Fiat Kobelco EX255 - EX285 Excavator Workshop Manual, Technical Operational Principle & Troubleshooting Manual
This complete service repair workshop manual PDF download for the Fiat Kobelco EX255 - EX285 Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
MANUAL COMPOSITION :
• The complete service manual consists of three books:
- Technical Manual - Operational Principle
- Technical Manual - Troubleshooting
- Workshop Manual
- The Technical Manual-Operational Principle includes the technical information concerning the operation of main devices and systems.
- The Technical Manual -Troubleshooting includes the technical information needed for operational performance tests, and troubleshooting procedures.
- The Workshop Manual includes information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, removal/installation and assembly/disassembly procedures.
• The Service Manual for EX255 and EX285 Excavators consists of the following book/print numbers:
- Technical Manual - Operational Principle - 604.13.191
- Technical Manual - Troubleshooting - 604.13.196
- Workshop Manual - 604.13.201
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 971
This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.
TABLE OF CONTENTS :
TECHNICAL MANUAL OPERATIONAL PRINCIPLE
INTRODUCTION
OPERATIONAL PRINCIPLE
GENERAL
Group 1 - Specification
EX255 EXCAVATOR DIMENSIONS
EX285 EXCAVATOR DIMENSIONS
EX255 EXCAVATOR PERFORMANCE
EX255 ENGINE DATA
EX255 ENGINE ACCESSORY
HYDRAULIC DEVICES EX255
EX255 ELECTRICAL EQUIPMENT
EX285 EXCAVATOR PERFORMANCE
EX285 ENGINE DATA
EX285 ENGINE ACCESSORY
EX285 HYDRAULIC DEVICES
EX285 ELECTRICAL EQUIPMENT
Group 2 - Component layout
MAIN COMPONENTS
ELECTRICAL SYSTEM (overall system)
ELECTRICAL SYSTEM (cab)
ELECTRICAL SYSTEM (monitor and switch panels)
ELECTRICAL SYSTEM (batteries compartment)
ELECTRICAL SYSTEM (fuses)
PUMP AND RELATED PARTS
OTHER COMPONENTS
SYSTEM
Group 1 - Control system
OUTLINE
ENGINE CONTROL
PUMP CONTROL
VALVE CONTROL
OTHER CONTROL FUNCTION
Group 2 - Hydraulic system
MAIN CIRCUIT
PILOT CIRCUIT
NEUTRAL CIRCUIT
SINGLE ACTUATOR OPERATION
COMBINED OPERATION
Group 3 - Electrical system
OUTLINE
ELECTRIC POWER CIRCUIT (Key switch: OFF)
BULB CHECK CIRCUIT (Key switch: ON)
ACCESSORY CIRCUIT (Key Switch: ACC)
PREHEAT CIRCUIT (Key switch: ON or START)
STARTING CIRCUIT (Key Switch: START)
CHARGING CIRCUIT (Key Switch: ON)
SURGE VOLTAGE PREVENTION CIRCUIT
ENGINE STOP CIRCUIT (Key Switch: OFF)
ENGINE AND PUMP CONTROL CIRCUIT
MONITOR CIRCUIT
COMPONENT OPERATION
Group 1 - Pump device
OUTLINE
MAIN PUMP
REGULATOR
PILOT PUMP
N SENSOR (ENGINE SPEED SENSOR)
PUMP PRESSURE SENSOR
