 110 (4.33) ←

l 643 (25.3) ←

m 471 (18.5) ←

n 110 (4.33) ←

o 0° ←

p 45° ←

q 661 (26) ←

(*) Arm: 3840 mm

EX455 W4-2-1

CYLINDERS

REMOVE AND INSTALL CYLINDERS

WARNING
Escaping pressure hydraulic oil can penetrate the skin or eyes, causing serious injury. Avoid this hazard by
relieving pressure before disconnecting hydraulic lines.
Hydraulic oil may be hot after operation. Hot hydraulic oil may spout, possibily causing severe burns. Be sure
to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off due to internal pressure if turned quickly. Slowly turn the cap to release
internal pressure before completely removing the cap.

Preparation

1. Park the machine on a firm, level surface.

Lower the front attachment to the ground.
2. Stop the engine. Move all control levers to release
any pressure remaining in the system. Slowly turn
the hydraulic oil tank cap approx. 30 degrees
counterclockwise to release any remaining pres-
SM1317
sure from the hydraulic oil tank.

Remove Bucket Cylinder

1. Place a wooden block under the bucket cylinder.

SM6958

2. Remove the stop screw after loosening nut and

locknut.

: 32 mm

SM6959

3. Remove the pin using a punch and a hammer.

Recover the shims.

SM6960
W4-2-2 EX455

CYLINDERS

4. Secure a cable to the bucket cylinder to hold the

relevant rod.

SM6961

5. Disconnect the hoses from the bucket cylinder

removing the half-flanges.
Apply plugs to the cylinder ducts and to the hoses.
Disconnect, also, the bucket cylinder lubrication
pipings.

: 10 mm
: 19 mm SM6962

6. Lift the bucket cylinder with a hoist.

SM6963

WARNING
Bucket cylinder weight: 388 kg (855 lb)

7. Remove the screw from the stop block and pull-out

the pin, then remove the cylinder from the rear
sleeve side.
SM6964
: 32 mm
EX455 W4-2-3

CYLINDERS

Install Bucket Cylinder

WARNING
Bucket cylinder weight: 388 kg (855 lb)
SM6965

1. After checking the proper condition of the seals

and the surface of the bush, mount the cylinder on
the arm cylinder. Prior to this operation, block the
rod with a cable. Otherwise, the rod could come
out suddenly with the risk of injuries or damages to
components of the machine.

Align the sleeve side of the cylinder with the arm

cylinder.

SM6964

2. Install the pin ensuring the alignment between the

hole on the pin itself and the hole on the stop.
Install the screw M22 x 2.5 x 200 and tighten the
locknuts.
: 32 mm
: 540 N•m (55 kgf•m, 400 lbf•ft)

3. Remove the plugs placed on the pipes and the

cylinder. Connect the hoses to the cylinder using
the half-flanges previously removed and connect
the greasing hose. Always replace the O-rings.
: 10 mm
SM6966

: 108 N•m (11 kgf•m, 80 lbf•ft)

: 19 mm
: 34 N•m (3.5 kgf•m, 25.5 lbf•ft)

4. Lift the cylinder with a hoist.

Align the first two links one at a time, the cylinder
rod, the third link, the shims and the remaining link,
introducing the pin.

SM6967
NOTE - The total axial play must be 1.5 mm.

5. After placing the pin, ensuring the alignment of the

holes, introduce the screw.
Tighten the locking nuts.
: 32 mm
: 540 N•m (55 kgf•m, 400 lbf•ft)

SM6968
W4-2-4 EX455

CYLINDERS

Remove Arm Cylinder

1. Place a wooden block under the arm cylinder.

SM6969

2. Remove the screw and two nuts.

: 32 mm

SM6970

3. Remove the pin using a punch and hammer.

SM6971

4. Secure a cable to the arm cylinder so as to hold it.

SM6972

5. Disconnect the hoses from the arm cylinder.

Plug the cylinder steel pipes and the hoses.

: 12 mm

SM6973
EX455 W4-2-5

CYLINDERS

6. Remove the lubrication piping from the arm cylin-

der.

: 19 mm

SM6974

7. Lift the cylinder with a hoist.

WARNING
Arm cylinder weight: 656 kg (1446 lb)

SM6975

8. Remove the screw from the stop and the pin, then
remove the arm cylinder.

: 32 mm

SM6976
W4-2-6 EX455

CYLINDERS

Install Arm Cylinder

WARNING
Arm cylinder weight: 656 kg (1446 lb)

1. Inspect the conditions of the parts removed, re-

placing the components that result to be damaged
or worn.
Keeping the rod blocked with a cable preventing a
sudden extension, mount the cylinder on the
sleeve side to the boom. SM6977

2. Insert the pin and the screw.

Scew M22 x 2.5 x 200.
: 32 mm
: 540 N•m (55 kgf•m, 400 lbf•ft)

SM6976

3. Install the lubrication piping on the arm cylinder.

: 19 mm
: 34 N•m (3.5 kgf•m, 25.5 lbf•ft)

SM6974

4. Connect the hoses to the cylinder using the half-

flanges previously removed.
Always replace the O-rings when reassembling.
Half-flange screw M14 x 2
: 12 mm
: 17.5 N•m (18 kgf•m, 130 lbf•ft)

SM6973
EX455 W4-2-7

CYLINDERS

5. Lift the cylinder with a hoist, the align the rod of the
cylinder with the arm.

SM6975

6. Install the pin, the screw and tighten the nut and
locknut.
: 32 mm
: 540 N•m (55 kgf•m, 400 lbf•ft)

SM6976

SM6977
W4-2-8 EX455

CYLINDERS

Remove Boom Cylinder

1. Disconnect the lubrication piping from the cylinder

on the rod side.

: 19 mm

WARNING
Boom cylinder weight: 387 kg (853 lb)
SM6978

2. Hold the cylinder with a hoist.

SM6979

Ring
3. Remove the screws complete with spring wash-
ers, te remove the plate and the ring.
Using a punch and hammer, push back the pin.

: 30 mm

Stop plate

SM6980

4. Free the cylinder and lower it placing it on a stand.

Remove the pin on the opposite side and lower
completely the cylinder.
Recover the pin complete with stop plates and
washers.

SM6981
EX455 W4-2-9

CYLINDERS

5. Secure a cable to the cylinder to hold its rod.

(Operate in the same manner for both cylinders).

SM6982

6. Disconnect the hoses from the cylinders.

Plug the ends of the steel pipes on the cylinders
and the hoses.

: 36 mm, 41 mm

SM6983

7. Holding the cylinder from the sleeve side, remove

the screw complete with washer and spring
washer.
Pull-back the pin recovering the spacer.

: 30 mm

SM6984

WARNING
Boom cylinder weight: 387 kg (853 lb)

8. Remove the cylinder.

Remove the cylinder on the opposite side follow-
ing the same procedure.

SM6985
W4-2-10 EX455

CYLINDERS

Install Boom Cylinder

WARNING
Boom cylinder weight: 367 kg (853 lb)

1. Inspect the conditions of the parts removed, re-

placing the components that result to be damaged
or worn.
Lift the cylinder with a hoist, then align the lower
end with the main frame.
SM6985

2. Install the pin with the spacer, tightening the pin

through the screw, washer and spring washer.

: 30 mm
: 490 N•m (50 kgf•m, 362 lbf•ft)

SM6984

3. Install the cylinder on the opposite side following

the same procedure.

SM6983

4. Connect the hoses to the cylinders.

Always replace the O-rings and tighten the connec-
tions.

: 36 mm, 41 mm
: 205 N•m (21 kgf•m, 152 lbf•ft)

5. Start the engine running it at idle speed until the

hydraulic oil temperature is 50 ± 5°C (122 ± 9°F).
Lift the cylinder with two hoists, then align the rods
with the boom, operating the pilot valve for the
boom lifting.

SM6986
EX455 W4-2-11

CYLINDERS

6. Mount the pin until it engages the eye of the rods.

SM6979

Ring
7. Install on both sides the rings and lock plates.
Secure the lock plates with the screws and spring
washers.

: 30 mm
: 490 N•m (50 kgf•m, 362 lbf•ft)

Stop plate

SM6980

8. Connect the lubrication piping to the cylinder.

: 19 mm
: 34 N•m (3.5 kgf•m, 25.5 lbf•ft)

SM6981
W4-2-12 EX455

CYLINDERS

DISASSEMBLE CYLINDERS

Boom Cylinder

11 1 2 3 4 8 7 5 6 9 10

13 20 15 16 21 23 22
12

SM6987
14 19 16 17 18 20 19 24

Bucket Cylinder

11 1 2 3 4 8 7 5 6 9 10

13 20 15 16 20 21 22
12

19 16 17 18 19 24 23
SM6988

1 - Wiper Ring 7 - Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2 - Backup Ring 8 - Socket Bolt (8 Used) 14 - Cushion Seal 20 - Slide Ring (2 Used)
3 - U-Ring 9 - Backup Ring 15 - Piston 21 - Shim
4 - Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5 - Bushing 11 - Cylinder Rod 17 - Seal Ring 23 - Steel Ball
6 - Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut
EX455 W4-2-13

CYLINDERS

Disassemble Boom and Bucket Cylinders

Be sure to thoroughly read all the "Precautions for 5. Remove set screw (22) and steel ball (23).
Disassembly and Assembly" on page W1-1-1 before
starting the disassembly procedure.

The disassembly procedure below starts on the premi- NOTE - Cut away its mushroomed portion using a drill
se that the hydraulic lines and the line securing bands first, as set screw (22) was mushroomed with a punch
have been removed. and hammer at two places after it had been screwed
in.

: 6 mm (Boom cylinder)
WARNING
Approximate weights of the cylinders are as : 8 mm (Boom cylinder)
follows:
Boom cylinder: 387 kg (853 lb) 6. Loosen nut (24) using special tool (75298624).
Bucket cylinder: 388 kg (855 lb) Remove shim (21), piston (15) and cushion bearing
(13).
For the boom cylinder, also remove and cushion
1. Lift and securely place the cylinder on a workbench seal (14).
using a crane. Be sure that the cylinder is placed Nut Turning Special Tools:
horizontally. Drain hydraulic oil from the cylinder. (Boom): 120 mm (75298552)
(Bucket): 130 mm (75301638)

SM1366

SM1364
7. Remove slide rings (19), (20), backup rings (16),
seal ring (17) and O-ring (18) from piston (15).
2. Fully extend cylinder rod (11). Secure the rod end
using a crane. Remove socket bolts (8) from 8. Remove cylinder head (7) from cylinder rod (11).
cylinder head (7).
: 19 mm
9. Remove O-rings (10), backup rings (9) and (2) from
cylinder head (7). Then remove wiper ring (1), U-
ring (3), buffer ring (4), snap ring (6), and bushing
3. Pull out cylinder head (7) from cylinder tube (12) by (5).
tapping with a plastic hammer.

IMPORTANT - Be sure to pull cylinder rod (11)

straight so as not to damage the sliding surfaces.

4. Pull-out cylinder rod (11) and secure it on special

tool (75298624). Put matching marks between
cylinder rod (11) and nut (24).

75298624

SM1365
W4-2-14 EX455

CYLINDERS

Arm Cylinder

11 1 2 3 4 8 7 5 6 9 10

13 20 15 16 21 23 22
12

SM6987
14 19 16 17 18 20 19 24

1 - Wiper Ring 7 - Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2 - Backup Ring 8 - Socket Bolt (8 Used) 14 - Cushion Seal 20 - Slide Ring (2 Used)
3 - U-Ring 9 - Backup Ring 15 - Piston 21 - Shim
4 - Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5 - Bushing 11 - Cylinder Rod 17 - Seal Ring 23 - Steel Ball
6 - Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut
EX455 W4-2-15

CYLINDERS

Disassemble Arm Cylinder

Be sure to thoroughly read all the "Precautions for 5. Remove set screw (22) and steel ball (23).
Disassembly and Assembly" on page W1-1-1 before
starting the disassembly procedure.

The disassembly procedure below starts on the premi- NOTE - Cut away its mushroomed portion using a drill
se that the hydraulic lines and the line securing bands first, as set screw (22) was mushroomed with a punch
have been removed. and hammer at two places after it had been screwed
in.

WARNING
Arm cylinder weight: 656 kg (1446 lb) : 8 mm

1. Place the cylinder horizontally on a workbench
using a crane and secure it.
Drain hydraulic oil from the cylinder.
6. Loosen nut (24) using special tool (75298624).
Remove shim (21), piston (15) and cushion bearing
(13) and cushion seal (14).
Nut (24) Turning Special Tool:
(Arm): 135 mm (75298504)

SM1366
SM1364

7. Remove slide ring (19), (20), backup ring (16), seal

2. Fully extend cylinder rod (11). Secure the rod end ring (17) and O-ring (18) from piston (15).
using a crane. Remove socket bolts (8) from
cylinder head (7).
8. Remove cylinder head (7) from cylinder rod (11).
: 22 mm

9. Remove O-rings (10), backup rings (9) and (2) from

3. Pull out cylinder head (7) from cylinder tube (12) by
tapping with a plastic hammer.
IMPORTANT - Be sure to pull cylinder rod (11)
straight so as not to damage the sliding surfaces.
cylinder head (7). Then remove wiper ring (1), U-
ring (3), buffer ring (4), snap ring (6), and bushing
(5).

4. Pull-out cylinder rod (11) and secure it on special

tool (75298624). Put matching marks between
cylinder rod (11) and nut (24).

75298624

SM1365
W4-2-16 EX455

CYLINDERS

ASSEMBLE CYLINDERS

Boom Cylinder

Face the slit

toward the piston

Slit
Green
Black

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

22-23

24

SM6989
Be sure that oil groove faces the correct
direction when assembling

Bucket Cylinder

Slit
Green

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

22-23

24

Be sure that oil groove faces SM5524

the correct direction when assembling

1 - Wiper Ring 9 - Backup Ring 17 - Seal Ring

2 - Backup Ring 10 - O-Ring 18 - O-Ring
3 - U-Ring 11 - Cylinder Rod 19 - Slide Ring (2 Used)
4 - Buffer Ring 12 - Cylinder Tube 20 - Slide Ring (2 Used)
5 - Bushing 13 - Cushion Bearing 21 - Shim
6 - Snap Ring 14 - Cushion Seal 22 - Set Screw
7 - Cylinder Head 15 - Piston 23 - Steel Ball
8 - Socket Bolt (8 Used) 16 - Backup Ring (2 Used) 24 - Nut
EX455 W4-2-17

CYLINDERS

Assemble Bucket and Boom Cylinder

1. Install bushing (5) to cylinder head (7) using a
press.
Special tools for bushing installation:
(Boom): Ø 115 mm (75301683)
(Bucket): Ø 120 mm (75301774)
7. Install cushion bearing (13) to cylinder rod (11).
For boom cylinder only, install cushion seal (14).
Install piston (15) to cylinder rod (11).
8. Install shim (21) to cylinder rod (11). Tighten nut
(24) using special tool (75298624).

IMPORTANT - Be sure that the rings are installed 75298624

correctly.

2. Install U-ring (3), backup ring (2), snap ring (6), and
buffer ring (4) to cylinder head (7). SM1365

3. Install wiper ring (1) to cylinder head (7) using a Be sure to align the machine mark on the rod with
plastic hammer. that on the nut.
Special tools: Nut (24) Turning Special Tools:
(Boom): (75301663) (Boom): 120 mm (75298552)
(Bucket): (75301773) (Bucket): 130 mm (75301638)

4. Install O-rings (10) and backup ring (9) to cylinder

head (7). : 14300 N m (1460 kgf m, 10546 lbf ft)
(Boom)
: 20900 N m (2130 kgf m, 15414 lbf ft)
5. Install O-ring (18), backup ring (16) (2 used), seal (Bucket)
ring (17), slide ring (19) (2 used), (20) (2 used) to
piston (15).
Special tools for seals assembly: 9. Align the holes on cylinder rod (11) and nut (24).
(Boom): (75301664) Insert steel ball (23) into the hole, and tighten set
(Bucket): (75301664) screw (22) into the hole.
Mushroom the head of set screw (22) at two places
using a punch and hammer.
: 6 mm (Boom)
: 56.9±10.7 N m
(5.8±1.09 kgf m, 42±7.9 lbf ft)
: 8 mm (Bucket)
: 96.6 N m
15 (9.85 kgf m, 71.2 lbf ft)

SM1367
IMPORTANT - Be sure to align cylinder rod (11) with
6. Install cylinder head (7) to cylinder rod (11).
the center of cylinder tube (12) when inserting, in order
Special tools:
to avoid damaging the rings.
(Boom): (75301776)
(Bucket): (75301775)
10. Secure cylinder tube (12) horizontally using a work
bench. Insert cylinder rod (11) into cylinder tube (12).

IMPORTANT - Be sure that the cushion seal slit faces 11. Install cylinder head (7) to cylinder tube (12).
toward the piston and that the cushion bearing oil Tighten socket bolts (8).
groove faces the correct direction. : 19 mm
: 1140±206 N m
(116±21 kgf m, 841±152 lbf ft)
W4-2-18 EX455

CYLINDERS

Arm Cylinder

Face the slit

toward the piston

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

22-23

24

SM6989
Be sure that oil groove faces the correct
direction when assembling

1 - Wiper Ring 9 - Backup Ring 17 - Seal Ring

2 - Backup Ring 10 - O-Ring 18 - O-Ring
3 - U-Ring 11 - Cylinder Rod 19 - Slide Ring (2 Used)
4 - Buffer Ring 12 - Cylinder Tube 20 - Slide Ring (2 Used)
5 - Bushing 13 - Cushion Bearing 21 - Shim
6 - Snap Ring 14 - Cushion Seal 22 - Set Screw
7 - Cylinder Head 15 - Piston 23 - Steel Ball
8 - Socket Bolt (8 Used) 16 - Backup Ring (2 Used) 24 - Nut
EX455
CYLINDERS
Assemble Arm Cylinder
1. Install bushing (5) to cylinder head (7) using a
press.
Special tools for bushing installation:
Ø 130 mm (75301786)
IMPORTANT- Be sure that the rings are installed
correctly.
2. Install U-ring (3), backup ring (2), buffer ring (4), and
snap ring (6) to cylinder head (7).
3. Install wiper ring (1) to cylinder head (7) using a
plastic hammer.
Special tools for wiper ring installation:
(75301324)
4. Install O-rings (10) and backup ring (9) to cylinder
head (7).
5. Install O -ring (18) buckup ring (16)(2 used), seal
ring (17), slide ring (19)(2 used), (20)(2 used),to
piston (15).
Special tool for seals assembly: (75301772)
15
SM1367
6. Install cylinder head (7) to cylinder rod (11).
Special tools for cylinder head installation:
(75301785)
IMPORTANT - Be sure that the cushion seal slit faces
toward the piston and that the cushion bearing oil
groove faces the correct direction.
7. Install cushion seal (14) to cylinder rod (11). Install
cushion bearing (13) and piston (15) to cylinder rod
(11).
W4-2-19
8. Install shim (21) to cylinder rod (11). Tighten nut
(24) using special tool (75298624).
75298624
SM1365
Be sure to align the machine mark on the rod with
that on the nut.
Nut Turning Special Tools: 135 mm (75298504)
: 27300 N m (2780 kgf m, 20134 lbf ft)
9. Align the holes on cylinder rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
screw (22) into the hole.
Mushroom the head of set screw (22) at two places
using a punch and hammer.
: 8 mm
: 96.6 N m (9.85 kgf m, 71.2 lbf ft)
IMPORTANT - Be sure that the cushion seal slit faces
toward the piston and that the cushion bearing oil
groove faces the correct direction.
IMPORTANT - Be sure to keep cylinder rod (11)
aligned with the center of cylinder tube (12) when
inserting, in order to avoid damaging the rings.
10.Secure cylinder tube (12) horizontally using a vise.
Insert cylinder rod (11) into cylinder tube (12).
11.Install cylinder head (7) to cylinder tube (12).
Tighten socket bolts (8).
: 22 mm
: 1560±294 N m
(162±30 kgf m, 1150±217 lbf ft)
W4-2-20 EX455

CYLINDERS

MAINTENANCE STANDARD

Rod

Unit: mm (in)
Cylinders STANDARD (A) Remedy
Boom 115 ± 0.025 (4.53 ± 0.001)
Replace or
Arm 130 ± 0.025 (5.12 ± 0.001) plate with
Bucket 120 ± 0.025 (4.72 ± 0.001) chromium
EX455 W4-2-21

CYLINDERS

SPECIAL TOOLS

Piston nut socket wrench:

75298552 for boom cylinders (120 mm)

75301638 for bucket cylinder (130 mm)
75298504 for arm cylinder (135 mm)

SM1366

Use nut loosening/tightening workbench: 75298624

Tools kit seals installation:

75301664 for boom cylinders

75301664 for bucket cylinder
75301772 for arm cylinder

SM1369

Wiper installation tool:

75301663 for boom cylinders

75301773 for bucket cylinder
75301324 for arm cylinder
SM1370

Bushing installation tool:

75301683 for boom cylinders (Ø 115 mm)

75301774 for bucket cylinder (Ø 120 mm)
75301786 for arm cylinder (Ø 130 mm)
SM1371

Head installation tool:

75301776 for boom cylinders

75301775 for bucket cylinder
75301785 for arm cylinder
SM1372
W4-2-22 EX455

CYLINDERS

NOTES
SECTION 5
ENGINE AND ACCESSORY
CONTENTS
Group 1 - General Information
General Repair Instructions .................... W5-1-1
External View ......................................... W5-1-3
Main Data and Specifications ................. W5-1-4
Performance Curve ................................ W5-1-6
Service Standards ................................. W5-1-7
Nut and Bolt Angular Tightening
Method .............................................. W5-1-13
Torque Specifications ........................... W5-1-15
Standard Bolt Torque Specifications ..... W5-1-22
Recommended Thread Locking
Agents .............................................. W5-1-24
Lubricant Applications .......................... W5-1-25
Sealant Applications ............................ W5-1-25
Special Tools ........................................ W5-1-26
Identification (Engine Serial Number) ... W5-1-28
Group 2 - Maintenance
Lubrication System ................................ W5-2-1
Fuel System .......................................... W5-2-1
Injection Timing Adjustment ................... W5-2-2
Injection Nozzle ..................................... W5-2-3
Air Bleeding ........................................... W5-2-4
Feed Pump Strainer ............................... W5-2-5
Fuel Tank ............................................... W5-2-5
Cooling System ..................................... W5-2-5
Valve Clearance Adjustment .................. W5-2-6
Compression Pressure Measure ............ W5-2-8
Recommended Lubricants ...................... W5-2-9
Engine Oil Viscosity Chart ..................... W5-2-9
Group 3 - Engine Overhaul
Service Precautions ............................... W5-3-1
General Description ................................ W5-3-1
Fan Center ............................................. W5-3-3
Turbocharger .......................................... W5-3-5
Exhaust Manifold ................................... W5-3-7
Inlet Manifold ......................................... W5-3-8
EX455
Water pump .......................................... W5-3-11
Alternator ............................................. W5-3-13
Oil Cooler ............................................. W5-3-14
Injection Pump ..................................... W5-3-16
Coupling Assembly .............................. W5-3-20
Cylinder Head ...................................... W5-3-23
Rocker Arm and Shaft Assembly ......... W5-3-42
Camshaft ............................................. W5-3-46
Timing Gears ....................................... W5-3-50
Flywheel Housing ................................. W5-3-58
Oil Pan ................................................. W5-3-61
Piston .................................................. W5-3-64
Crankshaft ........................................... W5-3-77
Crank Pulley ........................................ W5-3-87
Flywheel .............................................. W5-3-90
Cylinder Block ...................................... W5-3-92
Group 4 - Engine Lubrication
Service Precautions ............................... W5-4-1
General Description ................................ W5-4-1
Oil Pump ................................................ W5-4-3
Oil Cooler ............................................... W5-4-9
Group 5 - Engine Cooling
Service Precautions ............................... W5-5-1
General Description ................................ W5-5-1
Water Pump ........................................... W5-5-2
Thermostat ............................................ W5-5-7
Group 6 - Engine Fuel
Service Precautions ............................... W5-6-1
General Description ................................ W5-6-1
Fuel Filter ............................................... W5-6-4
Injection Nozzle Holder .......................... W5-6-6
Injection Pump ..................................... W5-6-11
SECTION 5 EX455

Group 7 - Engine Induction

Service Precautions ............................... W5-7-1
Turbocharger .......................................... W5-7-1

Group 8 - Starting and Charging

Service Precautions ............................... W5-8-1
Alternator ............................................... W5-8-1
Starter Motor ....................................... W5-8-10

Group 9 - Troubleshooting
Hard Starting ......................................... W5-9-1
Unstable Idling ....................................... W5-9-2
Insufficient power ................................... W5-9-3
Excessive fuel consumption .................. W5-9-4
Excessive oil consumption .................... W5-9-4
Engine cooling Trouble............................ W5-9-5
White Exhaust Smoke ........................... W5-9-5
Black Exhaust Smoke ........................... W5-9-5
Lubrication Problems ............................. W5-9-6
Abnormal Engine Noise .......................... W5-9-7
Alternator ............................................... W5-9-8
Starter Motor ......................................... W5-9-9
Turbocharger ........................................ W5-9-10

NOTE: Before using this section to perform maintenance and repairs, be sure to read the paragraph "General
Repair Instructions" included in Group 1 (General Information).
EX455 W5-1-1

GENERAL INFORMATION

GENERAL REPAIR INSTRUCTION

1. Before performing service operations, disconnect the ground cable from the battery to reduce the chance of
cable damage and burning due to short circuiting.

2. The use of proper tools and special tools, where specified, is important for efficient and reliable performance
of service repairs.

3. When replacement parts are required, consult the appropriate FIAT KOBELCO PARTS CATALOG.

4. Used cotter pins, plastic clips, gaskets, O-rings oil seals, lock washers, and self-locking nuts should be
discarded and new ones should be installed. Normal function of the parts cannot be maintained if these parts
are reused.

5. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping
fixing nuts and bolts separate is very important, as they vary in hardness and design depending on position
of installation.

6. Use identification labels or tags to mark valves, bearings, and pistons, to prevent confusing their proper order
and sequience.

7. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air, and make
certain they are free from restrictions.

8. Lubricate rotating and sliding faces of the parts with oil or grease before installation.

9. When necessary, use a sealer on gaskets to prevent leakage.

10. Carefully observe all specifications for nut and bolt torques.

11. When a service operation is completed, make a final check to be sure the service has been done properly and
the problem has been corrected.

12. Allow the engine to cool before beginning any service procedure.
This will eliminate the danger of fire and possible injury.

13. Hot steam under pressure may escape from the radiator if the coolant is drained while the engine is hot. This
can result in serious burns. Allow the engine to cool before draining the coolant.

14. The engine and engine oil can reach high working temperatures. Therefore, while carrying out this operation
with the engine still hot, the body must be protected with suitable clothing and protections to avoid burns and
personal injuries.

15. While working around a running engine, avoid contact with moving parts and hot surfaces to prevent injury.

16. Wear safety glasses when using compressed air. Flying particles may cause eye injury.

17. Always wear safety goggles when working with fuel to protect the eyes from fuel splash.
W5-1-2 EX455

GENERAL INFORMATION

18. Test fluid from the injection nozzle tester will spray out of the injection nozzle under great pressure.
It can easily puncture a person's skin.
Keep your hands away from the injection nozzle at all times.

19. Do not use your fingers to feel for fuel leaks at fittings. Fuel pressure is high enough to penetrate the skin.

20. Be careful when changing fuel system components: Diesel fuel is flammable. Be sure that the ignition key of
OFF. Do not smoke or allow open flame in the area while changing fuel system components.

21. Measurements are indicated by “standard” or “limit”:

- a “standard” value refers to the standard values at time of assembly;
- a “limit” value is a maximum or minimum: measurements up to that value are usable.
Measurement falling beyond that value mean the part must be serviced, adjusted, or replaced.

22. Directional indications adopted within this manual are as follows:

- Front: Toward the cooling fan when viewed from the flywheel side;
- Left: Toward the fuel injection pump when viewed from the flywheel side;
- Right: Toward the exhaust manifold when viewed from the flywheel side;
- Rear: Toward the engine’s flywheel side.

23. “Cylinder numbers” and “Engine rotation direction”: Cylinder numbers are counted in sequence beginning from
the front side of the engine.
As a result, the first cylinder at the very front of the engine is cylinder No. 1, while the last cylinder toward the
rear is cylinder No. 6. The direction of engine rotation is clockwise when viewed from the cooling fan side.

