TECHNICAL MANUAL OPERATIONAL PRINCIPLE
Allinformation,illustrationsandspecificationsinthismanualarebasedonthelatestproductinformationavailable at the time of publication.
The right is reserved to make changes at any time without notice.
Edition - VII - 1998
EXCAVATORS S.p.A.
ENGINEERING
FIAT-HITACHI
-
- FORM No. 604.06.847
EXCAVATOR
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
INTRODUCTION
TO THE READER
•This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
-Be sure to thoroughly read this manual for correct information concerning the service procedures.
-If you have any questions or comments, or if you found any errors regarding the contents of this manual, please contact:
FIAT-HITACHI EXCAVATORS S.p.A. Strada Settimo, 323 San Mauro Torinese (TO) 10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 6877357
ADDITIONAL REFERENCES
•Please refer to the materials listed below in addition to this service manual:
- Operator’s Manual
- Spare Parts Catalog
SERVICE MANUAL COMPOSITION
•The complete service manual consists of three books:
- Technical Manual - Operational Principle
- Technical Manual - Troubleshooting
- Excavator 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 Excavator 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 Excavator consists of the following book/print numbers:
BOOKPRINT NUMBER
-Technical Manual - Operational Principle604.06.847
-Technical Manual - Troubleshooting604.06.852
-Workshop Manual - Excavator604.06.857
NOTE - For the Engine Workshop Manual, make reference to the print No. 604.06.901
IN-1
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 :Excavator 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.
ToTo
QuantityconvertIntoMultiply byQuantityconvertIntoMultiply by from (SI)(Others)from (SI)(Others)
Lenghtmmin0.039 37PressureMPakgf/cm2 10.197
mmft0.003 281MPapsi145.0
LUS gal0.264 2PowerkWPS1.360
VolumeLUS qt1.057kWHP1.341
myd1.308Temperature°C°F°C x 1.8 + 32
WeightKglb2.205VelocityKm/hmph0.621 4
ForceNkgf0.101 97min-1 rpm1.0
Nlbf0.224 8Flow rateL/minUS gpm0.264 2
TorqueN.mKgf.m0.10197ML/revCc/rev1.0
N.mlbf.ft0.737 5
IN-2
INTRODUCTION
TECHNICAL MANUAL EX255
OPERATIONAL PRINCIPLE
SECTION AND GROUP CONTENTS
Section 1 -GENERAL
Group 1
Group 2
Specifications
Component Layout
Section 2 -SYSTEM
Group 1
Group 2
Group 3
Control System
Hydraulic System
Electrical System
Section 3 -COMPONENT OPERATION
Group 1
Group 2
Group 3
Group 4
Group 5
Group 6
Group 7
Pump Device
Swing Device
Control Valve
Pilot Valve
Travel Device
Other components (Upperstructure)
Other components (Undercarriage)
GENERAL CONTENTS
Group 1 -Specification
Excavator Dimensions
(Monoblock version)............................T1-1-1
Excavator Dimensions
(Triple articulation version)..................T1-1-2
Excavator performance.......................T1-1-3
Engine.................................................T1-1-3
Engine accessory................................T1-1-3
Hydraulic Devices...............................T1-1-4
Electrical Equipment...........................T1-1-5
Group 2 -Component layout
Main components................................T1-2-1
Electrical system
(Overall system)..................................T1-2-2
Electrical system
(Monitor and Switch panels)................T1-2-3
Electrical system
(Relays, Diodes, etc)...........................T1-2-4
Electrical system (Fuses)....................T1-2-5
Pump and related parts.......................T1-2-6
Other components...............................T1-2-7
EX255
SECTION 1
EXCAVATOR DIMENSIONS (Monoblock version)
T1-1-1
SPECIFICATIONS
OM0254 6 000 mm Boom Armmm2 1582 4802 950 3 600 A mm9 6509 86510 27710 903 A’ mm9 4629 68110 10010 737 B mm6 1726 4856 9487 597 B’ mm5 9406 2536 7377 429 C mm9 5519 4609 6359 988 D mm6 7706 7596 9467 279 E mm3 7893 9523 8653 892 DIGGING DATA OM0253 D/D' E F C A B H N M L G I VERSIONSABCDD’ (*)E F GHIL EX255 3 4634 2601 0902 9502 93710 1702 8152 940960460 EX255 E 3 8454 6421 0902 9502 93710 1702 8152 940960460 EX255 LC 3 8454 6421 0902 9502 93710 1702 8152 940960460 (*) Rear swing radius (**) Arm 1) 2158 mm, 2) 2480 mm, 3) 2950 mm, 4) 3600 mm EX255 EX255 E EX255 LC M-Track shoe width 600700800900600700800900600700800900 N-Maximum width 2 9903 0903 1903 2902 9903 0903 1903 2903 1903 2903 3903 490 Working weight 24 50024 75025 00025 25025 00025 30025 60025 90025 10025 40025 70026 000 Spec. Ground Press. 0.540.470.410.360.510.440.390.350.510.440.390.35 (mm) (mm) (mm) (mm) (mm) (kg) (bar) (**) 1) 3 206 2) 3 237 3) 2 991 4) 3 204
EXCAVATOR DIMENSIONS (Triple articulation version)
T1-1-2 SPECIFICATIONS
100 mm Boom Armmm2 1582 4802 9503 600 A mm9 7569 99310 42011 058 A’ mm9 5709 81210 24610 895 B mm5 7916 0676 5177 170 B’ mm5 6785 9586 4147 077 C mm11 09911 23711 37912 128 D mm6 3068 1465 8405 248 E mm2 8682 8962 5682 808 OM0256 DIGGING DATA OM0255 H N M L G I D/D' E F C A B VERSIONSABCDD’ (*)E F GHIL EX255 3 4634 2601 0902 9502 93710 1452 8152 940960460 EX255 E 3 8454 6421 0902 9502 93710 1452 8152 940960460 (*) Rear swing radius (**) Arm 1) 2158 mm, 2) 2480 mm, 3) 2950 mm, 4) 3600 mm EX255 EX255 E M-Track shoe width 600700800900600700800900 N-Maximum width 2 9903 0903 1903 2902 9903 0903 1903 290 Working weight 25 10025 35025 60025 85025 60025 90026 20026 500 Spec. Ground Press. 0.560.480.430.380.520.450.400.34 (mm) (mm) (mm) (mm) (kg) (bar) (**) 1) 3 083 2) 3 137 3) 3 019 4) 3 290