Group 2 - Swing device
OUTLINE
SWING MOTOR
SWING PARKING BRAKE
VALVE UNIT
SWING REDUCTION GEAR
Group 3 - Control valve
OUTLINE
HYDRAULIC CIRCUIT
FLOW COMBINER VALVE
PUMP CONTROL VALVE
MAIN RELIEF VALVE
OVERLOAD RELIEF VALVE (With Make-Up Function)
ARM REGENERATIVE VALVE
BOOM ANTI-DRIFT VALVE, ARM ANTIDRIFT VALVE
BUCKET FLOW CONTROL VALVE
TRAVEL FLOW CONTROL VALVE
TRAVEL/BOOM LOWER SELECTOR VALVE
BOOM REGENERATIVE VALVE
Group 4 - Pilot valve
OUTLINE
OPERATION
Group 5 - Travel device
OUTLINE
TRAVEL REDUCTION GEAR
TRAVEL MOTOR
TRAVEL BRAKE VALVE
PARKING BRAKE
Group 6 - Other components (Upperstructure)
PILOT SHUT-OFF VALVE
SHOCKLESS VALVE
SOLENOID VALVE UNIT
PILOT RELIEF VALVE
EC MOTOR
Group 7 - Other components (Undercarriage)
SWING BEARING
CENTER JOINT
TRACK ADJUSTER
TECHNICAL MANUAL TROUBLESHOOTING
INTRODUCTION
SAFETY PRECAUTIONS
TROUBLESHOOTING
OPERATIONAL PERFORMANCE
Group 1 - Introduction
OPERATIONAL PERFORMANCE TEST
PREPARATION FOR PERFORMANCE TESTS
Group 2 - Standard
EX255 OPERATIONAL PERFORMANCE STANDARD TABLES
EX255 MAIN PUMP P-Q DIAGRAM
EX285 OPERATIONAL PERFORMANCE STANDARD TABLES
EX285 MAIN PUMP P-Q DIAGRAM
Group 3 - Engine Test
ENGINE SPEED
ENGINE CHECK AND ADJUSTMENT
Group 4 - Excavator Test
TRAVEL SPEED
TRACK REVOLUTION SPEED
MISTRACK CHECK
TRAVEL PARKING FUNCTION CHECK
SWING SPEED
SWING FUNCTION DRIFT CHECK
SWING MOTOR LEAKAGE
SWING BEARING PLAY
MAXIMUM SWINGABLE SLANT ANGLE
HYDRAULIC CYLINDER CYCLE TIME
DIG FUNCTION DRIFT CHECK
CONTROL LEVER OPERATING FORCE
CONTROL LEVER STROKE
COMBINED BOOM RAISE/SWING FUNCTION CHECK
Group 5 - Component Test
PRIMARY PILOT PRESSURE
SECONDARY PILOT PRESSURE
SOLENOID VALVE SET PRESSURE
MAIN PUMP DELIVERY PRESSURE
MAIN RELIEF VALVE SET PRESSURE
OVERLOAD RELIEF VALVE SET PRESSURE
MAIN PUMPS FLOW TEST
SWING MOTOR DRAINAGE
TRAVEL MOTOR DRAINAGE
TROUBLESHOOTING
Group 1 - Diagnosing Procedure
INTRODUCTION
DIAGNOSING PROCEDURE
Dr.EX
Dr.EX START-UP PROCEDURE
Dr.EX FAULT CODE
Dr.EX MONITORING FUNCTION
Dr.EX SPECIAL FUNCTION (SERVICE MODE)
ADJUSTABLE DATA LIST
Group 2 - Component Layout
MAIN COMPONENTS
ELECTRICAL SYSTEM (overall system)
ELECTRICAL SYSTEM (cab)
ELECTRICAL SYSTEM (monitor and switch panels)
PUMP AND RELATED PARTS
OTHER COMPONENTS
Group 3 - Troubleshooting A
TROUBLESHOOTING A PROCEDURE
FAULT CODES
FAULT CODE 01 (EC SENSOR FAILURE)
FAULT CODE 02 (PUMP 1 DELIVERY PRESSURE SENSOR FAILURE) FAULT CODE 03 (PUMP 2 DELIVERY PRESSURE SENSOR FAILURE)
FAULT CODE 04 (PUMP 1 CONTROL PRESSURE SENSOR FAILURE) FAULT CODE 05 (PUMP 2 CONTROL PRESSURE SENSOR FAILURE)
FAULT CODE 06 (ARM ROLL-IN PILOT PRESSURE SENSOR FAILURE)
FAULT CODE 07 (ENGINE CONTROL DIAL FAILURE)