Left

Flywheel

Front
Rear

Right

Exhaust manifold Cooling fan

24. Maintenance procedure call for use of Special or Commercial Tools, where necessary.
The Special Tools required or recommended are identified by an ISUZU Part Number.
Any Special Tools are available in Europe making a purchase order to the following:

IED MAESA
BOOMSESTENWEG 42B
2630 AARTSELAAR
BELGIUM
EX455 W5-1-3

GENERAL INFORMATION

ENGINE EXTERNAL VIEW

Fuel pump Oil dipstick

Injection pump Fuel filter

Coupling cover Starter motor

Oil drain plug Water outlet pipe

Breather hose

Exhaust manifold Turbocharger Inlet duct

Cooling fan Fan pulley

Alternator Crank pulley

Water pump
Water draing plug Water inlet pipe

Oil port cover Thermostat housing

Oil filler cap
PCV

SM7700
W5-1-4 EX455

GENERAL INFORMATION

MAIN DATA AND SPECIFICATIONS

ITEMS 6WG1TQA

Engine type Four cycle, water cooled, in-line, overhead camshaft,

direct injection

Combustion chamber Open type in piston crown

Cylinder liner Dry type
Timing drive system Gear drive
No. of cylinders - bore x stroke mm (in) 6 - 147 x 154 (5.79 x 6.06)
Rated output kW/min-1 235.4/1800
Max. torque Nm/min-1 1274.9/1500
No. of piston rings Four rings (Compression rings: 3, Oil ring: 1)
Total piston displacement L (cid) 15.681 (956.9)
Compression ratio (to 1) 16.4
Compression pressure at 200 min-1
MPa (kg/cm2/psi) 2.94 (30/426) or more
Engine dimensions mm (in) 1,642 x 1007 x 1,287 (64.6 x 39.6 x 50.7)
Engine weight (Dry) kg (lb) 1,252 (2,764)
Fuel injection order 1-5-3-6-2-4
Fuel injection timing (TDC) deg 10
Specified fuel type SAE No.2 diesel fuel
Idling speed min-1 900
Valve clearances Intake mm (in) 0.40 (0.016)
Exhaust mm (in) 0.40 (0.016)
Intake valves Open at (BTDC) deg 21
Close at (ABDC) deg 27
Exhaust valves Open at (BBDC) deg 52
Close at (ATDC) deg 17
Injection pump Bosch, in-line P-Type
Governor type Mechanical
Injection nozzle Multi-hole type
Injection nozzle opening pressure
MPa (kg/cm2/psi) 19.9 (203/2,886)
Main fuel filter type Paper element
Lubrication system
Lubrication method Full flow pressure circulation
Specified engine oil (API grade) CD
Oil pressure (at oil gallery)
kPa (kg/cm2/psi)/min-1 300 (3.1/44.1)/1,200
390 (4.0/56.9)/2,000
Condition: SAE 30 API CD grade engine oil at an
oil temperature of 80 °C (176 °F)
Oil pump type Gear (Timing gear drive)
EX455 W5-1-5

GENERAL INFORMATION

ITEMS 6WG1TQA

Relief valve opening pressure

2
kPa (kg/cm /psi)
st
1 stage 440 (4.5/64.0)
nd
2 stage 690 (7.0/99.5)

Oil pressure switch operating pressure

2
kPa (kg/cm /psi) 10 (0.1 /0.7)
Main oil filter type Paper element
Bypass valve opening pressure
2
kPa (kg/cm /psi) 200 (2.0/28.4)
Oil volume L (qts) 52 (55) with combined main and partial oil filter
Oil cooler Plate type - Water cooled in water jacket
Oil thermostat opening temperature
°C (°F) 98.0 (208)
Cooling system Pressured compulsory circulation water
Coolant volume L (qts) 36 (38)
Water pump type Centrifugal impeller, Gear drive
Delivery volume
L/min (Imp. gal/US gal) 420 (92.4/111.0) Pump speed at 2,840 rpm
Thermostat type Wax pellet
Valve initial opening temperature °C (°F) 82 (180)
Valve lift mm (in) 11.0 (0.433)
Air cleaner
Alternator capacity V-A 24 - 50 Mitsubishi
Regulator type IC (Built-in)
Brush length mm (in) Brush less
Starter motor output V - kW 24 - 7 Mitsubishi
Number of poles 4
Turbocharger model RHC 92
Manufacturer Ishikawajima Harima Heavy Industry (IHI)
W5-1-6 EX455

GENERAL INFORMATION

PERFORMANCE CURVE

Condition
Break in period Fully Air cleaner Non
Cooling fan Ø850 Exhaust silencer Non
Alternator No load Ambient condition Standard

Torque (Nm)
Power Output (kW)

SFC (g/kWh)

2000

Engine Speed (min-1)

SM7701
EX455 W5-1-7

GENERAL INFORMATION

SERVICE STANDARDS

ITEMS SERVICE STANDARD SERVICE LIMIT

ENGINE
Compression Pressure
MPa(kg/cm2/psi)/min-1 27.5 (28 /400)/200 21.6 (22/312)
or more, after warm up
the engine

CYLINDER HEAD and VALVE

Camshaft End Play mm (in) 0.085-0.170 (0.0033-0.0067) 0.25 (0.0098)
Clearance between Camshaft and
Bracket mm (in) 0.065-0.125 (0.0026-0.0049) 0.15 (0.0059)
Idle Gear "C" End Play mm (in) 0.05 - 0.14 (0.0020-0.0055) 0.25 (0.0098)
Clearance between Shaft and
Idle "C" Gear mm (in) 0.04 - 0.105 (0.0016-0.0041) 0.2 (0.0079)
Valve Spring Free Height
Inlet mm (in) 79.3 (3.1220) 75.3 (2.965)
Exhaust
Outer mm (in) 102.7 (4.0433) 97.6 (3.843)
Inner mm (in) 96.5 (3.7992) 91.7 (3.6102)
Valve Spring Squareness
Inlet mm (in) 3.5 (0.1378) 4.8 (0.1890)
Exhaust
Outer mm (in) 4.5 (0.1772) 6.2 (0.2441)
Inner mm (in) 4.2 (0.1654) 5.9 (0.2323)
Valve Spring tension
Inlet N (kg/lb)/mm 392 (40.0/88.2)/64 372 (37.9/83.6)/64
Exhaust
Outer N (kg/lb)/mm 610 (62.2/137)/69 579 (59.0/130)/69
Inner N (kg/lb)/mm 224 (22.8/50.3)/66 213 (21.7/47.8)/66
Valve Stem and Guide Clearance
Inlet mm 0.040 - 0.077 0.15
(in) (0.0016 - 0.0030) (0.0059)
Exhaust mm 0.065 - 0.102 0.25
(in) (0.0026 - 0.0040) (0.0098)
W5-1-8 EX455

GENERAL INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

Valve Stem Outside Diameter

Inlet mm (in) 10.0 (0.3937) 9.92 (0.3906)
Exhaust mm (in) 10.0 (0.3937) 9.90 (0.3898)
Bridge Guide and Bridge Clearance mm (in) 0.020 - 0.057 (0080-0.002) 0.10 (0.0039)
Valve Thickness
Inlet mm (in) 2.14 (0.0843) 1.64 (0.0646)
Exhaust mm (in) 2.3 (0.0906) 1.8 (0.0709)
Valve Depression
Inlet mm (in) 1.9 (0.0748) 2.9 (0.1142)
Exhaust mm (in) 1.8 (0.0709) 2.8 (0.1102)
Valve Contact Width
Inlet mm (in) 3.3 (0.1299) 3.7 (0.1457)
Exhaust mm (in) 2.6 (0.1024) 3.0 (0.1181)
Valve Contact Surface Angle
Inlet deg 30 –
Exhaust deg 45 –
Valve Seat Angle
Inlet deg 30 –
Exhaust deg 45 –
Valve Bridge Guide Upper End Height mm (in) 49.0 (1.9291) –
Valve Guide Upper End Height
Inlet mm (in) 27.0 (1.0630) –
Exhaust mm (in) 29.0 (1.1417) –

ROCKER ARM AND CAMSHAFT

Rocker Arm Shaft Run Out mm (in) – 0.3 (0.012)
Rocker Arm Shaft Outside Diameter mm 27.979 - 28.000 27.85
(in) (1.1015 - 1.1024) (1.0965)
Rocker Arm Bushing Inside Diameter mm 28.020 - 28.053
–
(in) (1.1031 - 1.1044)
Rocker Arm and Rocker Arm Shaft
Clearance mm 0.020 - 0.074 0.2
(in) (0.0008 - 0.0029) (0.0079)
Rocker Arm Roller and Pin Clearance
mm 0.036 - 0.069 0.15
(in) (0.0014 - 0.0027) (0.0059)
Camshaft Journal Diameter mm 39.915 - 39.940 38.89
(in) (1.5715 - 1.5724) (1.57047)
Cam Height (Nose Height)
Inlet mm (in) 9.4 (0.3700) 8.85 (0.3484)
Exhaust mm (in) 10.4 (0.4094) 9.75 (0.3839)
Camshaft Run Out mm (in) 0.080 (0.0031) 0.100 (0.0039)
Camshaft Bearing Inside Diameter mm 40.015 - 40.040
–
(in) (1.5754 - 1.5764)
Clearance Camshaft and Cam Bearing
mm 0.065 - 0.125 0.15
(in) (0.0026 - 0.0049) (0.0059)
EX455 W5-1-9

GENERAL INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

TIMING GEAR TRAIN

Idle Gear Backlash mm 0.095 - 0.135 0.25
(in) (0.0037- 0.0053) (0.0098)
Idle Gear End Play
"A" mm 0.155 - 0.220 0.35
(in) (0.0061 - 0.0089) (0.0138)
"B" mm 0.050 - 0.140 0.25
(in) (0.0020 - 0.0055) (0.0098)
"C" mm 0.050 - 0.140 0.25
(in) (0.0020 - 0.0055) (0.0098)
Idle Gear Spindle Outside Diameter
"A" mm 56.93 - 56.96 56.85
(in) (2.2413 - 2.2425) (2.2382)
"B" mm 141.93 - 141.96 141.85
(in) (5.5878 - 5.5890) (5.5846)
"C" mm 48.93 - 48.96 48.85
(in) (1.9264- 1.9286) (1.9232)
Clearance Between Idle Gear and
Spindle
"A", "B", "C" mm 0.040 - 0.105 0.20
(in) (0.0015 - 0.0041) (0.0079)

CRANKSHAFT
Crankshaft End Play mm (in) 0.10 - 0.28 (0.0039-0.0110) 0.35 (0.0138)
Crankshaft Journal Diameter
No.4 mm 104.850 - 104.875
–
(in) (4.1279 - 4.1289)
Others mm 104.880 - 104.905
–
(in) (4.1291 - 4.1309)
Crankpin Diameter mm 91.895 - 91.925
–
(in) (3.6179 - 3.6191)
Crankshaft Run Out mm (in) 0.120 (0.0005) 0.15 (0.0059)
Crankshaft End Play mm 0.10 - 0.28 0.30
(in) (0.0039 - 0.0110) (0.0121)
Crank Bearing Spread mm (in) – 111.5 (4.3898)
Clearance Crankshaft journal and
Bearing
No.4 Journal mm 0.075 - 0.150 0.16
(in) (0.0030 - 0.0059) (0.0063)
Others mm 0.045 - 0.120 0.16
(in) (0.0018 - 0.0047) (0.0063)
W5-1-10 EX455

GENERAL INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

PISTON AND CONNECTING ROD

Piston Ring Gap
1st, 3rd mm 0.35 - 0.50
(in) (0.0138 - 0.0197)
2nd mm 0.80 - 0.95
1.00 (0.0394)
(in) (0.0315 - 0.0374)
Oil mm 0.30 - 0.50
(in) (0.0118 - 0.0197)
Clearance Piston Ring and Groove
1st mm 0.115-0.160 0.24
(in) (0.0045 - 0.0063) (0.0094)
2nd, 3rd mm 0.10 - 0.135 0.20
(in) (0.0039 - 0.0053) (0.0079)
Oil mm 0.025 - 0.065 0.15
(in) (0.0010 - 0.0026) (0.0059)
Piston Pin Diameter mm 55.995 - 56.000 55.970
(in) (2.2015 - 2.2047) (2.2035)
Clearance Piston Pin and Hole mm 0.008 - 0.021 0.05
(in) (0.0003 - 0.0008) (0.0020)
Clearance Connecting Rod Small End
Bushing and Piston Pin mm 0.020 - 0.037 0.10
(in) (0.0008 - 0.0015) (0.0039)
Connecting Rod Alignment mm (in) 0.05 (0.002) or less 0.10 (0.0039)
Clearance Crankpin and Connecting
Rod Bearing mm 0.033 - 0.103 0.16
(in) (0.0013 - 0.0041) (0.0063)
Clearance Connecting Rod and
Crankshaft mm 0.175 - 0.290 0.35
(in) (0.0069 - 0.0114) (0.0138)
Clearance Piston and Cylinder Liner mm 0.166 - 0.200
–
(in) (0.0065 - 0.0079)

PISTON AND CYLINDER LINER GRADE

Cylinder Measuring point mm (in) 130 (5.1181)
Cylinder Liner Inside Diameter mm 147.011 - 147.030
–
(in) (5.7878 - 5.7886)
Piston Measuring Point from
Piston Top mm (in) 113 (4.4488) –
Piston Outside Diameter mm 146.830 - 146.845
–
(in) (5.7807 - 5.7813)
Clearance Cylinder Liner and Cylinder
Block mm 0.001 - 0.030
(in) (0.00004 - 0.00118)
EX455 W5-1-11

GENERAL INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

CYLINDER BLOCK AND CYLINDER

LINER GRADE
Cylinder Block Bore Diameter
Grade
"1" mm 151.600 - 151.610
–
(in) (5.9685 - 5.9689)
"2", "3" mm 151.611 - 151.630
–
(in) (5.9689 - 5.9697)
Cylinder Liner Outside Diameter
Grade
"1X" mm 151.590 - 151.599
–
(in) (5.9681 - 5.9685)
"3X" mm 151.600 - 151.610
–
(in) (5.9685 - 5.9689)

CYLINDER BODY
Cylinder Liner Bore Nominal Measurement
mm (in) 147.0 (5.7874) 147.3 (5.7992)
Cylinder Block Upper Face Warpage mm (in) 0.0075 (0.0030) or less 0.2 (0.008)
Cylinder Liner Projection mm 0.05 - 0.09
–
(in) (0.0020 - 0.0035)
Projection Height Between Adjacent
Cylinder mm (in) 0.02 (0.0008) or less –

LUBRICATING SYSTEM
Clearance Oil Pump Body and Driven
Gear mm 0.050 - 0.098 0.15
(in) (0.0020 - 0.0039) (0.0059)
Side Clearance Oil Pump Cover and
Gear mm 0.040 - 0.094
–
(in) (0.0016 - 0.0037)
Oil Pump Gear Shaft Diameter mm (in) 20.0 (0.7874) 19.9 (0.7835)
Clearance Oil Pump Gear Shaft and
Body mm 0.040 - 0.074
–
(in) (0.0015 - 0.0029)
An Interference Oil Pump Drive Gear
and Driven Gear mm 0.019 - 0.047
–
(in) (0.0007 - 0.0019)
Oil Thermostat Opening Temperature °C (°F) 98.0 (208.4)
–

ENGINE COOLING SYSTEM

Clearance Water Pump Impeller and
Pump Body mm 1.7 - 2.7 3.2
(in) (0.0669 - 0.1063) (0.1260)
Thermostat Opening Temperature
Initial Opening °C (°F) 82 (180.0) –
Full Opening °C (°F) 95 (203.0) –
Thermostat Full Valve Lift mm (in) 11 (0.433) –
W5-1-12 EX455

GENERAL INFORMATION

ITEMS SERVICE STANDARD SERVICE LIMIT

ENGINE ELECTRICAL
Alternator
Rotor Coil Resistance Ohm 11.7 –
Starter Motor
Commutator Undercut mm (in) 0.5 (0.197) 0.2 (0.0079)
Commutator Outside Diameter mm (in) 32 (1.26) 31.4 (1.24)
Brush Length mm (in) 18 (0.709) 11 (0.43)

TURBOCHARGER
Turbine Shaft End Play mm 0.075 - 0.110 0.12
(in) (0.0030 - 0.0043) (0.0047)
Clearance Turbine Shaft and Bearing mm 0.130 - 0.235 0.275
(in) (0.0051 - 0.0093) (0.0108)
EX455 W5-1-13

GENERAL INFORMATION

NUT AND BOLT ANGULAR TIGHTENING

METHOD
Line
The angular tightening method uses the plastic region
of high tensile steel nuts and bolts to precision tighten
important engine fasteners.
Because of the method’s nature, there is a limit to the
number of times a particular fastener may be reused.
This limit is specified in this Manual where applicable.
1. Carefully wash the nuts and bolts to remove all oil
and grease.
2. Apply a coat of molybdenum disulfide grease to the
threads and setting faces of the nuts and bolts.
3. Tighten the nuts and bolts to the specified torque
(snug torque) with a torque wrench.
4. Draw a line A – B across the center of each nut SM7002
or bolt.
6. Draw another line F – G on the face of each of
Center line the parts to be clamped. This line will be in the
direction of the specified angle Q across the
center E of the nut or bolt.

Specified angle

SM7001

5. Draw another line C – D on the face of each of

the parts to be clamped. This line should be an
extension of the line A – B . Coincide line
SM7003
W5-1-14 EX455

GENERAL INFORMATION

7. Use a socket wrench to tighten each nut or bolt to

the point where the line A - B is aligned with the line
F - G.

Tighten

SM7004

Example: Specified Angle and Tightening Rotation

A 30° 1 / 12 of a turn
B 60° 1 / 6 of a turn
C 90° 1 / 4 of a turn
D 180° 1 / 2 of a turn
E 360° One full turn

SM7005
EX455 W5-1-15

GENERAL INFORMATION

TORQUE SPECIFICATIONS

Auxiliary Parts N•m (kgf•m/Ib ft)

118(12/87)

103(10.5/76)

52(5.3/38)

SM7702
W5-1-16 EX455

GENERAL INFORMATION

Engine External Parts N•m (kgf•m/Ib ft)

43(4.4/32)
52(5.3/38)

39(4.0/29)

88(9.0/65)
108(11/80)

43(4.4/32)
20(2.1/14)

50(5.1/37)

39(4.0/29)
43(4.4/32)

SM7703
EX455 W5-1-17

GENERAL INFORMATION

Cylinder Head N•m (kgf•m/Ib ft)

20 (2.05/14.8)

15 (1.5/11)

90 (9.2/67) 49(5.0/36)
Apply engine oil

137 (14/101)

M18: 177 (18/130)

→ 245 (25/181)
→ 60°~90°
M12: 76 (7.7/57)
M10: 38 (3.9/28)
M18: Apply molybdenum
disulfide grease
M12, M10: Apply engine oil

Apply engine oil

39(4.0/29)

Apply Loctite FMD-127

SM7704
W5-1-18 EX455

GENERAL INFORMATION

Oil Pan N•m (kgf•m/Ib ft)

69(7.0/51)

55(5.6/41)

38(3.8/28)

25(2.5/18)

SM7705
EX455 W5-1-19

GENERAL INFORMATION

Timing Gears N•m (kgf•m/Ib ft)

135(13.8/100)

49(5.0/36)

39(4.0/29)

Apply Loctite FMD-127

39(4.0/29)

108(11.0/80)

52(5.3/38)

46(4.7/34)

22(2.2/16)

96(9.8/71)

267(27.2/197)
Apply engine oil

SM7706
W5-1-20 EX455

GENERAL INFORMATION

Flywheel N•m (kgf•m/Ib ft)

136(13.8/100)

136(13.8/100)

Apply Loctite
FMD-127

136(13.8/100)

M14: 123(12.5/90)
M8: 22(2.2/16)

78(8.0/58)→60°→30° 136(13.8/100)

Apply molybdenum disulfide grease

SM7707
EX455 W5-1-21

GENERAL INFORMATION

Piston, Connecting Rod, Crankshaft N•m (kgf•m/Ib ft)

98(10/72)→30°→30°
Apply molybdenum disulfide grease

M12: 96(9.8/71)
Apply engine oil

M18: 49(5/36)→88(9/65)→105°
Apply molybdenum disulfide grease

SM7708
W5-1-22 EX455

GENERAL INFORMATION

STANDARD BOLT TORQUE SPECIFICATIONS

The tightening torque values given in the table below are applicable to all bolts unless otherwise specified.

Standard bolt
N•m (kgf•m/lb•ft)

Bolt
Identif.

Bolt
Diameter
x pitch
(mm)

M6 x 1.0 4 - 8 (0.4 - 0.8/3 - 6) 5 - 10 (0.5 - 1.0/4 - 7) –––––––

M8 x1.25 8 - 18 (0.8 - 1.8/6 - 13) 12 - 23 (1.2 - 2.3/9 - 17) 17 - 30 (1.7 - 3.11/2-22)

M10 x 1.25 21 - 34 (2.1 - 3.5/5 - 25) 28 - 46 (2.8 - 4.7/20 - 33) 37 - 62 (3.8 - 6.4/28 - 46)

* M10 x 1.5 20 - 33 (2.0 - 3.4/15 - 25) 28 - 45 (2.8 - 4.6/20 - 33) 36 - 60 (3.7 - 6.1/27- 44)

M12 x 1.25 49 - 74 (5.0 - 7.5/36 - 54) 61 - 91 (6.2 - 9.3/45 - 67) 76 - 114 (7.7 - 11.6/56 - 84)

* M12 x 1.75 45 - 69 (4.6 - 7.0/33 - 51) 57 - 84 (5.8 - 8.6/42 - 62) 72 - 107 (7.3 - 10.9/53 - 79)

M14 x 1.5 77 - 115 (7.8 - 11.7/56 - 85) 93 -139 (9.5 - 14.2/69 - 103) 114 - 171 (11.6 - 17.4/84 - 126)

* M14 x 2.0 72 - 107 (7.3 - 10.9/53 - 79) 88 - 131 (9.0 - 13.4/65 - 97) 107 - 160 (10.9 - 16.3/79 - 118)

M16 x 1.5 104 - 157 (10.6 - 16.0/77 - 116) 135 - 204 (13.8 - 20.8/100 - 150) 160 - 240 (16.3 - 24.5/118 -177)

* M16 x 2.0 100 - 149 (10.2 -15.2/74 -110) 129 - 194 (13.2 -19.8/96 - 143) 153 - 230 (15.6 - 23.4/113 -169)

M18 x 1.5 151 - 226 (15.4 - 23.0/110 - 166) 195 - 293 (19.9 - 29.9/144 - 216) 230 - 345 (23.4 - 35.2/169 - 255)

* M18 x 2.5 151 - 226 (15.4 - 23.0/110 - 166) 196 - 294 (20.0 - 30.0/145 - 217) 231 - 346 (23.6 - 35.5/171 - 255)

M20 x 1.5 206 - 310 (21.0 - 31.6/152 - 229) 270 - 405 (27.5 - 41.3/199 - 299) 317 - 476 (32.3 - 48.5/234 - 351)

* M20 x 2.5 190 - 286 (19.4 - 29.2/140 - 211) 249 - 375 (25.4 - 38.2/184 - 276) 293 - 440 (29.9 - 44.9/216 - 325)

M22 x 1.5 251 - 414 (25.6 - 42.2/185 - 305) 363 - 544 (37.0 - 55.5/268 - 401) 425 - 637 (43.3 - 64.9/313 - 469)

* M22 x 2.5 218 - 328 (22.2 - 23.4/161 - 242) 338 - 507 (34.5 - 51.7/250 - 374) 394 - 592 (40.2 - 60.4/291 - 437)

M24 x 2.0 359 - 540 (36.6 - 55.0/265 - 398) 431 - 711 (43.9 - 72.5/318 - 524) 554 - 831 (56.5 - 84.7/409 - 613)

* M24 x 3.0 338 - 507 (34.5 - 51.7/250 - 374) 406 - 608 (41.4 - 62.0/299 - 448) 521 - 782 (53.1 - 79.7/384 - 576)

An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting.
EX455 W5-1-23

GENERAL INFORMATION

The tightening torque values given in the table below are applicable to all bolts unless otherwise specified.

Flanged head bolt

N•m (kgf•m/lb•ft)

Bolt
Identif.

Bolt
Diameter
pitch
(mm)

M6 x 1.0 5 - 9 (0.5 - 0.9/4 - 7) 6 - 12 (0.6 - 1.2/4 - 9) –––––––

M8 x 1.25 11 - 20 (1.1 - 2.0/8 - 15) 15 - 28 (1.6 - 2.9/12 - 21) 18 - 34 (2.1 - 3.4/15 - 25)

M10 x 1.25 23 - 39 (2.4 - 3.9/17 - 28) 35 - 59 (3.6 - 6.1/26 - 44) 42 - 71 (4.3 - 7.2/31 - 52)

* M10 x 1.5 22 - 37 (2.3 - 3.8/17 - 28) 35 - 58 (3.5 - 5.8/25 - 42) 40 - 67 (4.1 - 6.8/30 - 49)

M12 x 1.25 55 - 82 (5.6 - 8.4/40 - 61) 77 - 117 (7.9 - 11.9/57 - 86) 85 - 128 (8.7 - 13.0/63 - 94)

* M12 x 1.75 51 - 77 (5.2 - 7.8/38 - 56) 71 - 107 (7.3 - 10.9/53 - 79) 80 - 119 (8.1 - 12.2/59 - 88)

M14 x 1.5 83 - 125 (8.5 - 12.7/62 - 92) 115 - 172 (11.7 - 17.6/85 - 127) 123 - 185 (12.6 - 18.9/91 - 137)

M14 x 2.0 77 - 116 (7.9 - 11.8/57 - 85) 108 - 162 (11.1 - 16.6/80 - 120) 116 - 173 (11.8 - 17.7/85 - 128)

M16 x 1.5 116 - 173 (11.8 - 17.7/85 - 128) 171 - 257 (17.4 - 26.2/126 - 190) 177 - 265 (18.0 - 17.1/130 - 196)

* M 16 x 2.0 109 - 164 (11.2 - 16.7/81 - 121) 163 - 244 (16.6 - 24.9/120 - 180) 169 - 253 (17.2 - 25.8/124 - 187)

A bolt with an asterisk (*) is used for female screws that are made of soft materials such as cast iron.
W5-1-24 EX455

GENERAL INFORMATION

RECOMMENDED THREAD LOCKING

AGENTS

LOCTITE Type LOCTITE Color

LOCTITE 242 Blue

LOCTITE 262 Red

LOCTITE 271 Red

Application Steps

1. Completely remove all lubricant and moisture from

the bolts and the female-threaded surfaces of the
parts to be joined. The surfaces must be perfectly
dry.

2. Apply LOCTITE to the bolts.

Apply LOCTITE to at least 1/3

of the bolt’s threaded area

SM7014

3. Tighten the bolts to the specified torque. After

tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until the
LOCTITE hardens.

NOTE: When the application procedures are speci-

fied in this manual, follow them.
EX455 W5-1-25

GENERAL INFORMATION

LUBRICANT APPLICATIONS

Name of Lubricant Lubrication for Application

Engine Oil Turbocharger bearings
Inside of camshaft bracket
Idle gear shaft & fixing bolt
Bridge
Rocker arm
Camshaft cam nose
Crank pulley fixing bolt threads and seating face
Inside and outside of cylinder liner
Connrod bearing sliding face
Crankshaft bearing sliding face
Thrust bearing
Piston and piston rings
Piston pin
Molybdenum disulfide grease Crankcase fixing bolt threads and seating face
Cylinder head fixing bolt thread and seating face
Connrod bearing fixing bolt thread and seating face

SEALANT APPLICATIONS

Location
Name of sealant
Name of part Name of mating part
1 Crankcase Cylinder block Loctite FMD-127
2 Gearcase Cylinder block Loctite FMD-127
3 Flywheel housing Cylinder block Loctite FMD-127
4 Gearcase Cylinder head Loctite FMD-127
5 Gearcase Upper cylinder block Loctite FMD-127
6 Upper and lower gearcase Cylinder head Loctite FMD-127
7 Crankcase Gearcase Cemedyn LG-010L
8 Crankcase Flywheel housing Cemedyn LG-020L
9 Oil cooler Cylinder block Three Bond 1207C
10 Nozzle sleeve Cylinder head Loctite TL290
Loctite No. 271 or
11 Thermometer unit threads Cylinder head
Three Bond No. 1241
Loctite No. 271 or
12 Oil pressure switch threads Cylinder block Three Bond No. 1241
W5-1-26 EX455

GENERAL INFORMATION

SPECIAL TOOLS

TOOL NO. TOOL NO.

ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

1-8523-0013-0 1 -8522-1187-0
Remover; Installer; Valve stem
Nozzle holder seal for intake

1-8531 -7019-0 1-85221-184-0

Adapter; Installer; Valve stem
Compression gauge seal for exhaust

5-8840-0266-0 1 -8522-1025-0
Angle gauge Setting tool;
Piston ring

1 -8523-5013-0 1 -8521 -0027-0

Compressor; Remover;
Valve spring Slinger

9-8523-1202-0 1 -8522-0059-0
Remover; Setting tool;
Valve guide/installer Piston

9-8522-1324-0 1 -8522-0043-0
Installer; Installer;
Valve bridge guide Oil seal
EX455 W5-1-27

GENERAL INFORMATION

TOOL NO.
ILLUSTRATION
TOOL NAME

1 -8521 -0064-0
Remover;
Crankshaft gear

1 -8522-0045-0
Installer;
Crankshaft gear

1 -8521 -0062-0
Remover;
Impeller
11.3 ± 0.1

1 -8522-0047-0
Installer;
Seal Unit

1 -8521 -0067-0
Puller;
Seal ring

1 -8522-1034-0
Installer;
Seal ring
W5-1-28 EX455

GENERAL INFORMATION

IDENTIFICATION

Engine Serial Number

The engine serial number is stamped on the front, upper area of the cylinder block.