3
SPECIFICATIONS
T1-1-3
EXCAVATOR PERFORMANCE GRADEABILITY..........................................................................................................35° (70%) in continuous TRAVEL SPEED....................................................................................................2.2 / 3.4 mph (3.5/5.4 km/h) -Slow .....................................................................................................................0 to 2.2 mph (0 to 3.5 km/h) -Fast.....................................................................................................................0 to 3.4 mph (0 to 5.4 km/h) ENGINE MAIN SPECIFICATIONS -Manufacturer.................................................................................................................................CUMMINS -Model..........................................................................................................................................6CT8.3-177 -Type.........................................................................................................4 stroke Diesel type, turbocharged -Net power to flywheel (DIN 6 271).......................................................................................................................125 kW (167.5 HP) -Net power to flywheel (SAE J1 349)......................................................................................................................................125 kW -Net power to flywheel (ISO 9249)..........................................................................................................................................125 kW -Net power to flywheel (CEE 80/1 269)..................................................................................................................................125 kW -Rated Speed..................................................................................................................................2 100 rpm -Displacement.................................................................................................................................8 300 cm3 -Number of cylinders.....................................................................................................................................6 -Bore and stroke........................................................................................................................114 x 135 mm STARTER MOTOR -Voltage - Output.........................................................................................................................24V - 7.5 kW ALTERNATOR -Voltage - Output.............................................................................................................................28V - 50A ENGINE ACCESSORY RADIATOR ASSEMBLY -Type............................................................................................Radiator/Oil Cooler tandem typ e assembly -Weight....................................................................................................................................143 kg (315 lb) -Radiator Capacity.................................................................................................................................12.2 L -Oil Cooler Capacity..............................................................................................................................10.2 L BATTERY -Capacity........................................................................................................................................160 Ah x 2 -Voltage...............................................................................................................................................12V x 2
SPECIFICATIONS
HYDRAULIC DEVICES
MAIN PUMP
-Model..........................................................................................................................................HPV102FW
-Type...............................................................Variable displacement plunger pump: regulator attached type
-Max. flow (Theoretical value)....................................................................................................194 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; HP Mode: 35.3 L/ min
CONTROL VALVE
-Model.........................................................................................................................................KVMG-200H
-Type...................................................................................................................Pilot pressure operated type (4-spool + 5-spool)
-Main relief pressure................................................................Normal: 34.3 MPa (350 kgf/cm 2) @ 140 L/min
Power Boost: 36.3 MPa (370 kgf/cm2) @ 140 L/min
-Overload relief pressure.........................................................................37.3 MPa (380 kgf/cm 2) @ 50 L/min (Boom raise / lower, Arm roll-in, Bucket roll-in) 39.2 MPa (400 kgf/cm2) @ 50 L/min (Arm roll-out, Bucket roll-out)