SENSOR OPERATING RANGE LIST
Group 4 - Troubleshooting B
TROUBLESHOOTING B PROCEDURE
RELATIONSHIP BETWEEN MACHINE TROUBLE SYMPTOMS AND PARTS IN TROUBLE
CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES
ENGINE TROUBLESHOOTING
OVERALL ACTUATOR SYSTEM TROUBLESHOOTING
FRONT ATTACHMENT CONTROL SYSTEM TROUBLESHOOTING
SWING SYSTEM TROUBLESHOOTING
TRAVEL SYSTEM TROUBLESHOOTING
TROUBLESHOOTING FOR OTHER FUNCTIONS
ENGINE SPEED ADJUSTMENT AND ENGINE LEARNING
EXCHANGE INSPECTION METHOD
BOOM LOWERING METHOD WHEN ENGINE STALLS
Group 5 - Troubleshooting
TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE
MALFUNCTION OF COOLANT TEMPERATURE GAUGE
MALFUNCTION FUEL GAUGE
MALFUNCTION OF FUEL LEVEL INDICATOR (RESERVE)
MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM
MALFUNCTION OF LEVEL CHECK SWITCH
MALFUNCTION OF ENGINE OIL LEVEL INDICATOR
MALFUNCTION OF COOLANT LEVEL INDICATOR
MALFUNCTION OF HYDRAULIC OIL LEVEL INDICATOR
MALFUNCTION OF ALTERNATOR INDICATOR
MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR
MALFUNCTION OF OVERHEAT INDICATOR
MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR
MALFUNCTION OF BUZZER
MALFUNCTION OF HOUR METER
Group 6 - Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
INSTRUCTIONS FOR DISCONNECTING CONNECTORS
FUSE CONTINUITY TEST
INSPECTION AND REPLACEMENT OF MAXI FUSIBLE LINKS
BATTERY VOLTAGE CHECK
HOW TO TROUBLESHOOT ALTERNATOR MALFUNCTIONS
CONTINUITY CHECK
VOLTAGE AND CURRENT CHECK
WIPER CONTROLLER
REPLACEMENT OF RELAY
RELAY BOX
REPLACEMENT OF QOS CONTROLLER
REPLACEMENT OF POWER OUTLET
Group 7 - Harness Check
CIRCUIT INSPECTION
WORKSHOP MANUAL
INTRODUCTION
SAFETY PRECAUTIONS
ESCAVATOR
GENERAL INFORMATION
Group 1 - Precautions for Disassembly and Assembly
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
Group 2 - Tightening Torque
TIGHTENING TORQUE SPECIFICATIONS
TORQUE CHART
PIPING JOINT
UPPERSTRUCTURE
Group 1 - Cab
REMOVE AND INSTALL CAB
Group 2 - Counterweight
REMOVE AND INSTALL COUNTERWEIGHT
Group 3 - Main Frame
REMOVE AND INSTALL MAIN FRAME
Group 4 - Pump Device
REMOVE AND INSTALL PUMP DEVICE
DISASSEMBLE PUMP DEVICE
ASSEMBLE PUMP DEVICE
DISASSEMBLE REGULATOR
ASSEMBLE REGULATOR
DISASSEMBLE AND ASSEMBLE PILOT PUMP
MAINTENANCE STANDARD
Group 5 - Control Valve
REMOVE AND INSTALL CONTROL VALVE
DISASSEMBLE CONTROL VALVE 1
ASSEMBLE CONTROL VALVE 1-1
ASSEMBLE CONTROL VALVE 1-2
DISASSEMBLE CONTROL VALVE 2
ASSEMBLE CONTROL VALVE 2-1
ASSEMBLE CONTROL VALVE 2-2
DISASSEMBLE CONTROL VALVE 3
ASSEMBLE CONTROL VALVE 3-1
ASSEMBLE CONTROL VALVE 3-2
DISASSEMBLE CONTROL VALVE 4
ASSEMBLE CONTROL VALVE 4-1
ASSEMBLE CONTROL VALVE 4-2
DISASSEMBLE CONTROL VALVE 5