Engine model Serial number

6WG1 000000

SM7709
EX455 W5-2-1

SERVICE INFORMATION

LUBRICATION SYSTEM 2. Before installing a new fuel filter, apply fuel to the
gasket of the cartridge.
Oil filter replacement 3. Turn the fuel filter until the filter gasket comes in
contact with the sealed face.
1. Set a filter wrench to the cartridge and remove the 4. Use the filter wrench to turn in the fuel filter an
oil filter. additional 2/3 of a turn.
Discard the used cartridge.
2. Before installing the new oil filter, apply engine oil
to the gasket of the cartridge.
3. Turn the oil filter until the filter gasket comes in
contact with its sealed face.
4. Use the filter wrench to turn in the oil filter an
additional one full turn.

SM7018

NOTE: Be careful not to spill the fuel remaining in the

fuel filter when the filter is removed. After changing the
fuel filter element, conduct fuel air bleeding and check
for fuel leaks.
SM7710

FUEL SYSTEM

Fuel filter replacement procedure

1. Use a filter wrench to remove the cartridge. Dis-

card the used cartridge.

SM7711
W5-2-2 EX455

SERVICE INFORMATION

INJECTION TIMING ADJUSTMENT

Injection Timing inspection

1. Disconnect the negative battery cable.

2. Rotate the crankshaft in the normal direction of
engine rotation to align the injection timing mark on
the damper with the timing pointer on the front
cover.
• Injection Timing (Static-TDC): 10 degree

SM7714

3. Loosen the two coupling bolts.

SM7714

3. Check that the timing advancer notched line is

aligned with the injection pump notched line.
If the notched lines are out of alignment, the
injection timing must be adjusted. SM7716

4. Move the timing advancer to the correct timing.

5. Tighten the two coupling bolts.
Torque: 88 N•m (9.0 kgm/65 Ibft)

6. Rotate the crankshaft two turns in the normal

direction of engine rotation.
7. Verify the new setting is the correct injection
timing.
8. Connect the negative battery cable.

SM7715

Injection Timing Adjustment

1. Rotate the crankshaft in the normal direction of

engine rotation until the timing mark on the timing
advancer can be seen.
2. Align the injection timing mark on the damper with
the pointer on the front cover.
SM7715
EX455 W5-2-3

SERVICE INFORMATION

INJECTION NOZZLE

Opening Pressure and Spray Condition Check

1. Use an injection nozzle tester to check the nozzle

opening pressure.
If the opening pressure is above or below the
specified value, the injection nozzle must be re-
placed or adjusted.
Refer to “Adjustment of Injection Nozzle Opening
Pressure” of ENGINE FUEL.

Injection Nozzle Opening Pressure:

19.9 MPa (203 kg/cm2 / 2 886 psi)

SM7020

Injection Nozzle Adjustment

1. Attach the injection nozzle holder to the injection

nozzle tester.
2. Apply pressure to the nozzle tester.
Note the pressure at which the injection nozzle
opens.
Injection Nozzle Opening Pressure:
19.9 MPa (203 kg/cm2 / 2 886 psi)

An adjusting shim of 0.007 mm (0.0003 in) allows the

press to change by about 98 kPa (1.0 kg/cm2 / 14.2 psi).
The adjusting shim thickness calculation method as
follows.
SM7019
The adjusting shim thickness calculation method.

P x π/4 x (A2 - B2)

= Shim thickness (mm)
WARNING C
Test fluid from the injection nozzle tester will spray
out of the injection nozzle under great pressure. It P (kPa) = (Target injection nozzle opening
can easily puncture a person’s skin. Keep your pressure - Indicated value (pres-
hands away from the injection nozzle at all times. sure) of nozzle tester)
A (cm) = Needle diameter 0.6 cm
B (cm) = Sheet diameter 0.3 cm
2. Check the spray condition. C (N/mm) = Spring constant 264.0 N/mm
If the spray condition is bad, the injection nozzle
must be replaced or reconditioned.
(1) Correct
(2) Incorrect (Restrictions in orifice)
(3) Incorrect (Dripping)

If lapping is required, refer to “Nozzle Lapping

Procedure” of ENGINE FUEL.
W5-2-4 EX455

SERVICE INFORMATION

After calculating shim thickness, select shims from AIR BLEEDING

below list.
Adjusting Shim Availability mm • Make sure that draining plug (3) and air bleeding
Thickness Part number plug (2) on water separator (1) are tightened. If air
bleeding plug (2) is not tightened, air is not expelled
0.50 5-15339-007-0
from the fuel system.
0.52 5-15339-018-0
• Loosen air bleeding plug (4) on the fuel filter.
0.54 5-15339-019-0
0.56 5-15339-020-0 • Loosen knob (5) of the fuel pump, actuate the
plunger until no air bubbles are seen in the fuel.
0.58 5-15339-021-0
0.60 5-15339-008-0 • Tighten air bleeding plug (4) on the fuel filter. Actuate
the fuel pump plunger until the effort becomes stiff.
0.70 5-15339-009-0
0.80 5-15339-010-0 • Press knob (5) of the fuel pump downwards and
tighten it.
0.90 5-15339-011-0
1.00 5-15339-012-0 • Start the engine and run it at low idle.
0.10 8-94128-982-0 • Check the fuel system leakages.
0.20 8-94128-983-0
0.30 8-94128-984-0
0.40 8-94128-985-0 4
2

OM1355a

OM1355b
EX455 W5-2-5

SERVICE INFORMATION

FEED PUMP STRAINER COOLING SYSTEM

• Remove connection (2) from fuel pump body (1). Fan Belt Inspection

• Remove filter (3) from connection joint (2) using a Check the drive belt tension. Depress the drive belt
screwdriver. mid-portion with a 100 N (10 kg/22 lb) force.

• Clean filter (3) using compressed air. Drive Belt Deflection: 8 - 12 mm (0.31 - 0.47 in)

• Install and tighten filter (3) in connection (2).

• Install and tighten connection (2) on fuel pump body

(1), then bleed the air from the fuel system.

3 2

SM7717

Check the drive belts for cracking and other damage.

1
2

OM1371

SM7027

FUEL TANK DRAINING

1. Remove the drain plug at the bottom of the fuel

tank.
2. Allow sufficient time for the sediment and water to
drain completely.
3. Reinstall the drain plug.
W5-2-6 EX455

SERVICE INFORMATION

VALVE CLEARANCE ADJUSTMENT

The following instructions assume that valve clear-

ance is adjusted beginning with the No. 1 piston at top
dead center (TDC) on the compression stroke.
Check the alignment timing mark between the timing
advancer and the mark line on the injection pump
body. If the timing marks are aligned, the No. 1 piston
is at TDC on the compression stroke.
Valve clearance must be adjusted when the engine is
cold.
When removing the head cover, wipe off spilled oil
with a rag.
1. Bring the piston in the No. 1 or No. 6 cylinder to the
top dead center on the compression stroke by
turning the crankshaft until the T.D.C. line on the
SM7718
damper is aligned with the timing pointer on the
front cover.
Check the rocker arm shaft bracket nuts for loose-
ness and retighten as necessary before adjusting Valve Clearance: 0.4 mm (0.0016 in)
the valve clearance.
b. Insert a feeler gauge between the rocker arm
and the bridge and adjust the valve clearance
by turning the adjusting screw on the rocker
arm until there is a sight drag on the feeler
gauge. Tighten the lock nut securely.

SM7714

2. Check that the No. 1 intake and exhaust rocker

arms have play. If they have play, it indicates that
the No. 1 piston is at TDC (Top Dead Center) on SM7719

the compression stroke. If the No. 1 exhaust

valves are depressed, the No. 6 piston is at TDC
on the compression stroke.
3. Adjust valve clearances for the No. 1 or No. 6
cylinder which its piston is at TDC on compression
stroke.
a. Loosen each adjusting screw on the bridge and
rocker arm.
c. With a feeler gauge inserted, screw in the
adjusting screw on the bridge gradually until it
touches the end of the valve stem. Make sure
that the movement of the feeler gauge be-
comes stiff.
EX455 W5-2-7

SERVICE INFORMATION

d. In this condition, the opposite end of the bridge

is raised. Readjust by loosening the adjusting
screw on the bridge until there is a slight drag No. 6 cylinder T. D. C.
on the feeler gauge. Tighten the lock nut se- (compression stroke)
curely.

No. 1 cylinder T. D. C.
(compression stroke)

Front

SM7031

Front
NOTE: Be sure to move the No. 1 cylinder to TDC on
the compression stroke after completing the valve
SM7030
clearance adjustment procedure.

Torque: 79 N•m (8.0 kg•m/58 Ib•ft)

4. Rotate the crankshaft 360 degrees and realign the
Rocker Arm Adjusting Screw Nut
T.C. mark on the flywheel with the pointer. Adjust
Torque: 54 N•m (5.5 kg•m/40 lb•ft)
clearance for remaining valves.
Bridge Adjusting Screw Nut
The “•” mark in the illustration indicates the cylin-
ders and valves to be adjusted.

Intake and Exhaust Valve Arrangement

Cylinder No. 1 2 3 4 5 6
Valve Names I E I E I E I E I E I E
No. 1 cylinder at TDC on compression O O O O O O
No. 6 cylinder at TDC on compression O O O O O O

I : Intake valve E: Exhaust valve

W5-2-8 EX455

SERVICE INFORMATION

COMPRESSION PRESSURE MEASURE

To measure the compression pressure, the engine

must be cold. Engine coolant temperature should be
at 20 °C. Battery and starter motor condition must be
normal.
1. Remove the injection nozzle assembly and the
injection fuel pipe from the each cylinder, using
nozzle holder remover: 1-8523-0013-0.

SM7723

4. Crank the engine with starter motor (about

200 min-1) and take the compression gauge read-
ing.
5. Repeat the procedure (Steps 2 to 4) for the
remaining cylinders.
Compression Pressure
Standard: 2.94 MPa (30.0 kg/cm2 / 426 psi)
SM7722
Limit: 2.26 MPa (23.0 kg/cm2 / 327 psi)

Compression pressure should be approximately

2. Install the compression gauge adapter 5-8531- the same for each cylinder.
7019-0 to the No. 1 cylinder injection nozzle A variation exceeding 200 kPa (2.0 kg/cm2 /
installation hole. 28 psi) is unacceptable.
3. Install the compression gauge to the compression
gauge adapter.
EX455 W5-2-9

SERVICE INFORMATION

RECOMMENDED LUBRICANTS

ENGINE TYPE TYPE OF LUBRICANT (API)

Diesel engine oil

With turbocharger
CD grade

ENGINE OIL VISCOSITY CHART

ENGINE OIL VISCOSITY GRADE-AMBIENT TEMPERATURE

[Single grade]

Ambient
temperature (5ºF) (59ºF) (77ºF) (86ºF)

[Multi-grade]

SM7033
W5-2-10 EX455

SERVICE INFORMATION

NOTE:
EX455
ENGINE OVERHAUL
SERVICE PRECAUTION
CAUTION
Always use the correct fastener in the proper loca-
tion. When you replace a fastener, use ONLY the
exact part number for that application. ISUZU will call
out those fasteners that require a replacement after
removal. ISUZU will also call out the fasteners that
require thread lockers or thread sealant. UNLESS
OTHERWISE SPECIFIED, do not use supplemental
coatings (Paints, greases, or other corrosion inhibi-
tors) on threaded fasteners or fastener joint inter-
faces. Generally, such coatings adversely affect the
fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners,
use the correct tightening sequence and specifica-
tions. Following these instructions can help you
avoid damage to parts and systems.
GENERAL DESCRIPTION
Engine Cleanliness and Care
An industrial engine is a combination of many ma-
chines, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protec-
tion of machined surfaces and friction areas is part of
the repair procedure. This is considered standard shop
practice even if not specifically stated.
• A liberal coating of engine oil should be applied to
all friction areas during assembly to protect and
lubricate the surfaces on initial operation.
• Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crank-
shaft journal bearings are removed for service,
they should be retained in oder.
• At the time of installation, they should be installed
in the same locations and with the same mating
surfaces as when removed.
• Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
• The in-line cylinders of this engine are identified by
numbers; cylinders 1, 2, 3...., as counted from
crankshaft pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:
W5-3-1
• When raising or supporting the engine for any
reason, do not use a jack under the oil pan. Due to
the small clearance between the oil pan and the oil
pump strainer, jacking against the oil pan may
cause damage to the oil pick-up unit.
• The 12 V electrical system is capable of damaging
circuits. When performing any work where electri-
cal terminals could possibly be grounded, the
ground cable of the battery should be disconnected
at the battery.
• Any time the intake air duct or air cleaner is
removed, the intake opening should be covered.
This will protect against accidental entrance of
foreign material into the cylinder which could cause
extensive damage when the engine is started.
General
The 6WG1 engine is a four-cycle, six-cylinder, in-line,
direct fuel injection type diesel engine with the piston
displacement of 15.681 L (957 cid). It features a
geardriven OHC (overhead camshaft) timing train and
unique mechanisms and systems designed for out-
standing quietness, economy and durability.
Cylinder Head
The cylinder head is made of cast iron and has a
crossflow layout with the intake system in the left side
and the exhaust system in the right side, designed to
reduce resistance in the intake and exhaust system.
The cylinder head gasket is of the laminated of least
fatigue in combination with the angular cylinder head
bolt tightening method, equally designed to increase
reliability against gaseous and water leakage.
Cylinder Block
The cylinder block is made of cast iron having dry
cylinder liner and seven bearings. The bearing cap has
a ladder frame construction integrating the crankcase
to increase rigidity.
The cylinder liner is made of thin special iron alloys and
is combined with the chrome-plate piston ring to
ensure good resistance against wear.
Piston
The piston is made of aluminum alloy. A ring trigger is
cast into the first and second ring groove and chrome
plating is applied to four sides of the first and third ring
to ensure sufficient strength and wear resistance of
the ring and the ring groove.
Crankshaft
The crankshaft is made of forge steel with seven
bearings and twelve counter weights to reduce revolu-
tion load to the bearing. The crankshaft is treated by
soft nitriding to enhance the crankshaft strength.
W5-3-2 EX455

ENGINE OVERHAUL

Gear Train
The gear train is located at the front of cylinder block
to minimize influence of the torsional vibration of the
crankshaft and the radiant sound.
Noise is further reduced, to the same level as a timing
belt driven system, by integrating the crankshaft gear
with the crankshaft by shrink fit careful tuning of the
gear precision, contact gear ratio, backlash, bearing
rigidity neutral frequency, etc.

Combustion System
The combustion chamber has a clean and simple
design for maximum operating economy also easy
starting. A direct fuel injection system is adopted.
The injection nozzles are placed at the center of each
cylinder. Intake ports generate optimum swirl effect
while exhaust ports minimize exhaust resistance.
Isuzu's unique combustion chamber design provides
maximum power output and fuel economy.

Value Arrangement
Each cylinder has two intake valves and two exhaust
valves.
To ensure high efficiency and complete combustion,
the intake system has a Isuzu's unique designed inlet
ports. The two exhaust valves are connected to a
single port.

Lubrication
AlI engine parts are lubricated by a gear pump pres-
sure circulation system.
Oil flows from the oil pump though oil cooler to main oil
filter for oil cooling and oil cleaning.
From the main oil filter it moves to the cylinder block
oil gallery and the oil circulates to lubricates the engine
parts.
Oil jets are installed to the cylinder block main oil
gallery. The jet spray oil to the inside portions of the
pistons for lubrication and cooling.

Oil Pump and Oil Filter

The oil pump is a gear type with a relief valve. The
pump is driven by the timing gear. A full flow main oil
filter with a highly efficient paper element used.
Should the element become clogged with sludge or
other foreign material, a by-pass valve open to route
the oil directly to the oil gallery.

Oil Cooler
The temperature of the engine oil circulating through
the lubricating system tends to rise with an accompa-
nying decrease in lubricating efficiency.
The oil cooler maintains the oil temperature at the
optimum level for effective engine lubrication.
The oil cooler consists of the body and the cooling
element.
EX455 W5-3-3

ENGINE OVERHAUL

FAN CENTER 3. Remove the fan center (1) from the timing gearcase
(2).
Removal
1. Remove the cooling fan (2) from the fan center (1).

SM7726

SM7724

2. Remove the fan belt.

• Loosen the alternator mounting bolt (2).
• Loosen the sliding piece nut (4).
• Adjust the adjusting bolt (3) to remove the fan
belt.

SM7725
W5-3-4 EX455

ENGINE OVERHAUL

Installation
1. Install the fan center (1) to the timing gearcase (2)
and tighten the fixing nuts to the specified torque.
Torque: 52 Nm (5.3 kgm)
4. Install the cooling fan to the fan center and tighten
the fixing nuts to the specified torque.
Torque: 52 N•m (5.3 kgm)

NOTE: Install the fan to the installation direction

properly.

SM7726

2. Install the fan belt.

3. Adjust the fan belt tension by adjusting the adjust- SM7724

ing bolt:

• Depress the fan belt at the midway between the

alternator pulley and fan center pulley with 100 N
(10 kg).
Belt deflection: 8-12 mm

• Tighten the alternator fixing nut to the specified

torque.
Torque: 147 N•m (15.0 kgm)

SM7717
EX455 W5-3-5

ENGINE OVERHAUL

TURBOCHARGER Installation
1. Install the turbocharger assembly with the gasket
Removal to the exhaust manifold and tighten the nuts to the
specified torque.
1. Remove the inlet pipe from the air cleaner to the
turbocharger. Torque: 40 N•m (4.1 kgm)

2. Remove the inlet duct from the inlet pipe to the

turbocharger. NOTE: Lubricate the turbine shaft dripping the engine
oil from the oil feed hole and turning the turbine wheel
3. Remove the oil feed pipe. by hand.

• Discard the gaskets.

4. Remove the oil drain pipe.

• Discard the gaskets.

5. Remove the turbocharger.

NOTE: Plug the turbocharger body oil ports and

openings to prevent the entry of foreign material or
dust.

SM7728

2. Install the oil drain pipe for the turbocharger and

tighten the bolt to the specified torque.
Torque: 50 N•m (5.1 kgm)

3. Install the oil feed pipe for the turbocharger and

tighten the bolt to the specified torque.
Torque:
Turbocharger side: 50 N•m (5.1 kgm)
SM7727
Oil port cover side: 34 N•m (3.5 kgm)

SM7729
W5-3-6 EX455

ENGINE OVERHAUL

4. Install the inlet duct from the inlet pipe to the

turbocharger and tighten the fixing bolts to the
specified torque.

• Connect the rubber hose between the inlet duct

and turbocharger.

• Install the heat protector to the rubber hose.

Torque: 43 N•m (4.4 kgm)

5. Install the inlet pipe from the air cleaner to the

turbocharger.
Tighten the inlet pipe fixing bolts to the specified
torque.
Inlet pipe at turbocharger side
Torque: 5.4 N•m (0.55 kgm)
Inlet pipe at bracket side
Torque: 52 N•m (5.3 kgm)
Inlet pipe bracket
Torque: 118 N•m (12 kgm)

SM7730
EX455 W5-3-7

ENGINE OVERHAUL

EXHAUST MANIFOLD

Removal Installation
1. Remove the inlet pipe from air cleaner to turbo- 1. Install the exhaust manifold assembly with the new
charger. gasket to the cylinder head.
Tighten the nuts to the specified torque in the order
2. Remove inlet duct from the inlet pipe to the turbo- shown.
charger. Torque: 37 N•m (3.8 kgm)

3. Remove the turbocharger oil feed pipe.

4. Remove the turbocharger oil drain pipe.

5. Remove the turbocharger. Refer to "Turbocharger"

in this section.

6. Remove the exhaust manifold. Clean the sealing

surfaces of the exhaust manifold.

Indicator

SM7732

2. Install the turbocharger assembly with the gasket

to the exhaust manifold.
Refer to "Turbocharger" in this section.

SM7731

SM7728

3. Install the oil drain pipe for the turbocharger.

4. Install the oil feed pipe for the turbocharger.

5. Install the inlet duct from the inlet pipe to the

turbocharger.

6. Install the inlet pipe from the air cleaner to the

turbocharger.
W5-3-8 EX455

ENGINE OVERHAUL

INLET MANIFOLD 2. Install the inlet cover with new gasket.

Tighten the fixing bolt to the specified torque.
Removal Torque: 43 N•m (4.4 kgm)
1. Remove the breather hose.

2. Remove the oil dipstick and guide tube.

3. Remove the fuel pipes.

4. Remove the air pipe for the boost.

5. Remove the injection pipes.

6. Remove the fuel filter and bracket.

7. Remove the inlet pipe.

NOTE: Plug the outlet of the turbocharger compres-

sor.
SM7734
8. Remove the inlet cover.

9. Remove the inlet manifold.

3. Install the inlet pipe with new gasket. Tighten the
10. Clean the sealing surfaces of the inlet manifold. fixing bolt to the specified torque.
Torque: 43 N•m (4.4 kgm)
Installation
1. Install the inlet manifold with new gaskets.
• Install the rubber boot and spring.
• Tighten the nut to the specified torque.
Torque: 20 N•m (2.0 kgm)

Rubber bolt

Indicator

SM7735

SM7733
EX455 W5-3-9

ENGINE OVERHAUL

4. Install the fuel filter and bracket to the inlet 6. Install the fuel pipe to tighten to the specified
manifold. Tighten the fixing bolt to the specified torque as follows.
torque. M8 eye bolt
Torque: Torque: 15 N•m (1.5 kgm)
Fuel Filter: 52 N•m (5 3 kgm) M10 eye bolt
Bracket :50 N•m (5.1 kgm) Torque: 27 N•m (2.8 kgm)
M12 eye bolt
Torque: 34 N•m (3.5 kgm)
M14 eye bolt
Torque: 41 N•m (4.2 kgm)

SM7736 SM7711

5. Install the injection pipes, tightening to the speci- 7. Install the guide tube to the cylinder block in the
fied. order shown.
Torque: Torque:
Cylinder head side: 29 N•m (3.0 kgm) Bolt (1) 88 N•m (9.0 kgm)
Injection pump side: 39 N•m (4.0 kgm) Bolt (2) 49 N•m (5.0 kgm)

SM7737 SM7738
W5-3-10 EX455

ENGINE OVERHAUL

8. Connect the breather hose to the breather and

clamp the hose.

SM7739
EX455 W5-3-11

ENGINE OVERHAUL

WATER PUMP 2. Install the thermostat housing.

Removal
1. Remove the water inlet pipe.
2. Remove the thermostat housing.
• Install the thermostat to the oil cooler.
Refer to "Thermostat installation" in this
manual.
• Tighten the bolts to the specified torque.
Torque: 39 N•m (4.0 kgm)

3. Remove the water pump (1).

SM7740 SM7741

Installation
1. Install the water pump (1) with new gasket, tighten
to the specified torque.
• First tighten the bolts (2) to the oil cooler side
then tighten other fixing bolts.
Torque: 39 N•m (4.0 kgm).

SM7740 SM7742
W5-3-12 EX455

ENGINE OVERHAUL

3. Install the water inlet pipe (1) to the oil cooler.

Tighten the bolts to the specified torque.
Torque: 43 N•m (4.4 kgm)

SM7743
EX455 W5-3-13

ENGINE OVERHAUL

ALTERNATOR

Removal
1. Remove the sliding piece nut (4).

2. Remove the adjust plate fixing bolt (1).

3. Remove the alternator fixing bolt (2).

4. Remove the fan belt.

5. Remove the aIternator.

SM7725

SM7725

Installation
1. Install the alternator.

2. Install the adjusting plate.

3. Install the fan belt. SM7717

4. Adjust the belt tension by adjusting the bolt (3).

• Depress the fan belt at the midway between the
alternator and the water pump.
Belt Deflection: 8-12 mm

5. Tighten the alternator fixing bolt to the specified

torque.
Torque: 147 N•m (15.0 kgm)
W5-3-14 EX455

ENGINE OVERHAUL

OIL COOLER

Removal
1. Remove the turbocharger oil feed pipe.
2. Remove the turbocharger oil drain pipe.
3. Remove the oil port cover.
4. Remove the water inlet pipe.
Installation
1. Install the oil cooler with gaskets.
• Install the gasket shown in the illustration.
• Install the oil cooler assembly to the cylinder
block and tighten the bolts to the specified
torque in the order shown.
Torque: 50 N•m (5.1 kgm)

5. Remove the water pump.

Refer to "Water Pump" in this section.

6. Remove the oil cooler assembly.

• Remove the water drain pipe (1).
• Install the two removed fixing bolts to the holes
(2) for replacement and screw the bolts, then
remove the oil cooler.

SM7745

• Install the water drain pipe (1) and tighten the

connector (2).
Torque: 79 N•m (8.0 kgm)
• Tighten the bracket (3) to the specified torque.
Torque: 69 N•m (7.0 kgm)

SM7744

SM7746
EX455 W5-3-15

ENGINE OVERHAUL

2. Install the thermostat housing. 3. Install the water inlet pipe to the oil cooler.

• Install the thermostat to the oil cooler. Refer to 4. Install the oil port cover with new gasket.
"Thermostat Installation" in this manual. Tighten the fixing bolts to the specified torque.
• Tighten the bolts to the specified torque. Torque: 43 N•m (4.4 kgm)
Torque: 39 N•m (4.0 kgm)

SM7741 SM7747

5. Install the turbocharger oil feed pipe.

6. Install the turbocharger oil drain pipe.

Refer to "Turbocharger" in this section.

SM7742
W5-3-16 EX455

ENGINE OVERHAUL

INJECTION PUMP
Removal
1. Remove the oil level gauge and guide tube.
2. Remove the coupling cover.
3. Remove the fuel pipes and fuel leak off pipe.
7. Loosen the two coupling fixing bolts and the four
injection pump fixing bolts.
8. Remove the injection pump.
NOTE: Plug the injection pump delivery holder ports
with the shipping caps or equivalent to prevent the
entry of the foreign material or dust.

SM7748

SM7749

4. Remove the injection pipe with clips.

9. Remove the injection pump bracket.

Installation
1. Install the injection pump bracket to the cylinder
block.
• Install the bracket into place over the bracket
locating dowel pin on the cylinder block.
• Install the gaskets on the bracket.
• Tighten the bracket fixing bolts to the specified
torque.
Torque: 108 N•m (11 kgm)

SM7737

5. Remove the air pipe for the boost.

6. Remove oil feed pipe and oil return pipe for the
injection pump.

SM7750
EX455 W5-3-17

ENGINE OVERHAUL

2. Install the injection pump • Install the injection pump assembly to the injec-
• Align the flywheel injection timing mark with the tion pump bracket.
flywheel housing pointer by rotating crankshaft • Tighten the bolts to the specified torque in the
counterclockwise. order shown.
Injection timing (BTDC): 11 deg. Torque: 39 N•m (4.0 kgm)

SM7714 SM7751

• Align the injection timing mark on the timing
advancer with the injection pump body pointer.
• Make sure the injection pump alignment on the
injection pump, and tighten the coupling bolts to
the specified torque.
Torque:
Timing advancer side: 62 N•m (6.3 kgm)
Coupling ASM side: 88 N•m (9.0 kgm)

SM7715 SM7752
W5-3-18 EX455

ENGINE OVERHAUL

3. Install the injection pump coupling cover. 5. Install the injection pipes.
Tighten the fixing bolts to the specified torque. Tighten the injection pipe sleeve nuts to the
Torque: specified torque.
Bolt (1): 50 N•m (5.1 kgm) Torque:
Bolt (2): 52 N•m (5.3 kgm) Cylinder head side: 29 N•m (3.0 kgm)
Bolt (3): 50 N•m (5.1 kgm) Injection pump side: 39 N•m (4.0 kgm)

SM7753 SM7737

6. Install the fuel pipe to tighten to the specified

4. Install the oil pipe to the injection pump. torque as follows.
Torque: M8 eye bolt
M10 27 N•m (2.8 kgm) Torque: 15 N•m (1.5 kgm)
M14 41 N•m (4.2 kgm) M10 eye bolt
M18 58 N•m (5.9 kgm) Torque: 28 N•m (2.8 kgm)
M12 eye bolt
Torque: 34 N•m (3.5 kgm)
M14 eye bolt
Torque: 41 N•m (4.2 kgm)

SM7754

SM7711
EX455 W5-3-19

ENGINE OVERHAUL

7. Install the air pipe for the boost.

8. Install the guide tube to the cylinder block in the

order shown.
Torque:
Bolt (1) 88 N•m (9.0 kgm)
Bolt (2) 49 N•m (5.0 kgm)

SM7738
W5-3-20 EX455

ENGINE OVERHAUL

COUPLING ASSEMBLY

Removal Installation

1. Remove the coupling cover.
2. Remove the oil feed pipe from the cylinder block
to coupling assembly.
3. Loosen the coupling fixing bolt (1) and remove the
coupling disc fixing bolt (2), (3).
1. Install the coupling assembly to the gearcase.
• Install the gear to the coupling assembly.
• Apply molybdenum disulfide grease to the thread
portion and flange surface of bolts and the
washer, tightening the bolts to the specified
torque in the order shown.
Torque: 39 N•m (4.0 kgm) → 105 deg.

