Fiat Kobelco EX255 - EX285 Excavator Technical & Workshop Manual

Fiat Kobelco EX255 - EX285 Excavator Workshop Manual, Technical Operational Principle & Troubleshooting Manual
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This complete service repair workshop manual PDF download for the EX255 - EX285 Fiat Kobelco 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.

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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
        
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