SWING DEVICE
-Type.......................................................................................................Two-stage planetary reduction type
SWING MOTOR
-Model..............................................................................................................................................M2X146B
-Type.............................................................................Swash-plate type, fixed-displacement plunger motor
SWING BRAKE VALVE
-Type.............................................................................................................Non counter balance valve type
-Relief pressure.....................................................................................31.4 MPa (320 kgf/cm2) @ 140 L/min
SWING PARKING BRAKE
-Type.............................................................................................................Multiple-wet-plate negative type
-Cracking pressure for release................................................................1.96 to 2.64 MPa (20 to 27 kgf/cm 2)
TRAVEL DEVICE
-Type.....................................................................................................Three-stage planetary reduction gear
TRAVEL MOTOR
-Model...............................................................................................................................................HMV116
-Type.............................................................................Bent-axis type, variable displacement plunger motor
TRAVEL BRAKE VALVE
-Type....................................................................................................................Counter balance valve type
-Relief pressure..........................................................................................................34.8 MPa (355 kgf/cm2)
TRAVEL PARKING BRAKE
-Type.............................................................................................................Multiple-wet-plate negative type
-Cracking pressure for release............................................................0.95 to 1.02 MPa (9,7 to 10.4 kgf/cm 2)
T1-1-4
BYPASS CHECK VALVE
SPECIFICATIONS
T1-1-5
CYLINDERS BoomArmBucketPositioning (*) Rod diameter90 mm100 mm85 mm90 mm Cylinder bore125 mm135 mm125 mm145 mm Stroke1350 mm1610 mm1075 mm1205 mm Fully retracted length1950 mm2235 mm1665 mm1799 mm
ATTACHMENT PILOT
-Model.................................................................................................................................HVP04S-040-101 TRAVEL PILOT VALVE -Model.................................................................................................................................HVP05D-040-101
VALVE UNIT -Functions...............................................................................................SC:Arm regenerative control
sensing control
boost control
motor swash angle control
COOLER
-Cracking pressure..........................................................................................392 KPa (4 kgf/cm 2) at 5 L/min ELECTRICAL EQUIPMENT BATTERY RELAY -Voltage - Current............................................................................................................................24V - 50A GLOW RELAY -Voltage - Current..........................................................................................................................24V - 180A HORN -Specifications....................................................................................................................24V - 1.5A, 113dB LIGHT -Specifications............................................................................................Work lights:Halogen 24V - 70W Dome light:24V - 10W
(*) Triple articulation version FRONT
VALVE
SOLENOID
SD:Speed
SG:Power
SI:Travel
OIL
T1-1-6
SPECIFICATIONS NOTES
MAIN COMPONENTS
T1-2-1
COMPONENT LAYOUT
1-Bucket Cylinder 2-Arm Cylinder 3-Boom Cylinder 4-Center Joint 5-Swing Bearing 6-Swing Device 7-Fuel Tank 8-Hydraulic Oil Tank 9-Control Valve 10-Pump Device 11-Engine 12-Radiator 13-Oil Cooler 14-Battery 15-Travel Device 16-Shockless Valve 17-Pilot Shut-Off Valve 18-Travel Pilot Valve 19-Front/Swing Pilot Valve SM3001 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Overall system)
1-Wiper Motor
2-Monitor Panel
3-Relays
4-Pressure Switch (Front)
5-Pressure Switch (Travel)
6-Work Light
7-Fuel Sensor with Fuel Low Level Switch
8-Solenoid Valve Unit
9-Hydraulic Oil Level Switch
10-PC Pressure Sensor (Upper: 5-Spool Side)
11-PC Pressure Sensor (Lower: 4-Spool Side) 12-N Sensor
16-Engine Oil Pressure Switch
17-Engine Oil Level Switch
18-Overheat Switch
19-Coolant Temperature Sensor
20-Alternator
21-Battery Relay
22-Glow Relay
Level
T1-2-2
Sensors
Sensor
Motor
13-Pump Delivery Pressure
14-EC
15-EC
(Main Controller)
Box SM3002 2 3 4 5 6 1 14 -15 12 13 10 -11 9 8 7 21 20 19 18 17 16 23 22 24 25 27 26 28 29 (on the side of engine pan)
23-Coolant
Switch 24-Battery 25-Starter Relay 26-Pressure Switch and Sensor 27-Windshield Washer Tank 28-MC
29-Fuse
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