SM7755 SM7757

4. Remove the coupling. • Align the flywheel "T/C" mark with the flywheel
housing pointer by rotating the crankshaft
5. Remove the coupling assembly fixing bolts and counterclockwise.
nut.

6. Remove the coupling assembly.

SM7756 SM7714
EX455 W5-3-21

ENGINE OVERHAUL

• Install the new gasket to the coupling assembly.
• Install the injection pump coupling to the coupling
assembly shaft.
• Align the mark "A" on the coupling with the
coupling assembly body pointer.
2. Install the coupling oil pipe from the cylinder block
to the coupling assembly.
Torque: M10 27 N•m (2.8 kgm)

Mark A

SM7757/A SM7759

• Install the coupling assembly to the gearcase. 3. Install the coupling.

• Check alignment mark "S" with the coupling • Tighten the coupling fixing bolt (1) to the speci-
assembly body pointer after installing the cou- fied torque.
pling assembly to the timing gearcase. Torque: 88 N•m (9.0 kgm)
• Tighten the coupling assembly fixing bolts and
• Tighten the fixing bolt (3) to the specified torque.
nut to the specified torque.
Torque: 133 N•m (13.6 kgm) Torque: 62 N•m (6.3 kgm)

SM7758 SM7755
W5-3-22 EX455

ENGINE OVERHAUL

• Align the injection timing mark on the flywheel

with the flywheel housing pointer by rotating
crankshaft counterclockwise.
Injection timing (BTDC): 10 deg.

SM7714

• Align the injection timing mark on the timing

advancer with the injection pump body pointer.

SM7715

• Tighten the coupling bolt to the specified torque.

Torque: 88 N•m (9.0 kgm)
• Rotate the crankshaft two turns in normal direc-
tion of crankshaft rotation. Verify that the injec-
tion timing is correct.

4. Install the coupling cover.

EX455 W5-3-23

ENGINE OVERHAUL

CYLINDER HEAD

SM7760

Legend 6. Leak off pipe

1. Cylinder head cover 7. Nozzle clamp
2. Gasket 8. Nozzle holder assembly
3. Rocker arm assembly 9. Idle gear C and shaft
4. Bridge 10. Cylinder head assembly
5. Camshaft assembly 11. Cylinder head gasket
W5-3-24 EX455

ENGINE OVERHAUL

Removal 4. Remove the bridge.

1. Remove the cylinder head cover (and Insulator).
NOTE: Sort or organise the bridge for assembly to
2. Remove the gasket of the cylinder head cover. original location.

SM7761 SM7763

3. Remove the rocker arm assembly. 5. Remove the camshaft.

• Loosen the rocker arm shaft bracket bolts from • Use a feeler gauge to measure the camshaft end
both outside bolt. play before removing.
Standard: 0.008 - 0.170 mm (0.0033 - 0.0067 in)
Limit: 0.25 mm (0.0098 in)

SM7762 SM7764
EX455 W5-3-25

ENGINE OVERHAUL

• Loosen the camshaft bracket fixing nuts from 10. Remove the cylinder head assembly.
both outside nut.
• First loosen the bolts B - D.
6. Remove the leak off pipe.
• Loosen the cylinder head bolts a little at a time
in the numerical order shown in the illustration.
7. Remove the nozzle clamp.

NOTE: Failure to loosen the cylinder bolts in numeri-

8. Remove the nozzle holder assembly. cal order a little at a time will adversely affect the
cylinder head lower surface.
• Use the nozzle holder remover 1-8523-0013-0 to
remove the nozzle holder.

NOTE: Take care not to damage the injection nozzle

tips during injection nozzle holder removal.

SM7722

9. Remove the idle gear "C" and shaft.

• Use a feeler gauge to measure the idle gear "C"

end play.
Standard: 0.05 - 0.14 mm (0.0020 - 0.0055 in)
Limit: 0.25 mm (0.098 in)

SM7766

11. Remove the cylinder head gasket.

Discard the cylinder head gasket.
SM7765
W5-3-26 EX455

ENGINE OVERHAUL

Installation • Apply molybdeum disulfide grease to the cylinder

head bolts (M18) threads and setting faces.
1. Install the new cylinder head gasket.
• Apply engine oil to the cylinder head bolts (M10
and M12) threads and setting faces.
• Clean the cylinder block surface.
• Tighten the M18 cylinder head bolts in three steps
• Apply Loctite FMD127 or equivalent to the cylin-
using the angular tightening method.
der block and the timing gearcase fitting faces.
Follow the tightening order shown in the illustra-
The sealant must be 1.0 - 2.0 mm (0.04 - 0.08 in)
tion.
thick and 5.0 mm (0.20 in) wide.
• Tighten the M10 and M12 cylinder head bolts to
The sealant must not obstruct the cylinder oil
the specified torque.
port.

NOTE: Cylinder head bolts may be installed as many

as four (4) times, and then must be replaced.
Replace if any doubt exists.

M18 bolt
Torque:
1st step 177 N•m (18 kgm)
2nd step 245 N•m (25 kgm)
3rd step 60 - 90 deg.
M12 bolt
Torque: 75 N•m (7.7 kgm)
M10 bolt
Torque: 38 N•m (3.9 kgm)
SM7767
NOTE: Cover the timing gear hole by cloth for prevent-
• Install the new cylinder head gasket to the cylin- ing into foreign materials.
der block.

2. Install the cylinder head assembly.

• Align the cylinder block dowel pins and the cylin-
der head dowel holes. Carefully place the cylinder
head on the cylinder head gasket.

SM7768

SM7769
EX455 W5-3-27

ENGINE OVERHAUL

3. Install the idle gear "C" and shaft. 6. Install the leak off pipe.
Tighten to specified torque.
• Apply engine oil to the idle gear "C" shaft bolts. Torque: 15 N•m (1.5 kgm)
• Tighten the idle gear "C" shaft bolt to the specified
torque.
Torque: 39 N•m (4.0 kgm)

SM7771

7. Install the camshaft assembly.

SM7770

• Align the flywheel TDC mark with the pointer by

rotating the crankshaft normal direction. Same
4. Install the nozzle holder assembly. time check alignment timing mark on injection
pump for No. 1 piston TDC.
5. Install the nozzle clamp.
Tighten the nozzle clamp bolt to the specified
torque.
Torque: 49 N•m (5.0 kgm)

SM7714

SM7722
W5-3-28 EX455

ENGINE OVERHAUL

• Apply engine oil to the camshaft bearing sliding
surfaces before installing the camshaft assem-
bly.
• Install the camshaft assembly to the cylinder
head.
• Carefully align the camshaft gear hole mark and
pointer (1) on the cylinder head shown in the
illustration.
8. Install the bridge.
• Loosen adjusting screw.
• Apply engine oil on the bridge guide.
• Install the bridge, the adjusting screw (1) facing
to the intake manifold side.
NOTE: Bridges must be reinstalled into their original
location and position.

SM7772 SM7774

• Apply engine oil to the camshaft bearing sliding 9. Install the rocker arm assembly.
surfaces.
• Install the camshaft bearing caps to use same
stamped mark (1).
• Apply engine oil to the threads and tighten to the
specified torque.
Torque: 76 N•m (7.7 kgm)

SM7773 SM7762
EX455 W5-3-29

ENGINE OVERHAUL

• Tighten the bolts in numerical order to the speci • Tighten cylinder head cover bolt, follow the nu-
fied torque shown in the illustration. merical order shown in the illustration.
Torque: 90 N•m (9.2 kgm) Torque: 20 N•m (2.1 kgm)

SM7775 SM7777

10. Install the gasket of the head cover.

11. Install the cylinder head cover.

• Apply Loctite FMD127 or equivalent to the upper

surface of cylinder head and timing gear case
fitting area shown as illustration.
The sealant must be 1.0 - 2.0 mm (0.04 - 0.08 in)
thick and 5.0 mm (0.20 in) wide.

SM7776
W5-3-30 EX455

ENGINE OVERHAUL

Disassembly

SM7778

Legend

1. Thermometer unit 12. Valve spring

2. Gearcase 13. Spring lower seat
3. Gasket 14. Valve
4. Idle gear shaft ("C") 15. Valve stem seal
5. Idle gear "C" 16. Valve guide
6. Gasket 17. Bridge guide
7. Inlet manifold 18. Valve seat insert
8. Exhaust manifold 19. Injection nozzle sleeve
9. Seal rings 20. Gasket
10. Split collar 21. Cylinder head
11. Spring upper seat
EX455 W5-3-31

ENGINE OVERHAUL

1. Remove the thermometer unit. 5. Remove the gasket of the inlet manifold.
2. Remove the gearcase. 6. Remove the inlet manifold assembly.
3. Remove the shaft of the idle gear "C". 7. Remove the exhaust manifold assembly.
Measure end play between the cylinder head and 8. Remove the seal rings.
idle gear "C". 9. Remove the split collar.
Standard: 0.05 - 0.014 mm (0.0020 - 0.0055 in) • Place the cylinder head on a flat wooden surface.
Limit: 0.25 mm (0.0098 in) • Use the valve spring compressor
1-8523-5013-0 to remove the split collar.

NOTE: Do not allow the valve to fall from the cylinder

head

10. Remove the spring upper seat.

SM7765

4. Remove the idle gear "C".

• Disassemble the shaft of idle gear "C"
• Disassemble the idle gear "C".
SM7779

11. Remove the valve spring.

12. Remove the spring lower seat.
13. Remove the valve. If the intake and exhaust
valves are to be reinstalled, mark their installation
position by tagging each valve with the cylinder
number from which it was removed. If the intake
and exhaust valves are to be replaced, the valve
guides must also be replaced.
14. Remove the valve stem seal. Discard the valve
stem seal.

SM7770
W5-3-32
ENGINE OVERHAUL
15. Remove the valve guide. Use valve guide re-
mover 9-8523-1202-0 to remove the valve guide.
SM7780
16. Remove the bridge guide.
• Electric welding (1) the bolt to bridge guide, use
sliding hammer to remove the bridge guide.
SM7781
EX455
17. Remove the valve seat insert.
• Heat up (about 600 - 700°C) two point on the
valve seat insert by gas torch, allow the valve
seat insert to cool for few minutes.
• This will invite contraction and make removal of
the valve seat insert easier.
• Use screwdriver to pry the valve seat insert
free. Take care not to damage the cylinder
head.
• Carefully remove carbon and other foreign
materials from the cylinder head insert bore.
SM7782
18. Remove the injection nozzle sleeve.
• Use suitable size brass bar to hit nozzle sleeve
from lower side cylinder head.
SM7783
EX455 W5-3-33

ENGINE OVERHAUL

Inspection and Repair
Make the necessary adjustments, repair and part
replacements if excessive wear or damage is discov-
ered during inspection.
BRIDGE
Inspect any cracking, damage on bridge and inspect
any separation wear out and damage on the surface of
bridge
SHAFT IDLE GEAR "C" AND IDLE GEAR "C"
1. Measure the outside diameter of shaft idle gear
“C”.
Standard: 48.93 - 48.96 mm (1.9264 - 1.9286 in)
Limit: 48.85 mm (1.9232 in)
2. Measure the clearance between the shaft and idle
gear "C".
Standard: 0.04 - 0.105 mm (0.0016 - 0.0041 in)
Limit: 0.2 mm (0.0079 in.)

SM7784 SM7786

CLEARANCE BETWEEN CAMSHAFT AND VALVE SPRING

BRACKET 1. Use a vernier calmer to measure the valve spring
Measure the clearance between the camshaft and free height. If the measured value is less than the
camshaft bracket. specified limit, the valve spring must be replaced.
Standard: 0.065 - 0.125 mm (0.0026 - 0.0049 in) Valve spring free height
Limit: 0.15 mm (0.0059 in) Inlet spring:
Standard: 79.3 mm (3.122 in)
Limit: 75.3 mm (2.965 in)

Exhaust spring: outer

Standard: 102.7 mm (4.0433 in)
Limit: 97.6 mm (3.0843 in)

Exhaust spring: inner

Standard: 96.4 mm (3.0795 in)
Limit: 91.7 mm (3.0610 in)

SM7785
W5-3-34 EX455

ENGINE OVERHAUL

3. Use a spring tester to measure the valve spring

tension.
If the measured value is less than the specified
limit, the valve spring must be replaced.
Valve spring tension
Inlet spring:
Standard: 392 N (40.0 kg)/64 mm
Limit: 294 N (38.0 kg)/64 mm

Exhaust spring: outer

Standard: 610 N (62.2 kg)/69 mm
Limit: 579 N (59.0 kg)/69 mm

Exhaust spring: inner

SM7136
Standard: 224 N (22.8 kg)/66 mm
Limit: 213 N (21.7 kg)/66 mm

2. Use a surface plate and a square to measure the

valve spring squareness.
If the measured value exceeds the specified limit,
the valve spring must be replaced.
Valve spring squareness
Inlet spring:
Standard: 3.5 mm (0.138 in)
Limit: 4.8 mm (0.189 in)

Exhaust spring: outer

Standard: 4.5 mm (0.177 in)
Limit: 6.2 mm (0.244 in)

Exhaust spring: inner

SM7138
Standard: 4.2 mm (0.165 in)
Limit: 5.9 mm (0.232 in)
VALVE STEM
1. Set the dial indicator to the valve stem measuring
point.
2. Move the valve stem end from side to side.
Read the dial indicator.
Note the total indicator reading.
If the measured value exceed the specified limit,
the valve and the valve guide must be replaced as
a set.
Valve stem and Valve guide clearance
Inlet:
Standard: 0.040 - 0.077 mm (0.0016 - 0.0030 in)
Limit: 0.15 mm (0.0059 in)
Exhaust:
Standard: 0.065 - 0.102 mm (0.0026 - 0.0040 in)
SM7137 Limit: 0.25 mm (0.0098 in)
EX455 W5-3-35

ENGINE OVERHAUL

BRIDGE GUIDE AND BRIDGE CLEARANCE

1. Use a caliper calibrator or a telescoping gauge to
measure the valve bridge (2) inside diameter.
2. Calculate the difference between the valve bridge
inside diameter and the valve bridge guide (1)
outside diameter.
If the clearance exceeds the specified limit, the
valve bridge must be replaced.
Bridge guide and bridge clearance
Standard: 0.020 - 0.057 mm (0.0080 - 0.0022 in)
Limit: 0.10 mm (0.0039 in)

SM7122

3. Measure the valve stem diameter at three points.

If the measured value is less than the specified
limit, the valve and the valve guide must be re-
placed as a set.
Valve stem outside diameter
Inlet:
Standard: 10.0 mm (0.3937 in)
Limit: 9.92 mm (0.3906 in)
Exhaust:
SM7788
Standard: 10.0 mm (0.3937 in)
Limit: 9.90 mm (0.3898 in)
VALVE THICKNESS AND DEPRESSION
1. Measure the valve thickness.
If the measured value is less than the specified
limit, the valve and the valve seat insert must be
replaced as a set.
Valve thickness
Inlet:
Standard: 2.14 mm (0.0843 in)
Limit: 1.64 mm (0.0646 in)
Exhaust:
Standard: 2.3 mm (0.0906 in)
Limit: 1.8 mm (0.0709 in)

SM7787
W5-3-36 EX455

ENGINE OVERHAUL

VALVE CONTACT WIDTH

1. Check the valve contact faces for roughness and
unevenness. Make smooth the valve contact sur-
faces.
2. Measure the valve contact width.
If the measured value exceeds the specified limit,
the valve seat insert must be corrected or re-
placed.
Valve contact width
Inlet:
Standard: 3.0 mm (0.1181 in)
Limit: 3.4 mm (0.1339 in)
Exhaust:
Standard 2.5 mm (0.0984 in)
SM7127
Limit: 2.9 mm (0.1141 in)

2. Install the new valve (1) to the cylinder head (2).

3. Use a depth gauge or a straight edge with steel
rule to measure the valve depression from the
cylinder head lower surface.
If the measured value exceeds the specified limit,
the valve seat insert and/or the valve must be
replaced.
Valve depression
Inlet:
Standard: 1.9 mm (0.0748 in)
Limit: 2.9 mm (0.1142 in)
Exhaust:
Standard: 1.8 mm (0.0709 in)
Limit: 2.8 mm (0.1102 in) SM7129

CONTACT SURFACE ANGLE ON VALVE

1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
valve, valve guide and valve seat as a set.
Valve contact surface angle
Standard:
Inlet: 30 degree
Exhaust: 45 degree

SM7128
EX455 W5-3-37

ENGINE OVERHAUL

3. Apply abrasive compound to the valve seat insert

surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. Check to see if the valve contact width is correct.
7. Check to see if the valve seat insert surface is in
contact with the entire circumference of the valve.

SM7134

VALVE SEAT INSERT CORRECTION

1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter (15°, 45°, and 75° blades) to
minimize scratches and other rough areas. This
will bring the contact width back to the standard
value. SM7135

Reassembly

1. Install the injection nozzle sleeve with new gasket

to the cylinder head.
• Clean the nozzle sleeve circumference and the
nozzle sleeve fitting faces of cylinder head.
• Apply the recommended sealant (LOCTITE
TL290 or equivalent) to the nozzle sleeve outer
circumference (1).
• Apply engine oil to the nozzle sleeve gaskets.
• Install the new gaskets to the nozzle sleeve
gasket groove.
• Use a bench press to install the nozzle sleeve.
Apply pressure to the nozzle sleeve gradually.
SM7132

CAUTION
Remove only the scratches and rough areas. Do Do not apply an excessive amount of pressure with
not cut away too much. Take care not to cut away the bench press. Damage to the injection nozzle
unblemished areas of the valve seat surface. sleeve and cylinder head will result.
Valve seat angle
Inlet: 30 degree
Exhaust: 45 degree

NOTE: Use an adjustable valve cutter pilot. Do not

allow the valve cutter pilot to wobble inside the valve
guide.
W5-3-38
ENGINE OVERHAUL
SM7789
2. Install the valve seat insert into the cylinder head.
• Carefully place the attachment (1) (having a
smaller outside diameter than the valve seat
insert) on the valve seat insert (2).
NOTE: The smooth side of the attachment must
contact the valve seat insert.
• Use a bench press (3) to gradually apply pres-
sure to the attachment and press the valve seat
insert into place.
CAUTION
Do not apply excessive amount of pressure with the
bench press. Damage to the valve seat insert will
result.
SM7782
• The valve should be lapped before final assem-
bly to ensure a good valve seal.
Refer to "Valve Seat Insert Correction" in this
section.
EX455
3. Install the bridge guide.
• Apply engine oil to the valve bridge guide outer
circumference.
• Attach the valve bridge guide installer
9-85221324-0 to the bridge guide.
• Use a brass hammer to tap the guide into position
from the cylinder head upper face.
• Measure the height of the valve bridge guide
upper end from the cylinder head upper face
(cylinder head cover fitting surface).
Valve bridge guide upper end height
Standard: 49.0 mm (1.929 in)
49.0mm
SM7790
4. Install the valve guide into the cylinder head.
• Apply engine oil to the valve guide outer circum-
ference.
• Attach the valve guide replacer 9-8523-1202-0
to the valve guide.
• Use a hammer to drive the valve guide into
position from the cylinder head upper face.
• Measure the height of the valve guide upper end
from the upper face of the cylinder head.
Valve guide upper end height
Intake side: 27.0 mm (1.0630 in)
Exhaust side: 29.0 mm (1.1417 in)
NOTE: If the valve guide has been removed, both the
valve and the valve guide must be replaced as a set.
EX455
ENGINE OVERHAUL
SM7791
5. Install the spring lower seat to the cylinder head.
6. Install the valve stem seal on the valve guide.
• Apply engine oil to the oil seal inner face.
• Use the oil seal installer 1-8522-1187-0 for inlet
and 1-8522-1184-0 for exhaust to install the oil
seal to the valve guide.
SM7791
8. Install the spring upper seat and split collar.
7. Install the valve spring and valve.
• Apply engine oil to each valve stem before
installation.
• Install the inlet and exhaust valves.
• Turn the cylinder head up to install the valve
springs.
Take care not to allow the installed valves to fall
free.
W5-3-39
SM7792
• Install the intake valve springs with their fine
pitched end facing down. (Painted yellow)
• There are not assembly direction on both inner
and outer exhaust valve spring.
SM7145
• Use the spring compressor 1-8523-5013-0 to
compress the valve spring.
• Install the split collars (1) to the valve stem. Do
not allow the valve to fall from the cylinder head.
• Set the split collars by tapping around the head of
each collar with a rubber hammer.
W5-3-40 EX455

ENGINE OVERHAUL

SM7779 SM7794

9. Install the exhaust manifold assembly to the cylin- • The bracket tightening manner as follows.
der head. Tighten the bracket (1 ) and (3) with out washer.
• Check that the seal ring (1) gaps are positioned Put the bracket (2) on the washer, and tighten
120 degrees apart form each other. together with exhaust manifold.
There is installation direction on seal ring as
illustration.
• Install the exhaust manifold gasket. The direc-
tion indicator must be faced lower side.

Indicator

Rear

SM7732

Front

10. Install the intake manifold assembly.

SM7793 • Tighten the nut to numerical order shown in the
illustration.
• Install the rubber boot and spring with tighten-
• Install distance tube (1), washer (3) and disk
ing specified torque.
spring (2).
The convex side of disk spring must be faced to Torque: 20 N•m (2.0 kgm)
exhaust manifold nut.
• Tighten the exhaust manifold nut to specified
torque. Follow the tightening order shown in the
illustration.
Torque: 37 N•m (3.8 kgm)
EX455 W5-3-41

ENGINE OVERHAUL

Rubber boot

Indicator

SM7733 SM7796

11. Install the idle gear "C" and the shaft of the idle 13. Install the thermometer unit.
gear "C". • Apply Loctite FMD127 or equivalent to thread
• Apply engine oil to the shaft of the idle gear "C". on thermometer unit.
• Install the shaft with idle gear "C" to cylinder head. • Tighten the thermometer unit to the specified
• Tighten the bolts to the specified torque. torque.
Torque: 39 N•m (4.0 kgm) Torque 20 N•m (2.0 kgm)

Cylinder
head side

SM7795 SM7797

12. Install the gearcase with new gasket (1).

• Apply Loctite FMD127 or equivalent to the gear
case fitting area (2) or the cylinder head shown
in the illustration.
The sealant must be 0.3 mm (0.012 in) thick and
5 mm (0.20 in) wide.
The sealant (2) must not obstruct the bolt holes
the of cylinder head.
• Tighten the bolts to the specified torque
Torque: 38 N•m (3.9 kgm)
W5-3-42 EX455

ENGINE OVERHAUL

ROCKER ARM AND SHAFT ASSEMBLY

Front mark

SM7798

Legend

1. Bracket 4. Bracket
2. Rocker Arm 5. Rocker Arm Shaft
3. Spring
EX455 W5-3-43

ENGINE OVERHAUL

Disassembly

1. Remove the rocker arm and shaft assembly.

• Loosen the bolt of the rocker arm shaft bracket
from out side bolt a little at time and remove
rocker arm and shaft assembly.
• Disassembly the bracket, rocker arm, spring,
bracket and rocker arm shaft.

SM7078

ROCKER ARM SHAFT OUTSIDE DIAMETER

Use a micrometer to measure the rocker arm fitting
portion outside diameter.
If the measured value is less than the specified limit,
the rocker arm shaft must be replaced.
Rocker arm shaft outside diameter
SM7762
Standard: 27.979 - 28.000 mm (1.1015 - 1.1024 in)
Limit: 27.85 mm (1.0965 in)
Inspection and Repair

Make the necessary adjustments, repairs, and part

replacements if excessive wear or damage is discov-
ered during inspection.

ROCKER ARM SHAFT RUN-OUT

1. Place the rocker arm shaft on V-blocks.
2. Use a dial indicator to measure the rocker arm
shaft central portion run-out.
If the run-out is very slight, correct the rocker arm
shaft run-out with a bench press. The rocker arm
must be at cold condition.
If the measured rocker arm shaft run-out exceeds
the specified limit, the rocker arm shaft must be
replaced.
Rocker arm shaft run-out SM7079

Limit: 0.3 mm (0.012 in)

W5-3-44
ENGINE OVERHAUL
ROCKER ARM BUSHING INSIDE DIAMETER
Use either a vernier caliper or a dial indicator to
measure the rocker arm bushing inside diameter.
Rocker arm bushing inside diameter
Standard: 28.020 - 28.053 mm (1.1031 - 1.1044 in)
Rocker arm and rocker arm shaft clearance
Standard: 0.020 - 0.074 mm (0.0008 - 0.0029 in)
Limit: 0.2 mm (0.0079 in)
SM7799
Check that the rocker arm and rocker arm shaft oil port
are free of obstructions. If necessary, use com-
pressed air to clean the rocker arm and rocker arm
shaft oil port.
SM7800
EX455
ROCKER ARM ROLLER AND ROCKER ARM PIN
1. Pass a string through the rocker arm-roller (1)
clearance and measure the roller protrusion while
pulling both ends of the string in the arrow indi-
cated directions to push out the roller.
2. Mark the measuring point and draw out the string.
Measure the roller protrusion again while the roller
is pushed in.
3. Note the difference in the above measurements is
the standard roller rocker arm and pin clearance.
If the clearance exceeds the limit, the rocker arm
must be replaced.
Rocker arm roller and pin clearance
Standard: 0.036 - 0.069 mm (0.0014 - 0.0027 in)
Limit: 0.15 mm (0.0059 in)
SM7083
EX455 W5-3-45

ENGINE OVERHAUL

Reassembly

1. Install the bracket, spring, rocker arm and bracket

to the rocker arm shaft.
2. Apply engine oil to the roller portion of the rocker
arm and threads of the adjusting screw.
3. Put the rocker arm and shaft assembly on the
cylinder head.
4. Temporally tighten the bolts of the rocker arm and
shaft assembly to the cylinder head, sufficiently
loosen the adjusting screw.
5. Tighten the bolts of the rocker arm and shaft
assembly to the specified torque by numerical
order shown in the illustration.
Torque: 90 N•m (9.2 kgm)

SM7762

SM7775
W5-3-46 EX455

ENGINE OVERHAUL

CAMSHAFT

SM7801

Legend

1. Camshaft gear 4. Camshaft bearing lower

2. Key 5. Camshaft
3. Camshaft bearing cap
EX455 W5-3-47

ENGINE OVERHAUL

Disassembly
1. Remove the camshaft gear.
• Check visually gear for excessive wear or dam-
age.
• Use an universal puller to pull out the camshaft
gear with wooden plate (1) for prevent make
damage gear.

2. Loosen nuts to remove the camshaft bearing cap.

3. Remove the camshaft.

SM7096

2. Measure the cam height A and B with a microm-

eter. If the measured value is less than the speci-
fied limit, the camshaft must be replaced.
Cam height (A - B)
Intake
Standard: 9.40 mm (0.370 in)
Limit: 8.85 mm (0.3484 in)
Exhaust
Standard: 10.40 mm (0.4094 in)
SM7802
Limit: 9.75 mm (0.3839 in)

Inspection and Repair

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discov-
ered during inspection.
1. Use a micrometer to measure each camshaft
journal diameter in two directions (1) and (2). If the
measured value is less than the specified limit, the
camshaft must be replaced.
Camshaft journal diameter
Standard:39.915 - 39.940 mm (1.5715 - 1.5724 in)
Limit: 39.89 mm (1.5705 in)

SM7097
W5-3-48
ENGINE OVERHAUL
3. Mount the camshaft on V-blocks. Measure the
run-out with a dial indicator at the No: 4 camshaft
journal. If the measured value exceeds the speci-
fied limit, the camshaft must be replaced.
Camshaft run-out
Standard: 0.080 mm (0.0031 in)
Limit: 0.100 mm (0.0039 in)
SM7098
EX455
4. Use an inside dial indicator to measure the cam-
shaft bearing inside diameter.
Camshaft bearing inside diameter
Standard: 40.015 - 40.040 mm
(1.5754 -1.5764 in)
If the clearance between the camshaft bearing
inside diameter and the journal exceeds the speci-
fied limit, the camshaft bearing must be replaced.
Camshaft bearing clearance
Standard: 0.065 - 0.125 mm
(0.0026 - 0.0049 in)
Limit: 0.15 mm (0.0059 in)
SM7803
EX455 W5-3-49

ENGINE OVERHAUL

Reassembly
1. Install the camshaft bearing lower.
• Install the camshaft bearing lower to the cylinder
head.
• Apply engine oil to the bearing portion.

2. Install the camshaft.

• Put camshaft onto the lower camshaft bearing.
• Apply engine oil to the journal of camshaft.

