Description

FIAT Kobelco EX135 Technical Manual

I’ve been in this trade since before most of you were born. When a FIAT Kobelco EX135 shows up with a hydraulic issue or a no-start condition, the last thing I want is some aftermarket PDF that skips steps. This FIAT Kobelco EX135 Technical Manual is the OEM factory documentation – 763 pages of the real deal. It covers the Operational Principle and Troubleshooting sections, with everything from the main pump regulator to the Dr.EX diagnostic system.

Let me tell you what you’re getting. The manual is split into two parts: Operational Principle and Troubleshooting. The Operational Principle part covers Section 1 (General specs), Section 2 (System – control, hydraulic, electrical), and Section 3 (Component Operation – pump, swing, control valve, pilot valve, travel device, etc.). The Troubleshooting part includes Section 4 (Operational Performance Test) and Section 5 (Troubleshooting with Dr.EX fault codes).

Engine Control and Valve Control: What the Manual Covers

The Engine control section details the fuel system and governor. The Valve control section explains the hydraulic control valve operation. You’ll find the exact pressure settings for the main relief valve and overload relief valve. If you’re rebuilding a control valve, the manual gives you the flow combiner valve and pump control valve operation. This is the kind of detail that separates a proper repair from a hack job.

7 Major Systems Documented – From Hydraulic Circuits to Electrical Diagrams

This manual breaks down the EX135 into seven major system groups: General, System, Component Operation, Operational Performance Test, Troubleshooting, and the component layout. Under the Electrical system, you get the electric power circuit, bulb check circuit, intake air heater circuit, starting circuit, charging circuit, surge voltage prevention circuit, accessory circuit, engine stop circuit, and engine emergency stop. Each circuit has a schematic that matches the actual machine – not a generic drawing.

Does This Manual Cover the Dr.EX Diagnostic System?

Yes. The Dr.EX system is the factory diagnostic tool for the EX135. The manual includes the Dr.EX start-up procedure, fault code list, monitoring function, and special function (service mode). You’ll also find the adjustable data list. If you’re getting a fault code on the monitor, this manual tells you what it means and how to test the circuit. This is a huge time-saver – no more guessing which sensor is bad. The manual also provides the component layout for the electrical system, including relays, monitor panels, and switch panels. You get the exact wire colors and connector pinouts. This is not a generic wiring diagram – it’s the factory drawing used by FIAT Kobelco technicians. If you’re diagnosing an intermittent electrical issue, having the correct schematic is the difference between a two-hour fix and a two-day headache.

Torque Specs and Fluid Capacities: Why You Need OEM Data

Every bolt on this machine has a torque spec. The manual provides the standard values for the main pump, swing motor, travel motor, and control valve. You need the exact torque for the main relief valve or the overload relief valve. Using the wrong torque can cause leaks or internal damage. The manual also gives you the fluid capacities for the hydraulic tank, engine oil, and cooling system – all in imperial units (gallons, quarts, psi).

Every bolt matters.

Source Authenticity: This Is Not Aftermarket Documentation

I’ve seen too many shops waste time with aftermarket manuals that have wrong specs. This is a genuine FIAT Kobelco factory publication. The part number is 604.13.141 (Operational Principle) and 604.13.146 (Troubleshooting). The manual was published in July 2002 by FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. in Italy. It’s the same manual the dealer techs use. If you’re working on an EX135, you need this. For other FIAT Kobelco machines, check out these related manuals:

• FIAT Kobelco W80 2004 Technical Manual – 46-Page OEM Factory Specs
• FIAT Kobelco 7055-3F Technical Manual – 24-Page Factory Specs
• FIAT Kobelco CK1600-II Technical Manual – 33-Page OEM Factory Specs

If you need general information about manual transmissions, you can refer to Manual Transmission and Manual Transmission. But for the EX135, this is the only source you should trust.

Get the Right Torque Data – Avoid Leaks and Stripped Threads

One of the most common mistakes I see is using a torque wrench on a hydraulic fitting without the spec. The manual gives you the torque for the main pump bolts, swing motor mounting bolts, and travel reduction gear bolts. Don’t guess. Use the factory spec.

Is this manual suitable for a complete beginner?

No. It’s written for experienced technicians.

Does the manual include wiring diagrams?

Yes, the Electrical System section (Group 3) includes detailed diagrams for the electric power circuit, bulb check circuit, intake air heater circuit, starting circuit, charging circuit, surge voltage prevention circuit, accessory circuit, engine stop circuit, and engine emergency stop. The manual also provides the Dr.EX diagnostic system startup procedure and fault code lists. You’ll find component layouts for relays, monitor panels, and switch panels. This is not a generic wiring diagram – it’s the factory drawing used by FIAT Kobelco technicians.

Access the Factory Manual and get the complete 763-page Technical Manual for the FIAT Kobelco EX135. You’ll have the engine specs, electrical schematics, hydraulic circuit diagrams, and troubleshooting procedures. This is the difference between a repair that lasts and a repair that comes back.