ASSEMBLE CONTROL VALVE 5
Group 6 - Swing Device
REMOVE AND INSTALL SWING DEVICE
DISASSEMBLE SWING DEVICE (EX255)
ASSEMBLE SWING DEVICE (EX255)
DISASSEMBLE SWING DEVICE (EX285)
ASSEMBLE SWING DEVICE (EX285)
DISASSEMBLE SWING MOTOR (EX255)
ASSEMBLE SWING MOTOR (EX255)
DISASSEMBLE SWING MOTOR (EX285)
ASSEMBLE SWING MOTOR (EX285)
DISASSEMBLE AND ASSEMBLE PARKING BRAKE RELEASE VALVE (EX285)
MAINTENANCE STANDARD
Group 7 - Pilot Valve
REMOVE AND INSTALL RIGHT PILOT VALVE
REMOVE AND INSTALL LEFT PILOT VALVE
REMOVE AND INSTALL TRAVEL PILOT VALVE
DISASSEMBLE RIGHT AND LEFT PILOT VALVE
ASSEMBLE RIGHT AND LEFT PILOT VALVE
DISASSEMBLE TRAVEL PILOT VALVE
ASSEMBLE TRAVEL PILOT VALVE
POSITIONING PILOT VALVE (triple articulation version)
SPECIAL TOOLS
Group 8 - Pilot Shut-off Valve
REMOVE AND INSTALL PILOT SHUT-OFF VALVE
DISASSEMBLE PILOT SHUT-OFF VALVE
ASSEMBLE PILOT SHUT-OFF VALVE
Group 9 - Shockless Valve
REMOVE AND INSTALL SHOCKLESS VALVE
DISASSEMBLE AND ASSEMBLE SHOCKLESS VALVE
Group 10 - Solenoid Valve Unit
REMOVE AND INSTALL SOLENOID VALVE UNIT
DISASSEMBLE PROPORTIONAL SOLENOID VALVE
ASSEMBLE PROPORTIONAL SOLENOID VALVE
Group 11 - Pilot Relief Valve Unit
REMOVE AND INSTALL PILOT RELIEF VALVE UNIT
DISASSEMBLE PILOT RELIEF VALVE
ASSEMBLE PILOT RELIEF VALVE
UNDERCARRIAGE
Group 1 - Swing Bearing
REMOVE AND INSTALL SWING BEARING
Group 2 - Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
TRAVEL DEVICE COMPONENTS (EX255)
TRAVEL MOTOR REMOVAL
DISASSEMBLE TRAVEL REDUCTION GEAR (EX255)
REASSEMBLY (EX255)
ASSEMBLE TRAVEL REDUCTION GEAR (EX255)
TRAVEL MOTOR INSTALLATION (EX255)
DISASSEMBLE TRAVEL DEVICE (EX285)
ASSEMBLE TRAVEL DEVICE (EX285)
DISASSEMBLE TRAVEL MOTOR (EX255)
ASSEMBLE TRAVEL MOTOR (EX255)
DISASSEMBLE BRAKE VALVE (EX255)
ASSEMBLE BRAKE VALVE (EX255)
DISASSEMBLE TRAVEL MOTOR (EX285)
ASSEMBLE TRAVEL MOTOR (EX285)
DISASSEMBLE BRAKE VALVE (EX285)
ASSEMBLE BRAKE VALVE (EX285)
MAINTENANCE STANDARD
Group 3 - Center Joint
REMOVE AND INSTALL CENTER JOINT
DISASSEMBLE CENTER JOINT
ASSEMBLE CENTER JOINT
MAINTENANCE STANDARD
Group 4 - Track Adjuster
REMOVE AND INSTALL TRACK ADJUSTER
DISASSEMBLE TRACK ADJUSTER
ASSEMBLE TRACK ADJUSTER
Group 5 - Front Idler
REMOVE AND INSTALL FRONT IDLER
DISASSEMBLE FRONT IDLER (EX255)
ASSEMBLE FRONT IDLER (EX255)
DISASSEMBLE FRONT IDLER (EX285)
ASSEMBLE FRONT IDLER (EX285)
MAINTENANCE STANDARD
Group 6 - Upper and Lower Roller
REMOVE AND INSTALL UPPER ROLLER
REMOVE AND INSTALL LOWER ROLLER
DISASSEMBLE UPPER ROLLER
DISASSEMBLE LOWER ROLLER
ASSEMBLE LOWER ROLLER
MAINTENANCE STANDARD
Gruppo 7 - Tracks
REMOVE AND INSTALL TRACKS
MAINTENANCE STANDARD
FRONT ATTACHMENT