3. Install the camshaft bearing cap.

• Install the camshaft bearing cap on the stud bolts
to use same stamped mark of lower bearing.
• Apply engine oil to the threads of the stud bolt
and nut seat.
SM7805
• Tighten the camshaft bearing cap nut to the
specified torque.
Torque: 76 N•m (7.7 kgm)

SM7804

4. Insert the key to the camshaft.

5. Install the camshaft gear and tighten the bolt to the

specified torque.
• Apply engine oil to the threads of the bolt.
Torque: 137 N•m (14.0 kgm)
W5-3-50 EX455

ENGINE OVERHAUL

TIMING GEAR

Timing Gear and Associated Parts

SM7806

Legend
1. Fan center assembly 6. Oil pump
2. Crank pulley 7. Gasket
3. Gearcase cover 8. Distance bolt
4. Gasket 9. Idle gear "A"
5. Oil seal (front) 10. Idle gear "B"
11. Timing gearcase
EX455 W5-3-51

ENGINE OVERHAUL

Removal 6. Remove the oil pump with the gasket.

Discard the gasket.
1. Remove the fan center.
7. Remove the idle gear "A".
2. Remove the crank pulley.
• Before loosening the idle gear fixing bolts, meas-
ure the backlash of the idle gear "A" and "B".
3. Remove the gearcase cover.
Idle gear backlash
Remove the gearcase cover gasket and discard it.
Standard: 0.095 - 0.135 mm (0.0037 - 0.0053 in)
Limit: 0.23 mm (0.0091 in)
4. Remove the front oil seal.

CAUTION
Take care not to damage or deform the sealing
flange surface of the gearcase.

SM7808

• Measure the end play of the idle gear "A" (1) anD
"B" (2).
Idle gear "A" end play
Standard: 0.155 - 0.220 mm (0.0061 - 0.0089 in)
SM7807
Limit: 0.35 mm (0.0138 in)
Idle gear "B" end play
Standard: 0.050 - 0.140 mm (0.0020 - 0.0055 in)
5. Remove the slinger to use the slinger remover
Limit: 0.25 mm (0.0098 in)
1-852 1 -0027-0.

SM7180 SM7809
W5-3-52 EX455

ENGINE OVERHAUL

8. Remove the idle gear "B". Inspection and Repair

1. Visually inspect the idle gear and idle gear spindle
• Scribe a front mark on the thrust plate to aid in
for damage or wear.
assembly.
2. Use a micrometer to measure the idle gear spindle
out side diameter.
Spindle outside diameter for idle gear "A"
Standard: 56.93 - 56.96 mm (2.2413 -2.2425 in)
Limit: 56.85 mm (2.2382 in)
Spindle outside diameter for idle gear "B"
Standard: 141. 93 - 141.96 mm (5.5878 - 5.5890 in)
Limit: 141.85 mm (5.5846 in)
Spindle outside diameter for idle gear "C"
Standard: 48.93 - 48.96 mm (1.9264 -1.9286 in)
Limit: 48.85 mm (1.9232 in)

3. Use a cylinder bore dial indicator to measure the

idle gear inside diameter.

4. Calculate the clearance between the idle gear and

SM7810 idle gear spindle.
Clearance for idle gear "A", "B", and "C"
Standard: 0.040 - 0.105 mm (0.0016 -0.0041 in)
Limit: 0.02 mm (0.0079 in)
If the measured value exceeds from the specified
limit, the idle gear spindle or idle gear must be
replaced.

SM7811
EX455 W5-3-53

ENGINE OVERHAUL

Installation

SM7812

Legend

1. Camshaft gear 4. Idle gear "A"

2. Idle gear "C" 5. Crankshaft gear
3. Injection pump gear 6. Idle gear "B"
W5-3-54 EX455

ENGINE OVERHAUL

1. Install the timing gearcase. 3. Install the idle gear "A" to the timing gearcase.
• Clean the sealing surface block and remove • Align the flywheel TDC mark with the pointer by
sealant residue. rotating the crankshaft normal direction. Same
• Apply a 4 mm bead of Loctite FMD127 or equiva- time check alignment of the timing mark on the
lent to the cylinder block. The sealant must not in injection pump for No. 1 piston TDC.
obstruct the cylinder block bolt holes.
• Install the timing gearcase to the cylinder block.
• Tighten the bolts to the specified torque.
M14 Bolt
Torque: 135 N•m (13.8 kgm)
M10 Bolt
Torque: 43 N•m (4.4 kgm)

SM7714

SM7813 • Apply engine oil to the bushing of the idle gear

"A".
• Install the idle gear "A" with the idle gear shaft to
2. Install the idle gear "B". the timing gearcase.
• Apply engine oil to the bushing area of the idle • The timing marks ("O", "I", "Y") must be aligned
gear and both thrust plate (1) surface. as shown in the illustration.
• Face front the scribed mark on the thrust plate. • Tighten the idle gear "A" shaft bolts to the
• Tighten the bolts to the specified torque. specified torque.
Torque: 39 N•m (4.0 kgm) Torque: 108 N•m (11.0 kgm)

SM7814 SM7815
EX455 W5-3-55

ENGINE OVERHAUL

4. Install the distance bolt to the gearcase. 6. Install the timing gearcase cover.
Tighten the distance bolts to the specified torque. • Apply Loctite FMD127 or equivalent to the timing
Torque: 39 N•m (4.0 kgm) gearcase fitting face.
• Install the timing gearcase cover with new gas-
ket.
• Tighten the bolts to the specified torque.
M10 bolts
Torque: 39 N•m (4.0 kgm)
M8 bolts
Torque: 26 N•m (2.6 kgm)

SM7816

5. Install the oil pump assembly.

• Install the new gasket to the oil pump assembly.
• Install the oil pump assembly to the cylinder
block.
•Tighten-the oil pump bolts to the specified torque.
Torque: 49 N•m (5.0 kgm) SM7818

CAUTION
Do not tighten arrow marked bolt shown in the
illustration.

SM7811

SM7817
W5-3-56 EX455

ENGINE OVERHAUL

7. Install the oil seal with the slinger.
• Apply engine oil to the entire circumference of
the oil seal.
• Use the oil seal installer 1-8522-0043-0 to install
the oil seal.
• Tighten the center bolt until the sleeve comes
into contact with the adapter stopper.
• After pressing the oil seal, make sure that the
distance between the crankshaft end surface
and the oil seal is A as specified.
Distance (A): 6.7 - 7.3 mm (0.264 -0.287 in)
• There is identification color on the oil seal.
For front oil seal: Dark violet color
For rear oil seal: Gray color
• If there is small scratch on the crankshaft, apply
Threebond 127C or equivalent to the oil slinger
shown in the illustration.

SM7819

After press

Before press
SM7821

SM7820

1. Crankshaft
2. Slinger
3. Oil seal
4. Adapter
5. Sleeve
EX455 W5-3-57

ENGINE OVERHAUL

8. Install the crankshaft pulley assembly.

• Install the crankshaft pulley.
• Apply engine oil to the bolt threads.
• Tighten the crankshaft pulley bolts to the speci-
fied torque.
Torque: 267 N•m (27.2 kgm)

SM7822

9. Install the fan center (1) to the gearcase cover (2).

Tighten the fixing nuts to the specified torque.
Torque: 52 N•m (5.3 kgm)

SM7823
W5-3-58 EX455

ENGINE OVERHAUL

FLYWHEEL HOUSING

SM7824

Legend

1. N-TDC sensor 5. Flywheel housing

2. Washer 6. Oil seal
3. Flywheel 7. Slinger
4. Stiffener
EX455 W5-3-59

ENGINE OVERHAUL

Removal Installation
1. Loosen the flywheel fixing bolts. 1. Install the flywheel housing to the cylinder block.
Remove the flywheel. • Apply a 4 mm bead of Loctite FMD127 or equiva-
lent to the cylinder block as shown in the illustra-
2. Remove the stiffeners. tion. The sealant must not obstruct the cylinder
bolt holes.
3. Remove the flywheel housing. • Install the flywheel housing. Tighten the fixing
bolts to the specified torque.
4. Remove the oil seal. M14 bolt
• Take care not to damage on the inserting surface
Torque: 123 N•m (12.5 kgm)
of the housing.
M8 bolt
Torque: 22 N•m (2.2 kgm)

SM7825

SM7826
5. Use the slinger remover 1-8521-0027-0 to re-
move the oil seal slinger from the crankshaft.

2. Install the stiffeners (1) to the flywheel housing.

Tighten the fixing bolts to the specified torque.
Torque: 136 N•m (13.9 kgm)

SM7180

SM7827
W5-3-60 EX455

ENGINE OVERHAUL

3. Install the oil seal with the slinger. 4. Install the flywheel to the crankshaft.
• Apply engine oil to the entire circumference of • Apply molybdenum disulfied grease to the bolt
the oil seal. and setting face.
• Use the oil seal installer 1-8522-0043-0 to install • Tighten the flywheel bolts in three steps using
the oil seal. the angular tightening method.
• Tighten the center bolt until the sleeve comes Torque:
into contact with the adapter stopper.
1st step: 79 N•m (8.0 kgm)
• After pressing the oil seal, make sure that the
distance between the crankshaft end surface 2nd step: 60 deg.
and the oil seal is A as specified. 3rd step: 30 deg.
Distance (A): 6.7 - 7.3 mm (0.264 - 0.287 in) • Follow the numerical order as shown in the
• There is identification color on the oil seal. illustration.
For front oil seal: Dark violet color
For rear oil seal: Gray color
• Do not make separation between the oil seal and
slinger.

SM7829

SM7828

1. Crankshaft
2. Slinger
3. Oil seal
4. Adapter
5. Sleeve
EX455 W5-3-61

ENGINE OVERHAUL

OIL PAN

SM7830

Legend

1. Oil pan 5. Oil strainer

2. Oil pan gasket 6. Oil strainer bracket
3. Oil pan spacer 7. Gasket
4. Oil pan spacer gasket 8. Oil jet assembly
W5-3-62 EX455

ENGINE OVERHAUL

Removal 2. Install the oil strainer with new gasket and the oil
strainer bracket.
1. Remove the oil pan. Remove the oil pan gasket. Tighten the bolts in numerical order as shown in
Discard the oil pan gasket. the illustration.
2. Remove the oil pan spacer. Remove the oil pan Torque: 55 N•m (5.6 kgm)
spacer gasket. Discard the oil pan spacer gasket.
3. Remove the oil strainer.
4. Remove the oil strainer bracket.
5. Remove the oil jet assembly.

CAUTION
Take care not to bend the oil jet tubing. Do not
attempt to repair a damaged oil jet. If damaged,
replace the oil jet with a new one.

Installation

1. Install the oil jet assembly to the cylinder block.

Tighten the joint bolt to the specified torque.
Torque: 69 N•m (7.0 kgm)
SM7832

3. Install the oil pan spacer with new gasket.

• Apply Cemedain LG-020L or equivalent to the
cylinder block, flywheel housing and gearcase
fitting face.
The sealant must be 3 - 4 mm of bead.

SM7831

Sealant

SM7833
EX455 W5-3-63

ENGINE OVERHAUL

• Tighten the bolts in numerical order as shown in

the illustration.
Torque: 38 N•m (3.9 kgm)

Front

SM7834

4. Install the oil pan with new gasket to the cylinder

block.
Tighten the bolts to the specified torque in numeri-
cal order as shown in the illustration.
Torque: 25 N•m (2.5 kgm)

Front

SM7835
W5-3-64 EX455

ENGINE OVERHAUL

PISTON

SM7836

Legend

1. Piston with connecting rod 3. Crankshaft

2. Connecting rod bearing 4. Connecting rod bearing cap
EX455
ENGINE OVERHAUL
Removal
1. Remove the cylinder head assembly.
Refer to “Cylinder Head Removal” in this manual.
2. Remove the oil pan.
Refer to “Oil Pan Removal” in this manual.
3. Remove the piston with connecting rod.
• Remove carbon deposits from the upper position
of the cylinder wall with a scraper.
• Loosen the connecting rod cap bolts.
• Move the piston to the top of the cylinder and tap
it with a hammer grip or similar object from the
connecting rod lower side to drive it out.
CAUTION
Take care not to damage the oil jets.
SM7200
SM7837
W5-3-65
4. Remove the connecting rod bearings.
• Keep the connecting rod bearings in order for
reinstallation to their original positions.
• Inspect the connecting rod bearings for damage
and wear.
Installation
1. Install the piston with connecting rod.
• Clean the piston in solvent to remove all sludge.
• Wipe away any foreign material in the cylinder
bores and on the pistons and connecting rods.
• Install the upper connecting rod bearings to the
connecting rods.
SM7202
• Install the lower connecting rod bearings to the
bearing caps.
• Apply engine oil to the cylinder wall, upper/lower
bearing surfaces and crank pins of the crank-
shaft. Apply engine oil to the entire circumference
of the piston rings.
W5-3-66 EX455

ENGINE OVERHAUL

SM7838 SM7839

• Position the piston ring gap as shown in the • Use the piston setting tool 1-8522-0059-1 to
illustration. install the piston with the connecting rod to the
Gap position: cylinder block. At this time rotate the crankshaft
until the crankpin is at bottom dead center.
1. 1st compression ring
2. 2nd compression ring
3. 3rd compression ring
4. Oil ring
5. Coil expander

Front mark

SM7840

CAUTION
Do not bend or damage the oil jet.
SM7203

• Apply molybdenum disulfide grease to the

• Position the piston head front mark (1) so that it threads and setting faces of each connecting rod
is facing the front of the engine. bolt.
EX455 W5-3-67

ENGINE OVERHAUL

SM7202

• Tighten the connecting rod cap bolts in three

steps using the angular tightening method.
Torque:
1st step: 98 N•m (1.0 kgm)
2nd step: 30 deg.
3rd step : 30 deg.
• Check that the crankshaft rotates smoothly.
2. Install the oil pan to the cylinder block.
Refer to “Oil Pan Installation” in this manual.
3. Install the cylinder head to the cylinder block.
Refer to “Cylinder Head Installation” in this manual.
W5-3-68 EX455

ENGINE OVERHAUL

Disassembly

SM7841

Legend

1. Piston rings 5. Connecting rod

2. Snap ring 6. Connecting rod cap
3. Piston pin 7. Bearings
4. Piston
EX455 W5-3-69

ENGINE OVERHAUL

4. Remove the snap ring (1).

CAUTION Use a pair of snap ring pliers to remove the snap
rings.
Do not bend or damage the oil jet.

NOTE: When removing the piston and connection rod

assembly, pull the connecting rod parallel to the
cylinder bore.

1. Remove the connecting rod cap.

2. Remove the bearings.
• Take out the connecting rod bearing cap bolts
and disassemble the bearing cap with the lower
bearing.
• Keep the connecting rod bearings in order for
reinstallation to their original position.
3. Remove the piston rings.
• Clamp the connecting rod in a vise. Take care
not to damage the connecting rod.
SM7209
• Use a piston ring replacer to remove the piston
rings.
Do not use some other tool to remove the piston
rings. Piston ring stretching will result in reduced 5. Remove the piston pin.
piston ring tension. 6. Remove the piston.
7. Remove the connecting rod.
Tap out the piston pin with a hammer and a brass
bar.
Keep the piston and piston rings in order for
installation to their original position.

Inspection and Repair

Make the necessary adjustments, repairs, and part

replacements if excessive wear or damage is discov-
ered during inspection.

PISTON RING GAP

1. Insert the piston ring horizontally (in the position it
would assume if it were installed to the piston) into
the cylinder liner bore.
SM7208
2. Push the piston ring into the cylinder liner bore until
it reaches the point where the cylinder liner bore is
the smallest.
Do not allow the piston ring to slant to one side or
the other. It must be perfectly horizontal.
W5-3-70 EX455

ENGINE OVERHAUL

PISTON RING AND PISTON RING GROOVE

CLEARANCE
1. Visually inspect the piston ring grooves.
If a piston ring groove is damaged or distorted, the
piston must be replaced.
2. Use a feeler gauge (1) to measure the clearance
between the piston ring and the piston ring groove
at several points around the piston.
3. When measuring the clearance for the 1st piston
ring, press the 1st piston ring with a straight gauge
(2) as shown in the illustration.

SM7210

3. Use a feeler gage to measure the piston ring gap.

If the measured value exceeds the specified limit,
the piston ring must be replaced.
Piston ring gap
1st, 3rd ring:
Standard: 0.35 - 0.50 mm (0.0138 - 0.0197 in)
Limit: 1.0 mm (0.0394 in)
2nd ring:
Standard: 0.80 - 0.95 mm (0.0315 - 0.0374 in)
SM7212
Limit: 1.0 mm (0.0394 in)
Oil ring:
Standard: 0.30 - 0.50 mm (0.0118 - 0.0197 in) Piston ring and piston ring groove clearance
Limit: 1.0 mm (0.0394 in) 1st ring:
Standard: 0.115 - 0.160 mm (0.0045 - 0.0063 in)
Limit: 0.24 mm (0.0094 in)
2nd, 3rd ring:
Standard: 0.10 - 0.135 mm (0.0039 - 0.0053 in)
Limit: 0.20 mm (0.787 in)
Oil ring:
Standard: 0.025 - 0.065 mm (0.0010 - 0.0026 in)
Limit: 0.15 mm (0.0059 in)

SM7211

SM7213
EX455 W5-3-71

ENGINE OVERHAUL

PISTON RING EXPANSION FORCE PISTON PIN HOLE AND PISTON PIN CLEARANCE
Use an expansion force gauge to measure the piston Use a inside dial indicator to measure the piston pin
ring expansion force. hole (in the piston).
Piston ring expansion force Piston pin hole and piston pin clearance
1st ring: Standard: 0.008 - 0.021 mm (0.0003 - 0.0008 in)
Standard: 38.5 - 49.2 N Limit: 0.05 mm (0.0020 in)
(3.92 - 8.64 kg/8.64 - 11.07 lb)
Limit: 29 N (3.0 kg/6.6 lb) PISTON PIN AND CONNECTING ROD SMALL END
2nd ring: BUSHING CLEARANCE
Standard: 29.9 - 38.7 N Use a caliper and dial indicator to measure the clear-
(3.05 - 3.95 kg/6.73 - 8.71 lb) ance between the piston pin and connecting rod small
Limit: 20 N (2.0 kg/4.4 lb) end bushing
3rd ring: If the clearance between the piston pin and the
Standard: 28.1 - 36.6 N connecting rod small end bushing exceeds the speci-
(2.87 - 3.73 kg/6.33 - 8.22 lb) fied limit, replace the piston pin and/or the connecting
Limit: 20 N (2.0 kg/4.4 lb) rod assembly.
Oil ring: Small end bushing clearance
Standard: 85.3 - 104.9 N Standard: 0.020 - 0.037 mm (0.0079 - 0.0016 in)
(8.7 - 10.7 kg/19.2 - 23.6 lb) Limit: 0.10 mm (0.0039 in)
Limit: 64 N (6.5 kg/14.3 lb)

PISTON PIN DIAMETER

Use a micrometer to measure the piston pin outside
diameter at several points
If the measured value is less than the specified limit,
the piston pin must be replaced.
Piston pin diameter
Standard: 55.995 - 56.000 mm (2.2015 - 2.2047 in)
Limit: 55.970 mm (2.2035 in)

SM7215

SM7214
W5-3-72
ENGINE OVERHAUL
CONNECTING ROD ALIGNMENT
Use a connecting rod aligner to measure the distor-
tion and the parallelism between the connecting rod
big end hole and the connecting rod small end hole. If
either the measured distortion or parallelism exceeds
the specified limit, the connecting rod must be re-
placed.
Connecting rod alignment
Per length of 100 mm (3.94 in)
Standard: 0.05 mm (0.002 in) or less
Limit: 0.20 mm (0.008 in)
SM7216
EX455
CRANKSHAFT AND CONNECTING ROD BEARING
CLEARANCE
1. Clean the crankshaft, connecting rod, bearing
cap, and bearings.
2. Install the bearing to the connecting rod and bear-
ing cap.
3. Apply a coat of molybdenum disulfide grease to
the bearing cap bolt threads and setting faces.
4. Prevent the connecting rod from moving.
5. Tighten the bearing cap to the specified torque.
Connecting rod bearing cap bolt torque
1st step: 98.1 N•m (10.0 kgm)
2nd step: 30 deg.
3rd step: 30 deg.
6. Use a dial indicator to measure the connecting rod
bearing inside diameter.
Crankpin and connecting rod bearing clear-
ance
Standard: 0.033 - 0.103 mm (0.0013- 0.0041 in)
Limit: 0.16 mm (0.0063 in)
SM7217
EX455
ENGINE OVERHAUL
7. If the clearance between the measured bearing
inside diameter and the crankpin exceeds the
specified limit, the bearing and/or crankshaft must
be replaced.
SM7218
CONNECTING ROD AND CRANKSHAFT CLEAR-
ANCE
1. Fix the connecting rod assembly to the crankshaft
using the specified torque.
2. Use a feeler gauge to measure the clearance
between the connecting rod and crankshaft. If the
measured value exceeds the specified limit, the
connecting rod must be replaced.
Connecting rod and crankshaft clearance
Standard: 0.175 - 0.290 mm (0.0069 - 0.0114 in)
Limit: 0.35 mm (0.0138 in)
SM7219
W5-3-73
PISTON AND LINER BORE CLEARANCE
If the cylinder liner has been replaced, install the
piston using service parts. The cylinder liner bore and
pistons have only one grade. It is not necessary to
select the piston grade.
1. Measure the cylinder liner bore. Refer to the
“Cylinder Liner Bore Measurement.” Measuring
Point 130 mm (5.118 in)
Cylinder liner bore
Standard: 147.011 - 147.030 mm
(5.7878 - 5.7886 in)
130mm
SM7842
2. Measure the piston outside diameter (Reference).
Piston Measuring Point: 113 mm (4.449 in)
113mm
SM7843
W5-3-74 EX455

ENGINE OVERHAUL

The grade mark is stamped on the top of the piston • Apply engine oil to the piston pin.
installed at the factory, but service part pistons do not • Insert the piston pin to the connecting rod
have any grade (single grade). through the piston pin hole in the piston.
Piston outside diameter • Install the snap ring.
3. Install the piston ring.
Standard: 146.830 - 146.845 mm
• Apply engine oil to the piston rings.
(5.7805 - 5.7813 in)
• Confirm the discrimination mark on the piston
Piston and Liner bore clearance ring.
Standard: 0.166 - 0.200 mm (0.0065 - 0.0079 in) Discrimination mark
If the piston and liner clearance exceeds the standard 1st ring: Red color
value, the piston and/or liner must be replaced.
2nd ring: Blue color
3rd ring: Green color
CAUTION Oil ring: Not available
Cylinder liner kit clearances are preset. However,
the cylinder liner installation procedure may result
in slight decreases in cylinder liner clearances.
Always measure the cylinder liner clearance after
installation to be sure that its is correct.

Reassembly

1. Install the snap ring (1).

Use a pair of snap ring pliers to reassemble the
snap ring to the piston.
2. Install the connecting rod and piston pin.
• Clamp the connecting rod in a vise. Take care
not to damage the connecting rod.
Red Blue Green
• Install the piston so that the piston head front
mark and the connecting rod front mark are set in
the same direction.
SM7844

SM7209

SM7222
EX455 W5-3-75

ENGINE OVERHAUL

• Use the piston ring setting tool 1-85221-029-0 to Gap position

reassemble the four piston rings according to 1. 1st compression ring
the top mark on the piston ring. 2. 2nd compression ring
The oil ring does not have a top mark. 3. 3rd compression ring
4. Oil ring
5. Coil expander
NOTE: Insert the expander coil into the oil ring groove
so that there is no gap on either side of the expander
coil before installing the oil ring.

Front mark

SM7203

• Apply molybdenum disulfide grease to the two

SM7208 piston skirts. This will facilitate smooth break-in
when the engine is first started after reassembly.
• Apply engine oil to the upper connecting rod
• Check that the piston rings rotate smoothly in the bearing.
piston ring grooves. • Apply engine oil to the cylinder wall.
• Position the front mark on the piston head so that
it is facing the front of the engine.

4. Install the connecting rod bearing.

Carefully wipe any oil or other foreign material
from the connecting rod bearing back faces and
the bearing fitting surfaces. Front mark
5. Install the connecting rod cap.
• Fit the lower connecting rod bearing to the
connecting rod cap.
Engine front
• Apply engine oil to the circumference of each
piston ring, piston and crankpin.
• Position the piston ring gaps as shown in the
illustration. Front mark

SM7845
W5-3-76 EX455

ENGINE OVERHAUL

• Use the piston ring setting tool 1-85222-0059-0

to compress the piston rings.

SM7202

SM7840

• Use a hummer grip to push the piston in until the

connecting rod marks contact the crankpin.
As the same time, rotate the crankshaft until the
crankpin is at bottom dead center.

CAUTION
Do not bend or damage the oil jet.

• Align the connection rod cap cylinder number

marks and the connecting rod cylinder number
marks.
• Install the connection rod caps.
• Apply molybdenum disuifide grease to the
threads and setting faces of each connecting rod
bolts and nuts.
• Tighten the connecting rod nut to the specified
torque.
Torque:
1st step: 93 N•m (10.0 kgm)
2nd step: 30°
3rd step: 30°
EX455 W5-3-77

ENGINE OVERHAUL

CRANKSHAFT

SM7846

Legend

1. Piston with connecting rod 4. Crankshaft

2. Connecting rod bearing 5. Crankshaft bearing
3. Lower crankcase 6. Crankshaft thrust bearing
W5-3-78 EX455

ENGINE OVERHAUL

Removal
1. Remove the cylinder head assembly.
Refer to "Cylinder Head" in this section.

2. Remove the oil pan.

Refer to "Oil Pan” in this section.

3. Remove the timing gear.

Refer to "Timing Gear" in this section.

4. Remove the flywheel.

Refer to "Flywheel" in this section.

5. Remove the piston with connecting rod.

Refer to "Piston" in this section.
SM7848
6. Measure the crankshaft end play at the No. 1
crankshaft journal before removing the crankshaft
thrust bearing. If the measured value exceeds the
8. Remove the crankshaft from the cylinder block.
specified limit, the crankshaft thrust bearing must
9. Remove the crankshaft bearing.
be replaced.
• Mark, sort or organize the connecting bearing for
Crankshaft end play
assembly to the original location.
Standard: 0.04 - 0.18 mm (0.0016 - 0.0070 in)
10. Remove the crankshaft thrust bearing.
Limit: 0.35 mm (0.0138 in)
Installation
1. Install the upper crankshaft bearings to the cylin-
der block.
• Carefully wipe any foreign material from the
upper crankshaft bearings and the cylinder
block bearing fitting surfaces.
All crankshaft bearings have oil grooves.
• Install the upper bearings to their original posi-
tion, if they are reused.

CAUTION
Do not apply engine oil to the bearing back faces
and cylinder block bearing surfaces.

SM7847

7. Remove the lower crankcase.

• Loosen the crankcase bolts a little at a time in
the numerical order shown in the illustration.
• Use M10 bolts into the holes (1) for replacement
to remove the crankcase lower.
EX455 W5-3-79

ENGINE OVERHAUL

Dowel pin hole

Cylinder body side

Crankcase side
Oil groove

SM7849 SM7851

4. Install the lower crankcase to the cylinder block.

2. Install the crankshaft to the cylinder block.
• Carefully wipe any foreign materials from the
• Clean the crankshaft in solvent. Remove all
fitting area of the crankcase.
sludge or restrictions from the oil passages.
• Apply Loctite FMD127 or equivalent to cylinder
• Apply engine oil to the crankshaft journal and
block lower surfaces.
crankshaft bearing surfaces before installing the
The sealant must be 0.3 mm thick and 4 mm wide.
crankshaft.
• Install the crankshaft bearings and thrust bearing.

CAUTION
Do not apply engine oil to the bearing back.

NOTE: The thrust bearing oil grooves must be facing

the sliding face.

SM7850

Apply FMD-127
3. Install the crankshaft thrust bearing.
• Apply engine oil to the thrust bearing oil grooves
side.
• Install the upper thrust bearing to both side of the
No. 1 journal by hand.
Cylinder body lower surface
NOTE: The thrust bearing oil groove must be faced the
sliding side.

SM7852
W5-3-80 EX455

ENGINE OVERHAUL

5. Install the piston with the connecting rod.

Refer to "Piston" in this section.

6. Install the flywheel to the crankshaft.

Refer to "Flywheel Housing" in this section.

7. Install the timing gears to the cylinder block.

Refer to "Timing Gear" in this section.

8. Install the oil pan to the cylinder block.

Oil groove
Refer to "Oil Pan" in this section.

9. Install the cylinder head to the cylinder block.

Refer to "Cylinder Head" in this section.

SM7853

• Install the lower crankcase to the cylinder block.

• Apply molybdenum disulfide grease to the crank-
case bolts (M18) threads and setting faces.
• Apply engine oil to the crankcase bolts (M12)
threads and setting faces.
Order 1 to 14 in the three steps using the angular
tightening method.
M18 bolt
Torque:
1st step: 49 N•m (5.0 kgm)
2nd step: 88 N•m (9.0 kgm)
3rd step: 90 - 120 deg.
M12 bolt
Torque: 96 N•m (9.8 kgm)

SM7854
EX455 W5-3-81

ENGINE OVERHAUL

Disassembly

SM7855

Legend

1. Crankshaft
2. Bearings
3. Crankshaft gear

1. Remove the crankshaft assembly (1) from the

cylinder block.

2. Remove the crankshaft bearing and thrust bearing

(2).

3. Use the crankshaft gear remover 1-8521-0064-0 to

remove the crankshaft gear (3).
If the slinger on the crankshaft remain, remove
slinger by the slinger remover 1-8521-0027-0.

CAUTION
The crankshaft must not be ground as it has been
treated by soft nitriding to enhance the crankshaft
strength. SM7240
W5-3-82 EX455

ENGINE OVERHAUL

Inspection and Repair CRANKSHAFT RUN-OUT

Make the necessary adjustments, repairs, and part 1. Set a dial indicator to the center of the No.4
replacements if excessive wear or damage is discov- crankshaft journal.
ered during inspection. 2. Gently turn the crankshaft in the normal direction of
engine rotation.
CRANKSHAFT JOURNAL AND CRANKPIN DIAM- Read the dial indicator as you turn the crankshaft.
ETER If the measured value exceeds the specified limit,
the crankshaft must be replaced.
1. Use a micrometer to measure the crankshaft jour-
nal diameter across points (1) - (1) and (2) - (2). Crankshaft run-out
2. Use the micrometer to measure the crankshaft Standard: 0.120 mm (0.0005 in)
journal diameter at the two points ((3) and (4)). Limit: 0.15 mm (0.0059 in)
3. Repeat Steps 1. and 2. to measure the crankshaft
pin diameter.
If the measured values are less than the standard
value, the crankshaft must be replaced.
Crankshaft journal and Crankpin diameter
Standard:
No. 4 journal: 104.850 - 104.875 mm
(4.1279 - 4.1289 in)
Others: 104.880 - 104.905 mm
(4.1291 - 4.1309 in)
Crankpin: 91.895 - 91.925 mm
(3.6179 - 3.6191 in)

SM7856 SM7242
EX455 W5-3-83

ENGINE OVERHAUL

BEARING SPREAD
Use a vernier caliper to measure the bearing spread.
If the measured value is less than the specified limit,
the bearing must be replaced.
Bearing spread:
Limit: 111.5 mm (4.3898 in)

SM7854

• Measure the crankshaft bearing inside diameter

by a dial indicator.
• If the clearance between the crankshaft journal
and bearing exceeds the specified limit, the
crankshaft must be replaced:
No. 4 journal
SM7857
Standard: 0.081 – 0.144 mm (0.0032 – 0.0057 in)
Limit: 0.16 mm (0.0063 in)
Others
CRANKSHAFT JOURNAL AND BEARING CLEAR- Standard: 0.051 – 0.114 mm (0.0020 – 0.0045 in)
ANCE
Limit: 0.16 mm (0.0063 in)
• Clean the cylinder block and lower crankcase, the
journal bearing fitting surface, and the journal
bearings.
• Install the bearing to the cylinder block and lower
crankcase
• Reasselbly the lower crankcase to cylinder block.
• Apply molybdenum disulfide grease to the M18
blolts and apply engine oil to the M12 bolts thread
and it seat.
• Tighten the lower crankcase to the specified
torque in the numerical order shown in the illustra-
tion.
Cranckcase bolt torque
M18 bolt
Torque:
1st step: 49 N•m (5.0 kgm)
2nd step: 88 N•m (9.0 kgm) SM7244
3rd step: 90 - 120°
M12 bolt
Torque: 96 N•m (9.8 kgm)
W5-3-84 EX455

ENGINE OVERHAUL

CRANKSHAFT JOURNAL AND BEARING CLEAR- • Tighten the lower crankcase to the specified
ANCE (WITH PLASTIGAGE) torque in the numerical order shown in the illustra-
tion.
• Clean the cylinder block and lower crankcase, the
Crankcase bolt torque
journal bearing fitting surface, and the journal
bearings. M18 bolt
• Install the bearings to the cylinder block and lower 1st step: 49 N•m (5.0 kgm)
crankcase. 2nd step: 88 N•m (9.0 kgm)
• Reassembly the crankshaft to the cylinder block.
3rd step: 90 - 120°
• Cut the plastigage same wide of crankshaft jour-
nal and put it on the crankshaft journal. M12 bolt
• Reassembly the lower crankcase to the cylinder Torque: 96 N•m (9.8 kgm)
block.
• Apply molybdenum disulfide grease to the M18
bolts and apply engine oil to the M12 bolts thread
and it seat.

SM7854

• Carefully disassembly the lower crankcase from

the cylinder block.
• Measure the width of plastigage by the scale
which printed on the plastigage envelop.
SM7858
• If the clearance between the crankshaft journal
and bearing exceeds the specified limit, the
crankshaft must be replaced.
Crankshaft journal and bearing clearance
No. 4 journal
Standard: 0.081 - 0.144 mm (0.0032- 0.0057 in.)
Limit: 0.16 mm (0.0063 in.)
Others
Standard: 0.051 - 0.114 mm (0.0020 - 0.0045 in.)
Limit: 0.16 mm (0.0063 in.)
EX455 W5-3-85

ENGINE OVERHAUL

CRANKSHAFT TUFFTRIDING JUDGMENT

• Wait for 30 to 40 seconds.
If there is no discoloration after 30 or 40 seconds,
the crankshaft is usable.
If discoloration appears (the surface being tested
will become the color of copper), the crankshaft
must be replaced.
• Steam clean the crankshaft surface immediately
after completing the test.

NOTE: The ammonium cuprous chloride solution is

highly corrosive. Because of this, it is imperative that
the surfaces being tested by cleaned immediately
after completing the test.
SM7859

CRANKSHAFT TUFFTRIDING INSPECTION

• Use an organic cleaner to thoroughly clean the
crankshaft. There must be no traces of oil on the
surface to be inspected.
• Prepare a 5 -10% solution of ammonium cuprous
chloride (dissolved in distilled water).
• Use a syringe to apply the solution to the surface to
be inspected.
Hold the surface perfectly horizontal to prevent the
solution from running.

NOTE: Do not allow the solution to come in contact

with the oil ports and their surrounding area.

The portion to be tested

must be held horizontally Test liquid should
so as not to let the test not be applied to
solution flow. the area around the
oil port.
The sliding surface
of the pin
or journal.

Approximatery
10 mm (0.4 in)

SM7245
W5-3-86 EX455

ENGINE OVERHAUL

Reassembly
1. Install the crankshaft gear to the crankshaft.
• Use the oil heater to heat the crankshaft gear to
170 -180 °C (338 - 356 °F).
• With the timing alignment mark "O" on the side of
crankshaft gear turned outward, align the key
groove on the crankshaft gear with the crankshaft
dowel pin position.
• Hammer it in with a crankshaft gear installer
1-8522-0045-0 until it hits the bottom.

CAUTION
When hammered in with the gear slanted, the
crankshaft gear may be caught in the middle and
cannot be hammered in fully. Hammer it in quickly
enough not to allow a shaft line along the gear and
the crankshaft to slant.

SM7860

2. Install the bearings.

Install the crankshaft bearings and thrust bearings.
Refer to "Crankshaft" in this section.

3. Install the crankshaft to the cylinder block.

Refer to "Crankshaft" in this section.
EX455 W5-3-87

ENGINE OVERHAUL

CRANK PULLEY

SM7861

Legend

1. Crank pulley
2. Crankshaft damper
W5-3-88 EX455

ENGINE OVERHAUL

Disassembly Inspection
1. Loose the crankshaft pulley fixing bolts to disas-
Visually inspect the crankshaft damper for cracking or
semble the crank pulley.
separation.

SM7822 SM7863

2. Loose the fixing bolts to disassemble the crank-

shaft damper.

SM7862
EX455 W5-3-89

ENGINE OVERHAUL

Reassembly
1. Install the crankshaft damper.
• Install the crankshaft damper to the pulley with
the two grooves face to the front side.
• Tighten the bolts in numerical order to the speci-
fied torque shown in the illustration.
Torque: 96 N•m (9.8 Kgm)

SM7862

2. Install the pulley and damper assembly to the

crankshaft.
• Apply engine oil to the threads of fixing bolts.
• Tighten the bolts in numerical order to the speci-
fied torque shown in the illustration.
Torque: 267 N•m (27.2 kgm)

SM7822
W5-3-90 EX455

ENGINE OVERHAUL

FLYWHEEL

SM7864

Legend

1. Ring gear
2. Flywheel
3. Washer
EX455 W5-3-91

ENGINE OVERHAUL

Disassembly Reassembly
1. Loose the fixing bolts to remove flywheel from the
crankshaft. 1. Heat the ring gear evenly with a burner to invite
2. Put the flywheel with ring gear on the wood piece thermal expansion.
and strike around the edges of the ring gear with Do not allow the temperature of the gas burner to
a hammer and brass bar to remove it. exceed 200 °C (392 °F).
2. Install the ring gear to the flywheel when it is
sufficiently heated.
The ring gear must be installed with the chamfer
facing the flywheel.

WARNING
Take care not to burn yourself on the heated ring
gear.

SM7865

Inspection and Repair

1. Visually inspect the flywheel for cracking, scratch-

ing or worn out.
2. Visually inspect the ring gear for damage.

SM7160

SM7866
W5-3-92 EX455

ENGINE OVERHAUL

CYLINDER BLOCK

SM7867

Legend

1. Oil relief valve 4. Oil pressure switch

2. Cylinder liner 5. Oil jet
3. Cylinder block 6. Lower crankcase
EX455 W5-3-93

ENGINE OVERHAUL

Disassembly Inspection and Repair

1. Remove the lower crankcase. Make the necessary adjustment, repairs, and part
• Loosen the fixing bolts to disassemble the lower replacements if excessive wear or damage is discov-
crankcase. ered during inspection.
• Place the crankcase on a flat piece of wool.
2. Remove the oil jet. CYLINDER BLOCK FLATNESS
Loosen the bolt to remove the oil jet. • Remove the cylinder liners.
• Inspect the cylinder block for cracks and other
NOTE: Take care not to bend or damage the oil jet. damage. Check the oil and water holes for clogging.
If possible, use dye pendant flow detector.
3. Remove the cylinder liner.
• Use a scraper to remove carbon deposits.
• Use a cylinder bore dial indicator to measure the
cylinder bore in the thrust and axial direction of
the crankshaft before removing the cylinder
liner.
Measuring point: 20 - 25 mm (0.79 -1.0 in)
If the measured value exceeds the specified
limit, the cylinder liner must be replaced.
Cylinder liner bore
Limit: 147.3 mm (5.7992 in)

NOTE: If the inside of the cylinder liner is scored or

scratched, the cylinder liner must be replaced.
SM7869

• Use a straight edge (1) and a feeler gauge (2) to

measure cylinder block upper face warpage (4 sides
and 2 diagonals as shown in the illustration).
Upper face warpage
Standard: 0.075 mm (0.0030 in) or less
Limit: 0.2 mm (0.008 in)

If the measured value exceeds the specified limit,

the cylinder block must be replaced.

SM7868

Visually inspect the cylinder block for damage.

SM7870
W5-3-94 EX455

ENGINE OVERHAUL

• Apply water under pressure to the cylinder body

water jacket to check for leakages.
Water Pressure: 490 kPa (5 kg/cm2/70 psi)
If water leakage is found, the cylinder block must be
replaced.

CYLINDER LINER GRADE SELECTION AND

STANDARD FITTING INTERFERENCE
Accurately measured fitting interference and proper Liner outside
cylinder liner grade selection are extremely impor- Grade No.
tant.
If the cylinder liner fitting interference is too small,
engine cooling efficiency will be adversely affected.
If the cylinder liner fitting interference is too large, it will
be difficult to insert the cylinder liner into the cylinder
block. SM7871
A mark was stamped on the left side of the cylinder
block during production to indicate the correct liner.
The liner grade (1, 2, 3) is indicated by a metal stamp.

Cylinder liner grade

Liner Cylinder Bore Service
Grade Diameter mm (in) Grade
151.600 - 151.610
1 1X
(5.9685 - 5.9689)
151.611 - 151.630
2-3 3X
(5.9689 - 5.9697)
Liner Outside
Diameter mm (in)
151.590 - 151.599
(5.9681 - 5.9685)
151.600 - 151.610
(5.9685 - 5.9689)

The cylinder liner grade is stamped on the outside of Grade No.

the cylinder liner.

SM7872
EX455 W5-3-95

ENGINE OVERHAUL

Lower Crankcase Relief Valve

Visually inspect the lower crankcase for cracking or Inspect the relief valve for choking.
damage.
If possible it is required to specially inspect by dye
penetrant flaw detector.

SM7875

SM7873
Cylinder Liner Projection

• Use a dial indicator or a straight edge and feeler

gauge to measure the cylinder liner projection.
Oil Jet
Cylinder liner projection
Check the oil port on the oil jet for choking. Standard: 0.05 - 0.09 mm (0.0020 - 0.0035 in)
The difference in the cylinder liner projection
height between any adjacent cylinders must not
exceed limit.
Projection height between adjacent cylinder:
0.02 mm (0.0008 in) or less

SM7874

SM7876
W5-3-96 EX455

ENGINE OVERHAUL

Reassembly

1. Install the cylinder liner into the cylinder block.

• Use new kerosene or diesel fuel to thoroughly
clean the cylinder liner and bore.
• Use compressed air to brow-dry cylinder liner
and bore surface.

WARNING
Pressure air can cause personal injury when using
pressure air for cleaning. Wear safety glasses and
protection clothing.

SM7876
NOTE: All foreign materials must be carefully re-
moved from the cylinder liner and the cylinder bore
before installation.
2. Install the oil jet to the cylinder block.
Tighten to the specified torque.
• Apply engine oil to outside surface cylinder liner.
Torque: 69 N•m (7.0 kgm)
• Install the cylinder liner into the cylinder block
from the top of the cylinder block by your hand. Be sure direction of the oil jet tip to cooling hole of
• Check cylinder liner projection. piston.
Do not bend or damage the oil jet.

NOTE:
1) Do not apply unreasonableness stress or hit the
cylinder liner during installing.
2) Take care to not remove the cylinder liner when
cylinder block turns over.

SM7877

3. Install the crankshaft to the cylinder block.

Refer to "Crankshaft" in this section.
4. Install the lower crankcase.
Refer to "Crankshaft" in this section.
SM7257
EX455 W5-3-97

ENGINE OVERHAUL

5. Install the oil relief valve.

• Apply engine oil to the relief valve assembly with
new gasket.
• Install the relief valve to the cylinder block to the
specified torque.
Torque: 20 N•m (2.0 kgm)

SM7878

6. Install the oil pressure unit.

• Install the adapter with new gasket to the cylin-
der block to the specified torque.
Torque: 41 N•m (4.2 kgm)

SM7878
W5-3-98 EX455

ENGINE OVERHAUL

NOTE:
EX455 W5-4-1

ENGINE LUBRICATION

SERVICE PRECAUTION

CAUTION
Always use the correct fastener in the proper
location. When you replace a fastener, use ONLY
the exact part number for that application. ISUZU
will call out those fasteners that require a replace-
ment after removal. ISUZU will also call out the
fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct tighten-
ing sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

GENERAL DESCRIPTION

Lubricating Oil Flow

Lubrication system is of pressure feed circulation
system with a gear type oil pump driven by crankshaft.
Oil flows from the oil pump though oil cooler to main oil
filter for oil cooling and oil cleaning.
From the main oil filter it moves to the cylinder block
oil gallery and the oil circulates to lubricates the engine
parts.
Oil jets are installed to the cylinder block main oil
gallery in the inside portion of the cylinder block.
The jet sprays oil to the inside portions of the pistons
for lubrication and cooling.

Oil Pump and Oil Filter

The oil pump is of a gear type with a relief valve. The
pump is driven by the timing gear.
A full flow main oil filter with a highly efficient paper
element used.
Should the element become clogged with sludge or
other foreign material, a by-pass valve open to route
the oil directly to the oil gallery.
A warning lamp will light at this time to warn the
operator of the equipment the oil directly to the oil
gallery.
The oil is cleaned and delivered to the oil pan.

Oil Cooler
The temperature of the engine oil circulating through
the lubricating system tends to rise with an accompa-
nying decrease in lubricating efficiency.
The oil cooler maintains the oil temperature at the
optimum level for effective engine lubrication.
The oil cooler consists of the body and the cooling
element.
 LUBRICANT FLOW CHART
W5-4-2

CYLINDER BODY
RIGHT AND OIL GALLERY CYLINDER BODY LEFT HAND OIL GALLERY

REMOTE OIL
TYPE PRESS. TIMING INJECTION
OIL CYLINDER HEAD UNIT & GEAR PUMP
FILTER SWITCH OILING
JET

TURBO
OIL CHARGER
FILTER OIL PORT
RELIEF COVER
VALVE CAMSHAFT IDLE IDLE
JOURNAL IDLE GEAR OILING JET GEAR
GEAR
(No & 5) “A” “C”
“B”

ROCKER
RELIEF CRANKSHAFT
OIL ARM
VALVE
COOLER SHAFT JOURNAL

OIL CAMSHAFT ROCKER

THERMOVALVE JOURNAL ARM & CRANKPIN
(No 1,3,4,6) VALVE
ENGINE LUBRICATION

CONNECTING
ROD
OIL BUSHING
RELIEF
PUMP
VALVE

OIL PAN
STRAINER

Relief valve opening kPa (kg/cm2/psi) ➃ Oil thermostat opening temperature °C (°F) 98 (208)
➀ 690 (7.0/99.5)
➁ 200 (2.0/28.4)
EX455

➂ 440 (4.5/64.0)
EX455 W5-4-3

ENGINE LUBRICATION

OIL PUMP

SM7881

Legend

1. Cover 7. Oil pump drive gear

2. Ball 8. Oil pump cover
3. Split pin 9. Oil pump driven gear
4. Spring seat 10. Drive gear shaft
5. Spring 11. Oil pump body
6. Oil relief valve
W5-4-4 EX455

ENGINE LUBRICATION

Disassembly
1. Loosen bolts to remove the cover 5. Loosen the fixing bolts to remove the oil pump
cover.
2. Take out the ball from the oil pump assembly.

3. Remove the split pin, spring seat, spring and oil

relief valve.

SM7882 SM7884

4. Use a gear puller to pull out the oil pump drive gear. 6. Take out the oil pump driven gears and drive gear
shaft from oil pump body.

SM7883 SM7885
EX455 W5-4-5

ENGINE LUBRICATION

Inspection and Repair SIDE CLEARANCE BETWEEN OIL PUMP COVER

AND GEARS
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discov- Use a feeler gauge to measure the side clearance
ered during inspection. between the oil pump cover and gears.
Standard: 0.040 - 0.094 mm (0.0016 - 0.0037 in)
BALL
Carefully inspect the ball scratches or damage.

OIL RELIEF VALVE

Inspect the oil relief valve seat portion damage and
spring damage.

NOTE: If there is some scratch or damage, the ball and

relief valve must be replaced.

SM7888

SM7886

CLEARANCE BETWEEN OIL PUMP BODY AND

DRIVEN GEAR
Use a feeler gauge to measure the clearance between
the oil pump body and driven gear.
Standard: 0.050 - 0.098 mm (0.0020 - 0.0039 in)
Limit: 0.15 mm (0.0059 in)

SM7887
W5-4-6 EX455

ENGINE LUBRICATION

OIL PUMP GEAR SHAFT OUTSIDE DIAMETER INTERFERENCE BETWEEN OIL PUMP DRIVE
AND CLEARANCE BETWEEN OIL PUMP GEAR GEAR AND DRIVE GEAR SHAFT
SHAFT AND OIL PUMP BODY
Measure the inside diameter of oil pump drive gear and
Use an inside and outside micrometer to measure the outside diameter of drive gear shaft.
oil pump gear shaft outside diameter and oil pump An interference
body holes.
Standard: 0.019 - 0.047 mm (0.0007 - 0.0019 in)
Oil pump gear shaft diameter
Nominal measurement: 20.0 mm (0.7874 in)
NOTE: If measuring value exceeds from limit or
Limit: 19.9 mm (0.7835 in)
standard, the parts must be replaced.
Clearance between oil pump gear shaft and oil
pump body
Standard: 0.040 - 0.074 mm (0.0016 - 0.0029 in)

NOTE: If measuring value exceeds, the parts must be

replaced.

SM7889 SM7890
EX455 W5-4-7

ENGINE LUBRICATION

Reassembly

SM7891

1. Oil pump body 7. Oil pump cover

2. Oil pump driven gear 8. Relief valve
3. Ball 9. Split pin
4. Driven gear 10. Spring seat
5. Drive gear 11. Spring
6. Driven gear

1. Apply engine oil to the drive gear (1) and install the
drive gear to the oil pump body.

2. Install the oil pump drive gear (2).

• Put the oil pump drive gear (2) on the bed of bench
press, place the oil pump body with the drive gear
shaft.
• Use bench press to press the drive gear shaft into
the oil pump drive gear as shown in the illustra-
tion.

SM7892
W5-4-8 EX455

ENGINE LUBRICATION

3. Install the oil pump driven gear.
• Apply engine oil and install the oil pump driven
gear to the oil pump body.
5. Install the oil relief valve, spring and spring seat to
the oil pump body.
6. Install the split pin into the oil pump body and lock
it.

7. Install the ball.

8. Install the cover.

SM7885

4. Install the oil pump cover.

Tighten the bolts to the specified torque.
Torque:
M8: 17 N•m (1.8 kgm)
SM7882
M10: 39 N•m (4.0 kgm)

NOTE: Make sure the oil pump assembly to move

smoothly.

SM7884

SM7893
EX455 W5-4-9

ENGINE LUBRICATION

OIL COOLER

SM7894

Legend

1. Water guide 7. Oil thermostat

2. Oil cooler element 8. Spacer
3. Gasket 9. Supporter
4. Gasket 10. Seal ring
5. Oil pipe 11. Oil cooler body
6. Gasket
W5-4-10 EX455

ENGINE LUBRICATION

Disassembly Inspection and Repair

1. Loosen the bolts to remove the water guide.
2. Loose the nuts to remove the oil cooler element with
the gaskets.
3. Loosen the bolts to remove the oil pipe with the
gasket.
Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is discov-
ered during inspection.
Oil Cooler Element
Inspect the oil cooler element for cracking or damage.

SM7274 SM7274

4. Carefully remove the oil thermostat.

Oil Thermostat
1. Inspect for wear or damage on the piston and valve
seat.

2. Check for damage or decrease of the spring force.

3. Inspect opening temperature with oil heater.

Opening temperature: 98.0 °C (208.4 °F)

SM7895

5. Remove the spacer, supporter and seal ring from

the oil cooler body.

SM7895
EX455 W5-4-11

ENGINE LUBRICATION

Reassembly
1. Be sure seal ring direction shown in the illustration.

SM7898

5. Install the oil cooler element with new gaskets.

• Apply Three Bond 1208 to grooves to install the
SM7896
gaskets.
• Install the gaskets to the oil cooler element.
1. Seal ring • Reassemble the oil cooler element to the oil
2. Rotation stopper cooler body.
3. Supporter • Tighten the fixing nuts for oil cooler element to the
specified torque.
Torque: 25 N•m (2.5 kgm)
2. Install the supporter into the oil cooler body.
• Align the rotation stopper (2) on the supporter to
the oil cooler body as shown in the illustration.

SM7899

6. InstalI the water guide.

SM7897

3. Install the spacer and oil thermostat into the oil

cooler body.

4. Install the oil pipe to the oil cooler body.

• Install the oil pipe with new gasket to the oil cooler
body.
• Tighten the oil pipe to the specified torque
Torque: 39 N•m (4.0 kgm)
W5-4-12 EX455

ENGINE LUBRICATION

NOTE:
EX455 W5-5-1

ENGINE COOLING

SERVICE PRECAUTIONS GENERAL DESCRIPTION

CAUTION
Always use the correct fastener in the proper
location. When you replace a fastener, use ONLY
the exact part number for that application. ISUZU
will call out those fasteners that require a replace-
ment after removal. ISUZU will also call out the
fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct tighten-
ing sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
Coolant Flow
The cooling system main parts consist of the radiator,
the water pump, the water outlet pipe and the thermo-
stat.
This top-bypass type cooling system controls the
cooling water temperature though the thermostat in-
stalled at the water pump inlet.
The system maintains optimum cooling water volume
and minimizes cooling water temperature fluctuation
and hunting.
Thermostat
A wax pellet type thermostat is used.

Coolant Flow Chart

Cylinder
Head
Radiator

Cylinder
Thermostat Water Pump Oil Cooler
Body

SM7900
W5-5-2 EX455

ENGINE COOLING

WATER PUMP

SM7901

Legend

1. Rear cover 7. Gasket

2. Bearing 8. Shaft
3. Gear 9. Seal unit
4. Bearing 10. Impeller
5. Oil seal 11. Joint pipe
6. Pump body 12. Front cover
EX455 W5-5-3

ENGINE COOLING

Disassembly • Use the bench press the rear cover side to

1. Loosen the rear cover fixing bolts to remove the disassemble the bearings (1) and gear (2).
front cover.

2. Use the impeller remover (1) 1-8521-0062-0 to

remove the impeller from the shaft.

SM7902 SM7904

3. Remove the rear cover. 8. Remove the oil seal (1) .

4. Remove the small bearing. 9. Remove the seal unit (2).

5. Remove the gear.

NOTE: Do not make scratch or damage seating
6. Remove the large bearing. surface of the oil seal and the seal unit on the pump
body when disassemble them from the bump body.
7. Remove the shaft.
• Use bench press from the impeller side to disas-
sembly the shaft with the bearings and the gear.

SM7903 SM7905

10.Remove the pump body.

W5-5-4 EX455

ENGINE COOLING

Inspection and Repair 3. Inspect the shaft for damage or worn out.
Make the necessary adjustments. repair and part
replacement if excessive or damage wear is discov-
ered during inspection.
1. Inspect the impeller for corrosion and the seal unit
for worn out touching surface or some damage.

SM7908

Reassembly
1. Install the oil seal to the pump body.
• Apply engine oil to inside and outside of the oil
seal.
SM7906 • Seal lip face to upper and carefully press fit the oil
seal to the pump body.

2. Inspect the bearings.

• Wash bearing in the clean kerosene.
• Visually check scratches or damages on the ball
and bearing race.
• Rotate the bearing on your hand for hearing
abnormal noise.
• Check abnormal clearance between the ball and
bearing race.

SM7909

SM7907
EX455
ENGINE COOLING
2. Install the large bearing to the shaft.
• Apply engine oil to the shaft.
• Use a bench press to press the large bearing onto
the shaft.
• Use a bench press to press the shaft with large
bearing into the pump body.
SM7910
SM7911
W5-5-5
3. Install the gear on the shaft.
• Place the gear long boss side facing to bearing
large on the shaft.
• Use a bench press to press the gear onto the shaft
as shown in the illustration.
SM7912
4. Use the bench press to gradually press the bearing
small (1) into the rear cover.
SM7913
W5-5-6 EX455

ENGINE COOLING

5. Install the rear cover.
• Use a bench press to install the rear cover
assembly into the shaft shown in the illustration.
• Same time align bolt holes between rear cover
and pump body.
7. Use the bench press to gradually press the impeller
(1) until make specified clearance between the
impeller and pump body (2).
Clearance between impeller and pump body
Standard: 1.7 - 2.7 mm (0.0669 - 0.1063 in)

SM7914 SM7916

6. Use seal unit installer (1) 1-8522-0047-0 to install

8. Set the gasket to the pump body.
the seal unit (2).
9. Install the front cover.
• Align bolt hole together with rear cover assembly.
• Tighten the bolt from rear cover side to the
specified torque.
Torque: 28 N•m (2.8 kgm)

SM7915
EX455 W5-5-7

ENGINE COOLING

THERMOSTAT

SM7917

Legend

1. Seal ring 4. Thermostat housing

2. Thermostat 5. Gasket
3. Gasket 6. Temperature switch
W5-5-8 EX455

ENGINE COOLING

Disassembly 2. Perform the operating test.

Completely submerge the thermostat in water.
1. Loosen the fixing bolts to remove the thermostat
Heat the water.
housing.
Stir the water constantly to avoid direct heat being
Discard the gaskets.
applied to the thermostat.
Measure the thermostat initial opening tempera-
2. Remove the thermostat housing.
ture.
• Carefully remove the thermostat from the oil Thermostat initial opening temperature:
cooler case. 79 °C (174 °F)
Measure the thermostat full opening temperature.
3. Remove the seal ring. Thermostat full opening temperature:
• Loosen the seal ring puller 1-8521-0067-0 to take 95 °C (203 °F)
out the seal rings. Measure the valve lift at the thermostat full open
position.
Valve lift at full open position: 11 mm (0.433 in)

SM7918

SM7920

Inspection and Repair

Make the necessary adjustments, repair and part
replacements if excessive or damage wear is discov-
ered during inspection.

1. Visually inspect leakage of wax pellet, some dam-

age of the spring or caulking position on the
thermostat.