Group 1 - Front attachment
REMOVE AND INSTALL FRONT ATTACHMENT
MAINTENANCE STANDARD
BUCKET TEETH
STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION
REMOVE AND INSTALL FRONT ATTACHMENT
MAINTENANCE STANDARD
Group 2 - Cylinders
REMOVE AND INSTALL CYLINDERS
HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE
CYLINDER AIR BLEEDING PROCEDURE
DISASSEMBLE CYLINDERS
ASSEMBLE CYLINDERS
MAINTENANCE STANDARD
SPECIAL TOOLS (EX255)
SPECIAL TOOLS (EX285)
ENGINE AND ACCESSORY
Group 1 - General Information
GENERAL REPAIR INSTRUCTIONS
NOTES ON THE FORMAT OF THIS MANUAL
EXTERNAL VIEW
MAIN DATA AND SPECIFICATIONS
ANGULAR NUT AND BOLT TIGHTENING METHOD
TORQUE SPECIFICATIONS
STANDARD TORQUE SPECIFICATION
SPECIAL TOOL LIST
IDENTIFICATIONS
Group 2 - Maintenance
LUBRICATING SYSTEM
FUEL SYSTEM
COOLING SYSTEM
VALVE CLEARANCE ADJUSTMENT
INJECTION TIMING
COMPRESSION PRESSURE MEASUREMENT
TURBOCHARGER INSPECTION
ENGINE REPAIR KIT
RECOMMENDED LUBRICANTS
ENGINE OIL VISCOSITY CHART
Group 3 - Engine Disassembly
EXTERNAL PARTS
MAJOR COMPONENTS
ROCKER ARM AND ROCKER ARM SHAFT
CYLINDER HEAD
PISTON AND CONNECTING ROD
Group 4 - Engine Inspection and Repair
CYLINDER HEAD
VALVE GUIDE
VALVE
VALVE SEAT INSERT
VALVE SPRING
TAPPET
ROCKER ARM SHAFT AND ROCKER ARM
PUSH ROD
IDLER GEAR AND IDLER GEAR SHAFT
CAMSHAFT
CYLINDER BODY AND LINER
PISTON AND PISTON RING
PISTON PIN
CONNECTING ROD
CRANKSHAFT
FLYWHEEL AND FLYWHEEL HOUSING
TIMING GEAR CASE COVER
Group 5 - Engine Reassembly
PISTON AND CONNECTING ROD
CYLINDER HEAD
ROCKER ARM AND ROCKER ARM SHAFT
MAJOR COMPONENT
EXTERNAL PARTS
ENGINE TUNING OPERATION
Group 6 - Lubricating System
GENERAL DESCRIPTION
OIL PUMP
OIL COOLER
Group 7 - Cooling System
GENERAL DESCRIPTION
THERMOSTAT
Group 8 - Fuel System
GENERAL DESCRIPTION
INJECTION NOZZLE
INJECTION PUMP CALIBRATION DATA
Group 9 - Turbocharger
GENERAL DESCRIPTION
TURBOCHARGER IDENTIFICATION
INSPECTION AND REPAIR
Group 10 - Starting and Charging
STARTER MOTOR
ALTERNATOR
Group 11 - Troubleshooting
HARD STARTING
1) STARTER INOPERATIVE
2) STARTER OPERATES BUT ENGINE DOES NOT TURN OVER
3) ENGINE TURNS OVER BUT DOES NOT START FUEL IS BEING DELIVERED TO THE INJECTION PUMP
4) ENGINE TURNS OVER BUT DOES NOT START FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP
UNSTABLE LOW IDLING
INSUFFICIENT POWER
OVERHEATING
WHITE EXHAUST SMOKE
DARK EXHAUST SMOKE
OIL PRESSURE DOES NOT RISE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ABNORMAL ENGINE NOISE
1) ENGINE KNOCKING
2) GAS LEAKAGE NOISE
3) CONTINUOUS NOISE
4) SLAPPING NOISE
Group 12 - Repair Standards
GENERAL RULES
Fiat Kobelco EX255 - EX285 Excavator Technical & Workshop Manual.pdf