SM7919
EX455 W5-5-9

ENGINE COOLING

Reassembly 3. Install the thermostat housing with new gaskets.

1. Use the seal ring installer 1-8522-1034-0 to install
the seal ring to the oil cooler case, as the direction
of seal bring shown in the illustration.
• Set the gasket to the thermostat housing to install
the thermostat housing with the new gasket.
• Pushing the thermostat housing to oil cooler
case, initially tighten the water pump side bolts
then tighten the oil cooler side bolts to the speci-
fied torque.
Bolt Torque: 39 N•m (4.0 kgm)

SM7921

2. Carefully install the thermostat to oil cooler case

shown in the illustration. SM7742

4. Install the temperature switch on the portion "A" of

the thermostat housing.

SM7741

SM7922
W5-5-10 EX455

ENGINE COOLING

NOTE:
EX455 W5-6-1

ENGINE FUEL

SERVICE PRECAUTION GENERAL DESCRIPTION

Fuel System Operation

CAUTION
Always use the correct fastener in the proper
The engine crankshaft drives the fuel injection pump
location. When you replace a fastener, use ONLY
which in turn, drives the fuel feed pump.
the exact part number for that application. ISUZU
The fuel feed pump draws fuel from the fuel tank,
will call out those fasteners that require a replace-
through the fuel/water separator and transfers it, by
ment after removal. ISUZU will also call out the
way of the secondary fuel filter, into the injection
fasteners that require thread lockers or thread
pump. The governor regulates the flow of fuel to the
sealant. UNLESS OTHERWISE SPECIFIED, do
delivery valves. At the correct timing intervals a
not use supplemental coatings (Paints, greases, or
plunger in the injection pump sends fuel, at high
other corrosion inhibitors) on threaded fasteners or
pressure, through a delivery valve to one of the fuel
fastener joint interfaces. Generally, such coatings
injection nozzles.
adversely affect the fastener torque and the joint
Fuel pressure causes a needle valve in the fuel
clamping force, and may damage the fastener.
injection nozzle to open. Fuel is then injected through
When you install fasteners, use the correct tighten-
injection nozzle holes into the cylinder in a fine spray.
ing sequence and specifications. Following these
Excess fuel is directed back to the fuel tank by means
instructions can help you avoid damage to parts and
of the fuel return lines.
systems.
When working on the fuel system, there are several
things to keep in mind:
• Any time the fuel system is being worked on,
disconnect the negative battery cable except for
those tests where the battery voltage is required.
• Always keep a dry chemical (Class B) fire extin-
guisher near the work area.
• Always relieve the line pressure before servicing
any fuel system components.
• Do not attempt repair on the fuel system until you
have read the instructions and checked the pic-
tures relating to the repair.
W5-6-2 EX455

ENGINE FUEL

Fuel Flow

SM7923

Fuel system components

The fuel system consists of the fuel tank, the fuel feed
pump, the water sedimentor, the fuel filter, the injec-
tion pump, and the injection nozzles.
Fuel is drawn from the fuel tank by the fuel feed pump.
It passes through the water sedimentor (water parti-
cle removal) and the fuel filter (solid particle removal)
before being delivered to the injection pump.
Precisely metered amounts of fuel are forced into
each of the injection nozzles at exact intervals to
provide efficient engine operation.
WATER SEDIMENTOR
The water sedimentor has a clear plastic body. There
is a warning line on the body. When the water level
reaches the warning line, the sedimentor must be
emptied.
Open the drain plug at the bottom of the sedimentor
to drain the water.
FUEL FILTER
The fuel filter removes solid particles from the fuel.
These particles, if allowed to reach the injection
nozzles, would cause serious abrasive damage.
FUEL FEED PUMP
The fuel feed pump draws fuel from the fuel tank and
delivers it to the injection pump. It maintains a high
pressure in the fuel line. An independent priming
pump permits manual fuel feed when the engine is off.
EX455 W5-6-3

ENGINE FUEL

INJECTION PUMP
Major injection pump components are the pump body,
the plungers, the governor, and the timing advancer.
The injection pump is the nucleus of the diesel engine
fuel system. It pressurizes and delivers precisely
timed and measured fuel charges to the engine cylin-
ders. Timing and volume are determined by engine
load and speed.
Each plunger is raised to the top of its stroke by a cam
lobe and forced to the bottom of its stroke by a return
spring.
Together, the plungers create a reciprocal motion.
Fuel enters the plunger barrel through the inlet port
when the plunger is at the bottom of its stroke.
Excess fuel leaves the plunger barrel through the
outlet port when the plunger is at the top of its stroke.
The injection pump has an identification tab attached
to its body.

GOVERNOR
The fuel system uses an RSV variable speed gover-
nor. Engine speed and load vary widely during normal
driving. If the engine speed is too low, the engine will
be sluggish and may stall. If engine speed is too high,
overrun occurs.
The governor operates to maintain engine speed
within acceptable limits thus preventing stalling and
overrun.
W5-6-4 EX455

ENGINE FUEL

FUEL FILTER

SM7305

Legend

1. Fuel filter 3. Fuel filter body

2. Overflow valve
EX455 W5-6-5

ENGINE FUEL

Disassembly
1. Remove the fuel filter with a filter wrench.
CAUTION
Be careful not to spill the fuel remaining in the fuel
filter when removing the filter.
Reassembly
1. Install the overflow valve to the fuel filter body.
2. Install the fuel filter.
• Before installating a new fuel filter, apply fuel to
the gasket.
• Turn in the new fuel filter until the filter gasket
comes in contact with its sealed face.
• Use a filter wrench to turn in the fuel filter an
additional 1 /2 - 3/4 of a turn.

SM7306

SM7018

2. Remove the overflow valve.

3. Remove the fuel filter body.

Inspection and Repair

Check the overflow valve for restrictions and/or leak-

age.
Overflow valve opening pressure:
280 - 310 kPa (40 - 46 psi)

SM7307
W5-6-6 EX455

ENGINE FUEL

INJECTION NOZZLE HOLDER

SM7924

Legend

1. Retainer nut 6. Nozzle holder body

2. Nozzle 7. Adjusting shim
3. Nozzle holder pin 8. Spring
4. Spring seat 9. Pin
5. Gasket 10. Spacer
EX455 W5-6-7

ENGINE FUEL

Disassembly 3. Remove the nozzle holder pin, spacer, spring seat,

spring and adjusting shim from the nozzle holder.
1. Remove the retaining nut.
Keep the adjusting shims in the original groups to
• Clamp the injection nozzle holder in a vice.
hold the initial shim to the nozzle spring combina-
• Use a wrench to remove the injection nozzle
tion.
retainer nut.
4. Remove the nozzle holder body.

CAUTION
1. Wash all the part removed and arrange them on
a cylinder basis, care should be taken not to miss
any parts.
2. Soak the nozzle assembly in a parts receptacle
filled clean diesel fuel.
3. Care should be taken not to miss shim, if used.

Inspection and Repair

Make the necessary adjustments, repair and part
replacements if excessive wear or damage is discov-
ered during inspection.
SM7925
RETAINING NUT

2. Remove the nozzle from the nozzle holder. Inspect the retaining nut for any wear or corrosion.
• Keep the nozzle along with the needle valve
separately to maintain the original nozzle to
needle valve combination.
• Clean the nozzle in the clean diesel fuel.

SM7927

SM7926
W5-6-8
ENGINE FUEL
INJECTION NOZZLE NEEDLE VALVE
1. Remove the needle valve from the nozzle body.
2. Carefully wash the nozzle needle and the nozzle
body in the clean diesel fuel.
3. Check that the nozzle needle moves smoothly
inside the nozzle body.
If the nozzle does not move smoothly, it must be
repaired (See "Nozzle Lapping Procedure") or re-
placed nozzle assembly.
SM7928
SPRING
Inspect the spring for any wear, fell and corrosion.
SM7929
EX455
NOZZLE BODY AND NEEDLE VALVE
Check the nozzle body and the needle valve for
damage and deformation.
The nozzle and body assembly must be replaced if
either of these two conditions are discovered during
inspection.
NOTE: New nozzles must be cleaned in a solvent to
remove protective coating. The nozzle body and
needle must always be replaced as an assembly.
SM7926
NOZZLE LAPPING PROCEDURE
1. Lap the nozzle needle (1), and the nozzle body (2)
by applying a compound of foxidized chrome with
animal oil.
NOTE: Do not apply an excessive amount of the
foxidized chrome with animal oil compound to the
injection needle valve seat area.
2. Carefully wash the needle valve and the nozzle
body in clean diesel fuel after lapping.
SM7930
EX455
ENGINE FUEL
Reassembly
1. Install the locating pin to the nozzle holder body.
2. Install the adjusting shim, spring and spring seat
into the nozzle holder body.
3. Install the spacer to the nozzle holder body over the
locating pin.
4. Install the locating pin to the nozzle.
5. Install the nozzle to the nozzle holder.
SM7931
6. Install the retaining nut.
• Clamp the injection nozzle holder in a vice.
Tighten the retaining nut to the specified torque.
Torque: 93 N•m (9.5 kgm)
SM7925
7. Install the new gasket to the nozzle holder.
W5-6-9
Adjustment of Injection Nozzle Opening Pressure
After reassembling the injection nozzle, recheck the
opening pressure and spray condition.
With the nozzle holder set to the nozzle tester, adjust
the pressure with an adjusting shim so that the
pressure becomes equal to the specified injection
nozzle opening pressure.
Injection nozzle opening pressure:
19.9 MPa (203 kg/cm2 - 2886 psi)
An adjusting shim of 0.007 mm (0.0003 in) allows the
press to change by about 100 kPa (14.2 psi).
The adjusting shim thickness calculation method as
follows.
WARNING
The test fluid from the injection nozzle tester will
spraying out of the injection nozzle under great
pressure. It can easily puncture a person's skin.
Keep your hands away from the injection nozzle at
all times.
The adjusting shim thickness calculation method.
P x π/4 x (A2-B2)
= Additional shim thickness (mm)
C x 100
P (kPa) = (Target injection nozzle opening pres-
sure - Indicated value (pressure) of noz-
zle tester)
A (cm) = Needle diameter 0.6 cm
B (cm) = Sheet diameter 0.3 cm
C (N/mm) = Spring constant 264.0
SM7019
W5-6-10 EX455

ENGINE FUEL

Adjusting Shims
After calculates shim thickness to select shims from
below list.

mm
Thickness Part number

0.50 5-15339-007-0

0.52 5-15339-018-0

0.54 5-15339-019-0

0.56 5-15339-020-0

0.58 5-15339-021-0

0.60 5-15339-008-0

0.70 5-15339-009-0

0.80 5-15339-010-0

0.90 5-15339-01-0

1.00 5-15339-012-0

0.10 8-94128-982-0

0.20 8-94128-983-0

0.30 8-94128-984-0

0.40 8-94128-985-0

Spray Pattern
Check the spray condition to shown in the illustration.
If the spray conditions is not suitable pattern, the
injection nozzle must be replaced or readjusted.

SM7020
EX455 W5-6-11

ENGINE FUEL

INJECTION PUMP
Identification
1. It is important that you refer to the injection pump
assembly number on the identification plate to
determine the applicable calibration data in this
section for the injection pump being serviced.

2. In the event this section does not contain calibra-

tion data applicable to the injection pump being
serviced, contact the nearest manufacturer's au-
thorised service facility (Bosch Automotive Sys-
tem Corp. or Robert Bosch GMBH).

3. Refer to the Isuzu Injection Pump Assembly

Number stamped on the injection pump assembly
Identification Plate to order a replacement injection
pump. SM7334

Injection Pump Calibration Data

TEST CONDITIONS

Injection nozzle ZEXEL No.105780-0000

Injection nozzle holder ZEXEL NO.105780-2080
Injection starting pressure 17.2 MPa
Injection line dimensions Inside diameter = 3 mm
Outside diameter= 8 mm
Length = 600 mm
Transfer pump pressure 255 kPa
Test diesel fuel ISO4113 or SAE standard test oil (SAEJ967d)
Fuel temperature 39 - 41 °C (109.2 - 114.8°F)
Pump rotation Clockwise viewed from the drive side
Overflow valve opening pressure 255 kPa (2.6 kg/cm2 /37.0 psi)

CAUTION
Strictly observe the above test conditions during
injection pump fuel injection volume adjustment.
Failure to observe the test conditions will result in
misadjustment of the injection pump fuel injection
volume.
Misadjustment of the fuel injection volume will
result in serious engine damage.

INJECTION TIMING

Pre-stroke 5.6 + 0.05 mm (0.220 + 0.01 in)

Injection order and interval 1-5-3-6-2-4
Plungers are numbered from the drive side.
Tappet clearance Manually rotate the camshaft several times to
make sure that it rotates smoothly.
W5-6-12 EX455

ENGINE FUEL

INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM

Injection Pump Assembly Number

ISUZU No. ZEXEL No. Remarks ISUZU No. ZEXEL No. Remarks
1 -15603-341 -0 106671 -6440

Injection Volume

Control rack Pump speed Injection volume Variance Boost pressure

Remarks
position (mm) (min-1) (mm3) (mm3)/1,000 strokes) (%) (kPa)
11.9 900 221 ± 2 ±3 more than 128 Basic
6.6 450 9 ± 3.2 ± 13
EX455 W5-6-13

ENGINE FUEL

GOVERNOR PERFORMANCE

NOTCH; 5
RACK LIMIT
IDLING SUB SPRING SET
BOOST COMPENSATION
RACK POSITION (mm) STROKE: 0.8 ± 0.1 mm

GOVERNOR SPRING SET

SM7932

SPEED CONTROL LEVER AND STOP LEVER

SPEED LEVER STOP LEVER

IDLE ~ STOP

STOP

FULL SPEED NORMAL

IDLE
SM7933
W5-6-14 EX455

ENGINE FUEL

NOTE:
EX455
ENGINE INDUCTION
SERVICE PRECAUTIONS
CAUTION
Always use the correct fastener in the proper
location. When you replace a fastener, use ONLY
the exact part number for that application. ISUZU
will call out those fasteners that require a replace-
ment after removal. ISUZU will also call out the
fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct tighten-
ing sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
W5-7-1
TURBOCHARGER
General Description
Major turbocharger components consist of the Center
Housing and Rotating Assembly (CHRA), the com-
pressor housing, and the turbine housing.
Rotating parts include the turbine shaft, the compres-
sor wheel, the shaft bearings, the thrust bearings and
the oil seal ring. There parts are supported by the
center housing.
The turbocharger increases air intake efficiency, the
results in increased engine power, reduced fuel con-
sumption and minimal engine noise.
Turbocharger rotating parts operate at very high
speeds and temperatures. The parts materials have
been carefully selected and machined to extremely
high precision.
SM7934
W5-7-2 EX455

ENGINE INDUCTION

Identification Turbocharger Servicing

The turbocharger name plate gives the date of manu-
facturer and other important information required to
identify the unit when service inquiries are made.
The turbocharger name plate has the following infor-
mation stamped on it. Refer to the illustration.
(1) Turbocharger specification, production year, and
production month.
Example: VIBU
(2) Production date, serial number, and production
line name.
Example: RHC92
(3) Part number assigned by ISUZU MOTORS LIM-
ITED.
Example: 1144003281
Part numbers (3) indicate specific designs or configu-
rations.
1. Refer to TROUBLESHOOTING in this Section to
determine whether or not turbocharger repair or
overhaul is required.
2. The following procedures should also be performed
(either with the turbocharger on the equipment or
removed from the equipment but not disassem-
bled) to determine whether or not turbocharger
repair or overhaul is required.
* Visual checks
* Clearance measurements
* End play measurements
Refer to INSPECTION AND REPAIR.
3. The turbocharger compressor and turbine housing
may be removed from the center housing and
rotating assembly (CHRA) for further visual inspec-
tion.
Refer to DISASSEMBLY and REASSEMBLY.

Precaution

Turbocharger servicing requires great care and exper-

Name plate sample tise.
Faulty turbocharger servicing procedures can result in
Turbo Spec.
serious damage to pistons, valves, cylinder liners, and
Serial No.RHC9
other important engine parts.
ISUZU does not recommend the performance of any
Part No. servicing procedure not described in this Manual.
Contact your nearest FIAT KOBELCO Dealer to have
the turbocharger assembly repaired or overhauled.
The identification plate and assembly number will be
SM7338 required by the service facility.
EX455 W5-7-3

ENGINE INDUCTION

Disassembly

SM7935

Legend

1. Lock plate and bolt 4. Compressor housing

2. Turbine housing 5. Center housing and rotating assembly
3. Lock plate and bolt
W5-7-4 EX455

ENGINE INDUCTION

1. Remove the lock plate and bolt. Apply a setting
mark across the center housing and rotating as-
sembly seal the turbine housing (2), and the com-
pressor housing (3).
Inspection and Repair
Make the necessary adjustment, repairs, and part
replacements if excessive wear or damage is discov-
ered during inspection.

Minor servicing operations are described in this Sec-

tion. Contact the nearest FIAT KOBELCO Dealer for
major repairs and maintenance.

TURBINE SHAFT END PLAY

1. Set a dial indictor to the turbine shaft end.

2. Apply a force of 11.7 N (1.2 kg) alternately to the

compressor wheel end and the the turbine wheel
end.

3. Read the dial indicator.

Turbine shaft end play
SM7936 Standard: 0.075 - 0.110 mm (0.0030 - 0.0043 in)
Limit: 0.12 mm (0.0047 in)

SM7937

2. Remove the turbine housing. SM7938

3. Remove the lock plate and bolt.

4. Remove the compressor housing.

5. Remove the center housing and rotating assembly.

• Loosen the lock plate bolts.
• Disassembly the parts. Handle the parts with
extreme care. Be particularly careful not to dam-
age the turbine wheel blades and the compressor
wheel blades.
Take care not to allow foreign material to enter the
center housing.

NOTE: Disassembly and servicing of the center hous-

ing and rotating assembly is not recommended.
EX455 W5-7-5

ENGINE INDUCTION

Turbine Shaft Bearing Clearance

Due to the unique location of the center housing

casting internal opening, access to the shaft wheel is
difficult. To check the turbine shaft and bearing clear-
ance, a special gauge arm assembly must be fabri-
cated for use with a dial gauge.
The assembly can be constructed from any conven-
iently available material. However, it must conform to
the dimensions shown in the illustration.

1. Pass the gauge arm assembly through the oil outlet

port and the casting internal opening. The curved
end of the gauge arm assembly must make contact
with the wheel shaft.

SM7939

2. Set the dial gauge to "0".

3. Grasp both ends of the shaft at the wheel hubs.

Move the shaft gently back and forth in a motion
that is parallel to the plane of the oil drain flange
face.
Note the dial gauge reading.
If the dial gauge reading is above or below the
standard range, the center housing and rotating
assembly must be replaced.
Standard: 0.130 -0.235 mm (0.0051 - 0.0093 in)
Limit: 0.275 mm (0.0108 in)
W5-7-6 EX455

ENGINE INDUCTION

Reassembly
1. Install the center housing and rotating assembly to
the compressor housing.
• Apply Threebond 1215 or equivalent to the flange
surface of compressor houisng shown in the
illustration.

SM7937

2. Install the turbine housing.

• Align the setting marks (applied at disassembly)
on the center housing and rotating assembly and
the turbine housing.
Handle the parts with extreme care to avoid
SM7940 damaging the turbine shaft wheel blades.
• Apply an anti-seizing agent (LOCTITE
ANTISEIZE LUBRICANT or equivalent) to the
• Align the setting marks (applied at disassembly)
bolt.
on the center housing and rotating assembly and
• Tighten the bolt to the specified torque.
the compressor housing.
Torque: 28 N•m (2.85 kgm)
Handle the parts with extreme care to avoid
damaging the compressor wheel blades. • Check that the rotating assembly turns smoothly.
• Apply an anti-seizing agent (LOCTITE
ANTISEIZE LUBRICANT or equivalent) to the
new bolt threads or the V-band threads.
• Install the new lock plate and bolts to the com-
pressor housing.
• Tighten the bolts to the specified torque.
Torque: 23 N•m (2.3 kgm)

SM7936
EX455
STARTING AND CHARGING
SERVICE PRECAUTION
CAUTION
Always use the correct fastener in the proper
location. When you replace a fastener, use ONLY
the exact part number for that application. ISUZU
will call out those fasteners that require a replace-
ment after removal. ISUZU will also call out the
fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct tighten-
ing sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
Identification
The alternator identification plate is attached to the
alternator rear bracket. The ISUZU part number, the
manufacturer’s code number, and other important
information are stamped on the plate.
Refer to the identification plate together with the “Main
Data and Specifications” Tables and accompanying
charts in this Manual when requesting service assist-
ance from a qualified electrical repair shop.
If you are unable to locate the data applicable to your
engine, please contact ISUZU MOTORS LIMITED
through your machine supplier.
W5-8-1
ALTERNATOR
General Description
The engine uses a brushless alternator. Main alterna-
tor components are the rotor, the stator, the rectifier,
the front and rear brackets, the IC regulator, the
bearings, and the pulley. Moving parts include the rotor
and the pulley. The field coil is installed to the rear
bracket. 6 main diodes (3 positive and 3 negative) in
conjunction with 2 sub-diodes provide 3-phase rectifi-
cation. The diodes are installed to the stator coil. An
additional 3 diodes (diode trio) are used to provide field
current. The alternator has 3 terminals.
a. Terminal B: DC power output
b. Terminal L: Exciting current input
c. Terminal R: Exciting current input
Terminal R is active only until the alternator begins to
generate electricity.
Terminal L also serves as a voltage output terminal.
When the voltage across terminal L is equal to the
battery voltage, the indicator lamp (no charging) turns
off.
Sealed bearings requiring no lubrication are used
throughout the alternator.
The IC regulator is a solid-state device and is serviced
as a unit. It cannot be disassembled.
MITSUBISHI IDENTIFICATION PLATE
SM7341
A: Isuzu part number
B: Manufacturer’s abbreviated name
C: System voltage output
D: Manufacturer’s lot No.
E: Bar code
W5-8-2 EX455

STARTING AND CHARGING

SM7342

Legend

1. Rear bracket 6. Rotor

2. IC regulator 7. Bearing
3. Bearing 8. Pulley
4. Rectifier 9. Front bracket
5. Stator 10. Field coil assembly
EX455 W5-8-3

STARTING AND CHARGING

Main Data and Specifications

Isuzu Part No. 1-81200-5901

Manufacturer’s code No. (MITSUBISHI) A004T05485
Rated voltage (V) 24
Rated output (A) 50
Rated speed (min-1) 5000
Rated output (A/V/min-1) 50/27/5000
-1
No-load output at 0 Amp. (V/min ) 24/900
Direction of rotation as viewed Clockwise
from pulley side
Ground polarity (-)
Pulley diameter mm (in) 80 (3.15)
Coil resistance at 20 °C
Field coil (Ω) 4.5 - 5.2
Isuzu part No. 1-81260-0170
Manufacturer’s code No. A866X38282

Charging Circuit

ADDITIONAL
DIODES
DIODE TRIO INDICATOR LAMP
STATOR COIL
KEY
SWITCH

BATTERY
(24V)

FIELD
COIL
IC REGULATOR

ALTERNATOR

SM7343
W5-8-4 EX455

STARTING AND CHARGING

Disassembly

SM7344

Legend

1. IC regulator 6. Nut
2. Terminal stud 7. Side entry terminal
3. Side entry terminal (Terminal B) 8. Terminal stud
4. Rectifier assembly 9. Tube
5. Cap
EX455
STARTING AND CHARGING
1. Scratch setting marks between the front and rear
brackets and the alternator body (2 locations).
This will ensure installation to its original position.
2. Remove the 4 through bolts.
3. Use the blade of a screwdriver to pry the front
bracket and the stator apart.
4. Carefully separate the front bracket, pulley, and
rotor from the stator and rear bracket.
NOTE:
• Do not push the screwdriver blade too deeply into
the stator. Coil damage will result.
• A vise may be used to secure the rotor. Be sure to
clamp the vise at points A (see illustration below).
Do not clamp the vise at points B. Damage to the
rotor will result.
SM7345
5. Remove the 2 screws (2) attaching the coil
terminal plate to the IC regulator.
6. Hold the coil assembly in your hand. Be careful
not to damage the terminal plate.
7. Remove the 3 screws (3) and the coil assembly.
8. Disconnect the connector (1).
NOTE: It is very important that Steps 5, 6 and 7 be
performed in that order. If Step 6 is performed before
Step 5, terminal damage will result.
W5-8-5
SM7346
9. Remove the cap and nut from the rectifier termi-
nal stud.
10. Use a screwdriver to pry the rear bracket and the
side entry terminal apart.
11. Remove the side entry terminal.
NOTE: The tube will remain in the rear bracket. Take
care not to lose it.
12. Remove the rectifier retaining screw and the 2 IC
regulator retaining screws.
13. Remove the stator and rectifier assembly (as a
single unit) from the rear bracket.
14. Remove the IC regulator.
15. Unsolder the 4 stator coil leads from the rectifier
terminals.
16. Remove the stator from the rectifier.
NOTE: High temperature solder with a melting point
of 230 °C connects the stator coil leads to the rectifier.
Use a 180~280 watt soldering iron to free the leads as
quickly as possible. Do not apply the soldering iron for
more than 5 seconds. Diode damage will result.
BEARING REMOVAL
NOTE: Bearings are not normally removed. If they are
removed, they must be replaced with new ones.
Front bracket bearing
Remove the 4 retainer screws. Press out the bearing
with a suitable tool.
Rotor bearing
Use an ordinary bearing puller.
W5-8-6 EX455

STARTING AND CHARGING

Inspections and Repair ROTOR

STATOR
1. Check the stator for damage, loose connections,
and discolored windings.
2. Use a circuit tester to check for continuity between
each pair of stator coil leads (1). Replace the stator
if there is no continuity.
1. Turn the rotor. Listen for bearing noise (a scraping
sound). Feel for rough rotation. Replace the rotor
if either of these conditions is present.
2. Check for grease leakage. If leakage is minimal,
wipe it away. If leakage is excessive, replace the
rotor.
NOTE: It is recommended that inspection be made
with the bearing fitted to the rotor shaft. Coil Assem-
bly.

COIL
Use an ohmmeter to measure the coil resistance
between both terminals (1) and the terminal plate (2).
Replace the coil assembly if the resistance is outside
the specifications.
Coil resistance at 20 °C: 4.5 - 5.2 Ohms

SM7347

3. Use a circuit tester to check for continuity between

each of the stator coil leads (1) and the stator core
(2). Replace the stator if there is continuity.

SM7349

RECTIFIER
1. Use a circuit tester to test for continuity between
each diode terminal (2) and the positive heat sink.
Test in both directions.
If there is continuity and/or an open circuit. in both
directions, the rectifier must be replaced.
2. Use a circuit tester to test for continuity between
SM7348 each diode terminal (2) and the negative heat sink.
Test in both directions.
If there is continuity and/or an open circuit in both
directions, the rectifier must be replaced.
EX455 W5-8-7

STARTING AND CHARGING

3. Check the diode trio for continuity in both direc- • Bracket, rotor, and stator reassembly is difficult
tions. If there is continuity and/or an open circuit in because of the tight fit of the components. To make
both directions, the rectifier must be replaced. reassembly easier, heat the area around the rear
bracket bearing box to approximately 55 °C.
Tightening torques
Pulley fixing nut: 147 N•m (15 kgm)
Through bolts: 5.1 N•m (0.52 kgm)
Bearing retainer screws:
3.6 N•m (0.37 kgm)
Coil retaining screws:
3.6 N•m (0.37 kgm)
Rectifier retaining screws:
3.6 N•m (0.37 kgm)
Regulator retaining screws:
3.4 N•m (0.35 kgm)
Nuts for stud bolts: 8.8 N•m (0.9 kgm)

SM7350

1. Positive diode
2. Diode terminals
3. A part of negative diode

FRONT BRACKET
Turn the bracket. Listen for bearing noise (a scraping
sound). Feel for rough rotation. Replace the bracket
if either of these conditions is present.
Check for grease leakage. If leakage is minimal, wipe
it away. If leakage is excessive, replace the bracket.

REGULATOR
The regulator cannot be checked in the absence of
the other components. Check regulator operation
after alternator reassembly.

Reassembly

Follow the disassembly steps in the reverse order.

Note the following precautions.
• No lubrication is required. Bearings are
prelubricated.
• Wipe away any grease leakage from the bearing
area.
• Use high-temperature solder (melting point of
230 °C).
• Use a 180 - 270 Watt soldering iron to solder the
leads as quickly as possible. Do not apply the
soldering iron for more than 5 seconds. Diode dam-
age will result.
W5-8-8 EX455

STARTING AND CHARGING

Bench testing CURRENT OUTPUT

1. Operate the alternator at minimum speed.
Perform bench tests on the reassembled alternator. 2. Close switch 1. Check that the lamp lights.
3. Set the load resistor to its maximum resistance
VOLTAGE REGULATION (minimum current).
1. Make connections as shown in the illustration on 4. Close switch 2.
the following page. Use an ammeter with a scale 5. Increase the alternator speed to a constant 5,000
of 0 100 amperes and voltmeter with a scale of min-1.
0 - 30 volts. 6. Adjust the load resistor for maximum current out-
2. Close switch 1 and open switch 2. The lamp put.
should light. 7. Allow the alternator to run for 15 minutes. Output
If the lamp does not light, check the voltage at should increase as alternator temperature in-
terminal-L. creases.
If the voltage is nearly equal to battery voltage 8. Once again, adjust the load resistor for maximum
(24V), check the alternator. current output.
If the voltage is low, check for an open lamp and The maximum current output must equal the
related circuitry. specified value. If it does not, the alternator must
3. Slowly increase alternator speed. be rechecked.
The lamp should turn off as alternator speed
approaches 1,300 min-1. Alternator output:
4. Check the voltage as alternator speed increases. 50 A/27 V/5,000min-1
If the voltage fluctuates wildly during alternator
speed increase and rises above 30 volts, the IC
regulator is probably defective.
If the voltage does not exceed battery voltage
(24V), the alternator is defective (no generation of
electricity). Check alternator components again.
5. Increase alternator speed to approximately 500.
min-1.
6. Note the ammeter reading.
If the reading is 5 amperes or less, note the
voltmeter reading (be sure that alternator speed
remains constant). This is the regulated voltage.
If the reading is more than 5 amperes, continue to
operate the ammeter at 500 min-1 until the reading
falls to 5 amperes or less.
If the reading does not fall, replace the battery.
If the reading still does not fall, the alternator is
defective and must be repaired or replaced.

ALTERNATOR

AMMETER SWITCH 1

LAMP (24V)
(3W MAX.) SWITCH 2

BATTERY
(24V)
LOAD
VOLTMETER
RESISTOR

SM7351
EX455 W5-8-9

STARTING AND CHARGING

Troubleshooting

Condition Possible Cause Correction

No output Bad terminal connection Repair
Open or shorted circuit Repair
Open field coil Replace
Defective diode Replace
Defective IC regulator Replace
Low output Loose terminal connection Tighten
Loose cooling fan belt Adjust belt tension
Defective diode Replace
Shorted field coil Replace
Shorted stator coil Replace
Defective regulator Replace
Defective battery Replace
Poor terminal contact Repair
Overcharging Defective regulator Replace
Defective battery Replace
Unstable current Poor terminal contact Repair
Loose cooling fan belt Adjust belt tension
Short field coil Replace
Shorted stator coil Replace
Intermittent contact in wiring Replace
Poor terminal contact Repair
Defective regulator Replace
Abnormal noise Improper alternator installation Correct
Defective bearing Replace
Contact between the rotor core and Replace the rotor core and/or stator
stator core core
Defective diode Replace
Shorted stator coil Replace
W5-8-10 EX455

STARTING AND CHARGING

STARTER MOTOR

General Description

SM7352

The starter motor has a reduction gear assembly that

uses planetary gears.

Identification

MITSUBISHI starter motor is identified by the name

plate attached to the yoke (illustration).
1. Manufacturer’s type
2. Isuzu part number
3. Bar code

NOTE: Always check the identification number be-

fore beginning a service operation. Applicable service
data will vary according to the identification number.
Use of the wrong service data will result in starter
damage.

SM7353
EX455 W5-8-11

STARTING AND CHARGING

Main Data and Specifictions

Isuzu Part No. 1-81100-3411

Mitsubishi code No. M009T80971
Rated voltage V 24
Rated output kW 7.0
Rating s 30
Direction of rotation Clockwise
(Viewed from the pinion side)
Terminal voltage (No load) V 23
Minimum current (No load) A 85
-1
Starter motor minimum operating speed min 3300
(No load)
Pinion gear
Modules 3.5
Number of teeth 11
Outside diameter mm (in) 48.9 (1.93)
Yoke outside diameter mm (in) 105 (4.13)
Brush length
Standard mm (in) 18 (0.71)
Limit mm (in) 11 (0.43)
Brush spring standard fitting load N 29 - 39
Commutator
Outside diameter
Standard mm (in) 32 (1.26)
Limit mm (in) 31.4 (1.23)
Depth of undercut mica
Standard mm (in) 0.5 (0.02)
Limit mm (in) 0.2 (0.008)
Pinion projection
Standard mm (in) 0.5 - 2.0 (0.0197 - 0.079)
W5-8-12 EX455

STARTING AND CHARGING

Disassembly

SM7941

Legend

1. Snap ring 15. Planetary gear

2. Stop ring 16. Ball
3. Pinion 17. Gasekt
4. Pinion spring 18. Plate
5. Screw 19. Armature
6. Pinion case 20. Bearing
7. Bearing 21. Gasket
8. Magnetic switch 22. Yoke
9. Lever 23. Brush
10. Clutch 24. Gasket
11. Internal gear 25. Brush holder
12. Washer 26. Rear cover
13. E-type stop ring 27. Through bolt
14. Gear shaft
EX455 W5-8-13

STARTING AND CHARGING

1. Place matching marks on the magnetic switch

and yoke to ensure reassembly to their original
positions.
2. Connect the starter motor to a battery. The pinion
rises and begins to rotate.
3. Open switch-2 to stop pinion rotation.

SM7356

1. Pinion
2. Clutch shaft
3. Snap ring
4. Stop ring
5. Pipe
SM7355 6. Pinion spring

4. Separate the stop ring by striking it with a pipe

and bar. 7. Remove the magnetic switch.
5. Remove the stop ring, the snap ring, the pinion, 8. Loosen the brush holder fixing screws and the
and the pinion spring. through bolt.
6. Discard the stop ring. 9. Remove the rear bracket and gasket.
10. Discard the gasket.
11. Use a socket wrench with a 32 mm diameter to
NOTE: Pinion removal should require no more than hold the armature commutator in place. Remove
10 seconds. If more time is required, heat from the the yoke assembly.
armature will cause the starter damage. 12. Slide the brush on to the socket.
13. Lift the brush spring and remove the brush.
14. Remove the brush holder.
15. Pull the armature from the planetary gear.
16. Use a bearing puller to remove the bearing. Be
careful not to lose the ball.
17. Remove the plate and gasket.
18. Remove the planetary gear.
19. Hold the internal gear, the gear shaft overrunning
clutch, and the lever together. Remove them as
a unit from the front bracket.
20. Remove the lever from the gear shaft (mark its
installation position).
21. Remove the E-type stop ring from the gear shaft
and discard it.
22. Remove the overrunning clutch from the gear
shaft.
23. Remove the internal gear and washers.
W5-8-14
STARTING AND CHARGING
Inspection and Repair
ARMATURE
1. Use a circuit tester to check armature continuity.
Hold the circuit tester probes against 2 commuta-
tor segments. Repeat the procedure for several
other segment pairs. There must be continuity
between all commutator segments. If there is not,
the commutator must be replaced.
SM7357
2. Use a circuit tester to check the armature ground.
Hold one probe against a commutator segment.
Hold the other probe against the armature shaft. If
there is continuity, the armature is grounded. It
must be replaced.
SM7358
EX455
3. Measure the commutator outside diameter.
4. If the measured diameter is less than the specified
limit, the commutator must be replaced.
Commutator outside diameter
Standard: 32 mm (1.28 in)
Limit: 31.4 mm (1.256 in)
SM7359
5. Inspect the commutator mica segments for exces-
sive wear and damage.
6. Measure the depth of the commutator mica seg-
ments. If the depth is less than the specified limit,
the commutator must be replaced.
Commutator mica segment depth
Standard: 0.5 mm (0.02 in)
Limit: 0.2 mm (0.008 in)
SM7360
EX455
STARTING AND CHARGING
7. Inspect the gear for excessive wear and damage.
Replace if required.
8. Rotate the commutator with your hand. Listen for
abnormal noise or rattling from the bearing. Check
for grease leakage. Replace if required.
FIELD COIL
1. Use a circuit tester to check for continuity between
the field coil and the lead wire.
If there is no continuity, a field coil wire is broken.
The field coil must be replaced.
SM7361
2. Check for continuity between the field coil and the
yoke.
If there is continuity, the yoke must be repaired or
replaced.
SM7362
W5-8-15
BRUSH AND BRUSH HOLDER
1. Measure the brush length. If the brush length is
less than the specified limit, the brush and/or yoke
must be replaced.
Brush length
Standard: 18mm (0.72 in)
Limit: 11 mm (0.44 in)
2. Check the brush spring for weakness and corro-
sion. Replace the spring if required.
3. Use a spring balancer to measure the brush spring
tension. If the spring tension is less than the
specified limit, the spring must be replaced.
Brush spring tension
Standard: 29 - 39 N (3 - 4 kg)
Limit: 13.7 N (1.4 kg)
4. Use a circuit tester to check the brush holder
insulation. Touch one probe to the field winding
lead wire and the other probe to the brush. If there
is continuity between the lead wire and the brush,
the insulation is bad. Repair or replace the. brush
holder.
SM7363
W5-8-16 EX455

STARTING AND CHARGING

OVERRUNNING CLUTCH AND PINION MAGNETIC SWITCH

1. Wipe away dirt and grime adhering to the
overrunning clutch and pinion.
2. Check the pinion teeth for excessive wear and
damage.
3. Rotate the pinion in the direction of normal rota-
tion. It must turn smoothly.
4. Rotate the pinion in the opposite direction. It must
lock.
Replace the overrunning clutch if any problems
are discovered during inspection.
1. Use a circuit tester to check for continuity between
the magnetic switch terminal-M (1) and the body
(2). If there is no continuity, the switch must be
replaced.
2. Check for continuity between the magnetic switch
terminal-M (1) and terminal-B (3). If there is conti-
nuity, the switch must be replaced.

NOTE: The inside of the overrunning clutch is packed

with grease. Do not soak the clutch in liquid cleaner or
solvent to clean it. Grease leakage will result.

SM7365

Reassembly

To reassemble the starter motor, follow the disas-

sembly steps in the reverse order. Pay close attention
SM7364
to the following.
• Lubrication points and recommended lubricants

No. Lubrication area Lubricant

FRONT BRACKET 1 Armature bearing area
Check the front bracket bearing and oil seal for (Light lubrication)
damage. Replace if required. 2 Plunger
(Light lubrication)
INTERNAL GEAR AND PLANETARY GEAR
3 Gear shaft spline and MUL TEMP
Check the gears for excessive wear and damage. sliding parts
Replace if required. OA-171 or
4 Clutch shaft equivalent
5 Oil seal
6 Pinion
(Overrunning clutch)
7 Lever sliding surfaces
(Overrunning clutch)
Molycoat R
8 Sleeve bearing and ball
AG650 or
9 Armature shaft gear,
equivalent
internal gear, and
planetary gears
EX455 W5-8-17

STARTING AND CHARGING

SM7366

• Tighten the fixing bolts to the specified torque. ARMATURE SHAFT AXIAL PLAY
Torque Install the ball to the top of the armature shaft.
Nut (1): 23 N•m (2.3 kgm) No adjustment is required.
Bolt (2): 6.8 N•m (0.7 kgm)
GEAR SHAFT AXIAL PLAY
Bolt (3): 9.8 N•m (1.0 kgm)
Install the washer between the internal gear and the
Bolt (4): 3.4 N•m (0.35 kgm) gear shaft.
No adjustment is required.

SM7367
W5-8-18 EX455

STARTING AND CHARGING

PINION PROJECTION
1. Connect the starter motor to the battery.
2. Turn switch-1 and switch-2 on. The pinion moves
forward to the cranking position and the armature
rotates.
3. Turn switch-2 off. The armature stops rotating.
4. Measure the pinion projection.
Pinion projection: 0.5 - 2 mm (0.02 - 0.08 in)

SM7368

1. Overrunning clutch
2. Internal gear
3. Washer
4. E-type stop ring
5. Gear shaft

GEAR SHAFT SM7370

1. Install the washer, internal gear, and overrunning

clutch to the gear shaft.
2. Install the pinion spring (5), the pinion (1), and the
stop ring (4) to the clutch shaft (2).
3. Install the snap ring (3).
4. Attach the stop ring to the snap ring.

SM7369
EX455 W5-8-19

STARTING AND CHARGING

OVERRUNNING CLUTCH SHAFT RETURN 2. Turn the switch on.

Press against the head of the overrunning clutch with
your hand. Measure the movement (return) of the
clutch shaft. If the return is outside the specified
range, adjust the packing between the front bracket
and the magnetic switch. If adjustment is not possible.
Replace the lever.
3. Measure the starter motor speed, the current, and
the voltage.
If the starter motor speed is less than the specified
value, the starter motor requires further servicing.
Starter motor minimum speed: 3,300 min-1 (No
load)
If the measured starter motor minimum current
and/or terminal voltage is different from the speci-
fied value, the starter motor requires further serv-
icing.
Starter motor minimum current: 85 A (No load)
Starter motor terminal voltage: 23 V (No load)

SM7371

PERFORMANCE TEST
1. Connect the starter motor as shown in the illustra-
tion.

SM7372

1. Battery
2. Ammeter
3. Voltmeter
W5-8-20 EX455

STARTING AND CHARGING

NOTE
EX455
TROUBLESHOOTING
HARD STARTING
Condition Possible Cause
Starter motor does not Loose battery cable terminals
turn over Poor battery connections due to rusting
Battery discharged or weak
Fusible link shorted
Defective starter switch or starter relay
Defective magnetic switch of starter
motor or starter relay
Defective starter motor
Starter motor operates Loose battery cable terminals
but engine does not Poor battery connections due to rusting
turn over
Battery discharged or weak
Loose fan belt
Defective starter motor pinion gear
Defective magnetic switch of the starter
motor
Worn starter motor
Weak brush spring
Piston,crank bearing seizure,or other
damage
Engine turns over but Air in the fuel system
does not start Defective engine stop mechanism
Control wire improperly adjusted
Fuel tank is empty
Clogged or damaged fuel lines
Loose fuel line connections
Clogged fuel filter element
Fuel feed pump strainer is clogged
Defective feed pump
Poor return of the engine stop button
Use of the wrong fuel
Water particles in the fuel
Air in the injection pump
Injection nozzle sticking
Injection nozzle starting pressure
too low
Improper spray condition
Improper injection pump control rack
operation
Injection pump plunger worn or stuck
Injection pump camshaft seizure or
other damage
W5-9-1
Correction
Clean and/or retighten the battery
cable terminals
Recharge or replace the battery
Replace the fusible link
Replace the starter switch or starter
relay
Repair or replace the magnetic
switch or starter relay
Repair or replace the starter motor
Clean and/or retighten the battery
cable terminals
Recharge or replace the battery
Adjust the fan belt tension
Replace pinion gear
Repair or replace the magnetic
switch
Replace the brush and /or brush
spring
Repair or replace the related parts
Bleed air from the fuel system
Replace the engine stop mechanism
Adjust the control wire
Fill the fuel tank
Repair or replace the fuel lines
Retighten the fuel line connections
Replace the fuel filter element
or cartridge
Clean the fuel pump strainer
Repair or replace the feed pump
Completely return the engine stop
button
Use the recommended fuel
Change fuel
Bleed air from the fuel system
Replace the injection nozzle
Adjust or replace the injection
nozzle
Repair or replace the injection pump
control rack
Replace the injection pump plunger
assembly
Replace the injection pump
camshaft
W5-9-2
TROUBLESHOOTING
UNSTABLE IDLING
Condition Possible Cause
Trouble in the engin Poor return of the engine stop button
stop mechanism
Trouble in the fuel Fuel system leakage or blockage
system Air in the fuel system
Water particles in the fuel
Clogged fuel filter element
Injection nozzle sticking
Injection nozzle starting pressure too
Low
Improper spray condition
Defective delivery valve resulting in fuel
drippage after fuel injection
Injection timing improperly adjusted
Insufficient injection volume
Broken plunger spring of the injection
pump
Worn plunger of the injection pump
Worn camshaft of the injection pump
Worn roller tappet of the injection pump
Trouble in the valve Valve clearance improperly adjusted
gear train Worn camshaft
Low compression Blown out cylinder head gasket
pressure Worn cylinder liner
Piston ring sticking or broken
Improper seating between the valve and
valve seat
EX455
Correction
Completely return the engine stop
button
Repair or replace the fuel system
Bleed the air from the fuel system
Replace fuel
Replace the fuel filter element or
cartridge
Replace the injection nozzle
Adjust or replace the injection nozzle
Replace the delivery valve
Adjust the injection timing
Adjust the injection volume
Replace the plunger spring
Replace the plunger assembly
Replace the camshaft
Replace the roller tappet
Adjust the valve clearance
Replace the camshaft
Replace the related parts
EX455 W5-9-3

TROUBLESHOOTING

INSUFFICIENT POWER

Condition Possible Cause Correction

Trouble in the air Clogged air cleaner element
intake system
Trouble in the fuel Water particles in fuel system
system Clogged fuel filter element
Clogged strainer or defective fuel feed
pump
Injection nozzle sticking
Injection nozzle starting pressure too
low
Improper spray condition
Fuel injection pipes damaged or
obstructed
Defective delivery valve
Injection timing improperly adjusted
Worn plunger of the injection pump
Worn camshaft of the injection pump
Trouble in the Exhaust gas leakage from the exhaust
turbocharger system system
Air leakage from the intake system
Defective turbocharger assembly
Low compression Blown out cylinder head gasket
pressure Worn cylinder liner
Piston ring sticking or broken
Improper seating between the valve and
valve seat
Trouble in the valve Valve clearance improperly adjusted
gear train Worn camshaft lobe
Valve spring weak or broken
Clean or replace the air cleaner
element
Replace fuel
Replace the fuel filter element or
cartridge
Repair or replace the feed pump
Replace the injection nozzle
Adjust or replace the injection
nozzle
Adjust or replace the injection
nozzle
Replace the injection pipes
Replace the delivery valve
Adjust the injection timing
Repair or replace the timing
advancer
Replace the plunger assembly
Replace the camshaft
Repair or replace the related parts
Repair or replace the related parts
Replace the turbocharger assembly
Replace the related parts
Adjust the valve clearance
Replace the camshaft
Replace the valve spring
W5-9-4 EX455

TROUBLESHOOTING

EXCESSIVE FUEL CONSUMPTION

Condition Possible Cause Correction

Trouble in the fuel Fuel leakage Repair or replace the fuel system
system related parts
Injection nozzle starting pressure too Adjust or replace the injection nozzle
low
Improper spray condition Adjust or replace the injection
nozzle
Injection timing improperly adjusted Adjust the injection timing
Trouble in the air intake Clogged air cleaner element Clean or replace air cleaner
system element
Improper idle speed Poorly adjusted idling speed Adjust idling speed
Trouble in the cooling Defective thermostat Replace
system
Trouble in the Improper engine oil viscosity Replace engine oil
lubricating system
Trouble in turbocharger Air leakage from the turbocharger intake Repair the turbocharger intake side
system side
Defective turbocharger assembly Replace the turbocharger assembly
Low compression Blown out cylinder head gasket Replace the related parts
pressure Worn cylinder liner
Piston ring sticking or broken
Improper seating between the valve and
valve seat.
Trouble in the valve Valve clearance improperly adjusted Adjust the camshaft
gear train Worn camshaft lobe Replace the camshaft
Valve spring weak or broken Replace the valve spring

EXCESSIVE OIL CONSUMPTION

Condition Possible Cause Correction

Trouble in the Engine oil unsuitable Replace engine oil
lubricating system Too much engine oil Correct engine oil volume
Leakage Oil leakage from the oil seal and/or Replace the oil seal and/or gasket
gasket
Oil leaking into the Worn valve stems and valve guides Replace the intake and exhaust
combustion chamber valves and valve guides
due to poor seal in the
valve system
Worn valve stem oil seal Replace the oil seal
Improper sealing Worn or broken seal ring in the Replace the seal ring
turbocharger
Low compression Blown out cylinder head gasket Replace the related parts
pressure Worn cylinder liner
Piston ring sticking or broken
Improper seating between the valve and
valve seat.
Poor engine ventilation Clogged air breather Clean the air breather
EX455 W5-9-5

TROUBLESHOOTING

ENGINE COOLING TROUBLE

Condition Possible Cause Correction

Overheating Insufficient coolant Replenish coolant
Defective pressure cap or clogged Replace the radiator pressure cap or
radiator core clean radiator core
Defective water pump Repair or replace the water pump
Defective sealing cap resulting in the Replace the sealing cap
cooling water leakage
Defective thermostat Replace the thermostat
Cooling system clogged by foreign Remove foreign material from the
material cooling system
Fuel injection timing improperly Adjust the fuel injection timing
adjusted

WHITE EXHAUST SMOKE

Condition Possible Cause Correction

Trouble in the fuel Water particles in fuel Replace the fuel
system Retarded fuel injection timing Adjust the fuel injection timing
Low compression Blown out cylinder head gasket Replace the related parts
pressure Worn cylinder liner
Piston ring sticking or broken
Improper seating between the valve and
valve seat.
Trouble in the cooling Defective thermostat Replace the thermostat
system
Trouble in the Defective turbocharger Repair or replace
turbocharger
system

BLACK EXHAUST SMOKE

Condition Possible Cause Correction

Trouble in the fuel Clogged air cleaner element Clean or replace the air cleaner
system element
Trouble in the fuel Injection nozzle starting pressure tool Adjust or replace the injection nozzle
injection system low
Improper spray condition
Advanced fuel injection timing Adjust the fuel injection timing
Excessive injection volume Adjust the injection volume
Trouble in the valve Worn camshaft lobe Replace the camshaft
train
W5-9-6
TROUBLESHOOTING
LUBRICATION PROBLEMS
Condition Possible Cause
Oil pressure does not Improper engine oil viscosity
rise Insufficient engine oil
Defective oil pressure gauge or unit
Clogged oil filter element
Relief valve sticking and/or weak
by-pass valve spring
Clogged oil pump strainer
Worn oil pump
Worn rocker arm bushing
Worn camshaft and camshaft bearing
Worn crankshaft and bearings
Oiling jet valve does not close
EX455
Correction
Replace the engine oil
Add engine oil
Repair or replace the oil pressure
gauge or unit
Replace the oil filter element or
cartridge
Replace the relief valve and/or
by-pass valve spring
Clean the oil pump strainer
Replace the oil pump related parts
Replace the rocker arm bushing
Replace the camshaft and camshaft
bearing
Replace the crankshaft and/or
bearing
Replace the oiling jet
EX455
TROUBLESHOOTING
ABNORMAL ENGINE NOISE
Start the engine and allow it to warm up before beginning the troubleshooting procedure.
Condition Possible Cause
Engine knocking Use of wrong fuel
Fuel injection timing improperly
adjusted
Improper injection nozzle starting
pressure
Improper spray condition
Broken piston ring resulting in low
compression pressure
Defective fuel injection nozzle resulting
in fuel drippage after fuel injection
Gas leakage noise Loosely connected exhaust pipes
Broken exhaust pipes
Loose injection nozzles and/or glow
plugs
Loosely connected exhaust manifold
Damaged cylinder head gasket
Continuous noise Loose fan belt
Loose cooling fan
Worn or damaged water pump bearing
Worn or damaged alternator bearing
Valve clearance improperly adjusted
Slapping noise Valve clearance improperly adjusted
Damaged rocker arm
Worn or damaged crankshaft and/or
thrust bearings
Worn or damaged crankshaft and/or
connecting rod bearings
Worn or damaged connecting rod
bushing and piston pin
Worn or damaged piston and cylinder
liner
Foreign material in the cylinder
W5-9-7
Correction
Use correct fuel
Adjust the injection timing
Adjust or replace the injection nozzle
Replace the piston ring
Replace the fuel injection nozzle
Tighten the exhaust pipe
connections
Replace the exhaust pipes
Tighten the injection nozzles and/or
glow plugs
Replace the washers
Tighten the exhaust manifold
connections
Replace the cylinder head gasket
Readjust the belt tension
Retighten cooling fan
Replace the water pump bearing
Replace the alternator bearing
Adjust the valve clearance
Adjust the valve clearance
Replace the rocker arm
Replace the crankshaft and/or thrust
bearings
Replace the crankshaft and/or
connecting rod bearings
Replace the connecting rod bushing
and/or piston pin
Replace the piston and cylinder liner
W5-9-8 EX455

TROUBLESHOOTING

ALTERNATOR

Condition Possible Cause Correction

Battery dead Loose alternator drive belt Adjust
Low battery fluid Replenish
Defective battery terminals Replace
Blown fuse Replace
Poor contact between the fuse holder Repair
and fuse
Low battery fluid specific gravity Adjust
Broken or poorly connected starter Repair
switch and regulator terminal wire
Broken or poorly connected regulator Repair
terminal and alternator terminal wire
Defective alternator ground circuit Repair
Defective voltage regulator Replace
Defective diode Replace
Grounded or broken alternator stator Repair or replace
coil
Broken rotor coil Replace
Excessive electrical load Check the alternator output at
normal operating speed
Battery overcharged Poor connections or open circuit Correct
Poor ground connection of voltage Correct
regulator
Voltage set of regulator too high Replace
Defective voltage regulator Replace
Flashing charge light or Loose belt Adjust
fluctuating ammeter Defective starter switch contacts Replace
indication
Broken or poorly connected wiring Replace or reconnect
Charge light on but dim Loose starter switch terminal wiring Retighten
during operation Excessive resistance of alternator and Replace the wire with a larger one
fuse holder terminal wire
Defective starter switch contacts Replace
Alternator noise Defective alternator bearing Replace or regrease
Exposed stator coil wires Replace
Short circuit of the stator coil Replace
Charge circuit fuse Grounded terminal wiring Repair
blown Defective alternator end flame diode Replace the end flame assembly
Out of voltage regulator adjustment Replace
Reversed battery connections Correct
EX455 W5-9-9

TROUBLESHOOTING

STARTER MOTOR

Condition Possible Cause Correction

Starter and magnetic Low battery fluid level Replenish
switch does not operate Low battery specific gravity Recharge or replace
Poor battery switch contacts Replace
Defective starter switch Replace
Defective magnetic switch pull-in coil Replace
and plunger
Broken armature coil Replace
Broken field coil Replace
Broken magnetic switch Replace
Broken holding coil Replace
Magnetic switch Low battery fluid level Replenish
operates but the Low battery specific gravity Recharge or replace
starter does not turn
Poor starting circuit contacts Repair
Poor contacts of magnetic switch Replace
terminal
Worn brushes Replace
Shorted armature Repair or replace
Starter runs slowly Bad contact of magnetic terminal circuit Repair
switches
Excessive brush wear Replace
Shorted starter motor armature Repair or replace
Starter operates but Pinion and ring gear not engaged Repair or replace the running clutch
the engine does not and driving lever
start Overrunning clutch slippage Replace
Excessive brush wear Replace
Abnormal operating Excessive bushing wear Replace
noise Excessive pinion gear wear Replace overrunning clutch and
pinion gear
Rough sliding action pinion gear Lubricate or replace the overrunning
clutch
Excessive ring gear wear Replace overrunning clutch and ring
gear
Excessive brush wear Replace
W5-9-10 EX455

TROUBLESHOOTING

TURBOCHARGER

Condition Possible Cause Correction

Engine has less than Restricted air cleaner Clean or replace
normal power Restricted intake pipe and hose Clean or replace
Loose connection of the turbocharger Repair
inlet and outlet
Restricted exhaust and silencers Repair
Restricted air breather Clean or replace
Compressor wheel damage Replace
Turbine wheel damage Replace
Carbon build-up on the turbine wheel Replace
Dragging or seized rotating assembly Replace
Blue or black smoke Restricted air cleaner Clean or replace
Leakage from turbocharger oil seal Replace
Restricted turbocharger oil drain pipe Repair or replace
Restricted air breather Clean
Compressor wheel damage Replace
Turbine wheel damage Replace
Restricted center housing oil drain Clean or replace
passage
Excessive oil Restricted air breather Clean
consumption Leakage from turbocharger oil seal Replace
Compressor wheel damage Replace
Turbine wheel damage Replace
Excessive oil pressure Repair
Restricted center housing oil drain Clean or replace
passage
Excessive turbocharger Restricted intake and exhaust system Repair
noise joints
Damaged intake and exhaust system Repair
gaskets
Rough rotation of turbocharger parts Replace
Compressor wheel rubbing against Replace
housing
Damaged compressor wheel Replace
Turbine wheel rubbing against housing Replace
Damaged turbine wheel Replace
Carbon build-up on the turbine wheel Clean or replace
Low engine oil level Correct
Contaminated oil Replace oil
Restricted turbocharger oil feed pipe Repair or replace
Carbon build-up on the turbine housing Clean
Dirty compressor housing Clean
Worn turbine shaft bearings Replace
Excessive rotating part Contaminated engine oil Change
wear Wrong grade or type of engine oil Change
Restricted turbocharger oil feed pipe Clean or replace
Defective turbocharger oil seal Replace
Restricted center housing oil drain passage Clean or replace
Turbine shaft sludge and/or coking Replace
Inadequate oil supply Correct
COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.
Documentation Centre
Strada di Settimo, 323 - S. MAURO T.SE (TO) ITALY

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in whole or in part, is strictly prohibited

Print No. 604.13.226 - VII - 2002

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