TECHNICAL MANUAL OPERATIONAL PRINCIPLE
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-HITACHI EXCAVATORS S.p.A. - ENGINEERING - FORM No. 604.06.927
Edition - V - 1999
• 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
TECHNICAL MANUAL EX355
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)
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
- 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 EX355 Excavator consists of the following book/print numbers:
IN-1
BOOK PRINT NUMBER -Technical Manual - Operational Principle 604.06.927 -Technical Manual - Troubleshooting 604.06.932 -Workshop Manual 604.06.937
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.
5
IN-2
ToTo QuantityconvertIntoMultiply byQuantityconvertIntoMultiply by from (SI)(Others)from (SI)(Others) Lenghtmmin 0.039 37 PressureMPa kgf/cm2 10.197 mmft0.003 281MPapsi 145.0 LUS gal0.264 2 PowerkWPS1.360 VolumeLUS qt1.057kWHP1.341 m 3 yd 3 1.308 Temperature°C°F°C x 1.8 + 32 WeightKglb 2.205Velocity Km/hmph0.621 4 ForceNkgf0.101 97min-1 rpm1.0 Nlbf0.224 8Flow rate L/minUS gpm 0.264 2 TorqueN.m Kgf.m 0.10197 ML/revCc/rev1.0 N.mlbf.ft 0.737
INTRODUCTION
SECTION 1 EX355
Group 1 -Specifications 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................................ T1-1-4 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 Other components T1-2-6
GENERAL CONTENTS
T1-1-1
EXCAVATOR DIMENSIONS (Monoblock version) OM0553 G ▲ L ▲ M ▲ ▲ N H ▲ ▲ I ▲ ▲ ▲ ▲ F ▲ ▲ ▲ ▲ E ▲ ▲ D/D' ▲ ▲ B ▲ ▲ A ▲ ▲ C VERSIONABCDD '(*)EF (**)GHIL EX355 E (mm) 4052495212503280330011040300030201020530 EX355 LC (mm) 4052495212503280330011040300030201020530 1) 3490 2) 3420 3) 3170 4) 3517 (*) Rear swing radius(**) Arm 1) 2300 mm, 2) 2650 mm, 3) 3190 mm, 4) 3990 mm M-Track shoe width (mm) 600700800900600700800900 N-Maximum width (mm) 30003100320033003190329033903490 Working weight(kg) 3340033825342503467533650340753450034925 Spec. Ground Press (bar) 0.660.570.500.450.660.570.500.45 EX355 EEX355 LC OM0554 DIGGING DATA 6400 mm Boom Armmm2300265031903990 A mm10320105801110011870 A' mm10100103601090011680 B mm6490683073608160
mm6290665072108030
mm992099101027010660
mm7030703072707620 E mm4560465044904540
SPECIFICATIONS
B'
C
D
EXCAVATOR DIMENSIONS (Triple articulation version)
VERSIONSABCDD'(*)EF (**)GHIL
T1-1-2 SPECIFICATIONS
OM0556
EX355 E (mm) 4052495212503280330010980300030201020530 EX355 LC (mm) 4052495212503280330010980300030201020530 1) 3275 2) 3291 3) 3237 4) 3679 (*) Rear swing radius (**) Arm 1) 2300 mm, 2) 2650 mm, 3) 3190 mm, 4) 3990 mm M-Track shoe width (mm) 600700800900600700800900 N-Maximum width (mm) 30003100320033003190329033903490 Working weight(kg) 3400034425348503527534250346753510035525 Spec. Ground Press (bar) 0.670.580.510.460.670.580.510.46 EX355 EEX355 LC DIGGING DATA 3400 mm Boom Armmm2300265031903990 A mm10430107201126012040 A' mm10210105101106011850 B mm6010632068707660 B' mm5900622067707580 C mm11940121401263013310 D mm86208820933010020 E mm3220315029403290 OM0555 G ▲ L ▲ M ▲ ▲ N H ▲ ▲ I ▲ ▲ ▲ ▲ F ▲ ▲ ▲ ▲ E ▲ ▲ D/D' ▲ ▲ B ▲ ▲ A ▲ ▲ C
SPECIFICATIONS
EXCAVATOR PERFORMANCE
GRADEABILITY...........................................................................................................35° (70%) in continuous TRAVEL SPEED....................................................................................................2.2 / 3.4 mph (3.6/5.5 km/h)
-Slow .....................................................................................................................0 to 2.2 mph (0 to 3.6 km/h) -Fast.....................................................................................................................0 to 3.4 mph (0 to 5.5 km/h)
ENGINE
MAIN SPECIFICATIONS
- Manufacturer.......................................................................................................................................... ISUZU
- Model.......................................................................................................................................B-6SD1TQA-01
- Type...........................................................................Diesel, 4 cycle, vertical, 6-cylinder inline, water-cooled, direct injection type
- Cyl. No.-bore x stroke..........................................................................6-120 mm x 145 mm (4.72 in x 5.71 in)
- Piston displacement............................................................................................................9839 cm3 (600 in3)
- Rated output.....................................................................................169.2 kW/1900 min-1 (230 PS/1900 rpm) HP Mode: 176.5 kW/2000 min-1 (240 PS/2000 rpm)
- Compression ratio...................................................................................................................................... 16.0
- Dry weight...............................................................................................................................715 kg (1576 lb)
- Firing order................................................................................................................. 1-5-3-6-2-4
- Rotation direction..............................................................................................Clockwise (view from fan side)
COOLING SYSTEM
- Cooling fan...............................................................................................Dia. 800 mm, 6 blades, draw-in type
- Fan pulley ratio....................................................................................................................Engine rpm x 0.87
- Thermostat....................................................Cracking temp. : 76.5 °C (170 °F) (under atmospheric pressure) Full open (Stroke: 10 mm or larger) temp. : 90 °C (194 °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-7.4 kW
PRE-HEAT SYSTEM
- Heating method.................................................................................................................................Glow plug
ENGINE STOP SYSTEM
- Stop method........................................................................................................................................Fuel cut
ALTERNATOR
- Type............................................................................................................................AC type (with regulator)
- Voltage-Output......................................................................................................24 V-40 A (Brush-less type)
SUPERCHARGING SYSTEM
- Type..........................................................................................................Exhaust-gas-turbo type MHI TF08L
FUEL SYSTEM
- Injection pump model......................................................................................................................Bosch type
- Governor.......................................................................................................Centrifugal al l speed control RSV
- Injection nozzle.......................................................................................................................Multihole nozzle
T1-1-3
SPECIFICATIONS
ENGINE
ACCESSORY
RADIATOR ASSEMBLY -Type ..............................................................................................Radiator/Oil Cooler tandem type assembly
lb)
HYDRAULIC DEVICES MAIN PUMP
-Model ............................................................................................................................................. PF300E5U
-Type .................................................................Variable displacement plunger pump: regulator attached type -Max. flow (Theoretical value).....................................................................................................262 L/min x 2
PILOT PUMP -Model .....................................................................................................................................HY/ZFS 11/16.8 -Type ........................................................................................................Fixed displacement type gear pump
-Model KMX15H
-Type ....................................................................................................................Pilot pressure operated type (4-spool + 5-spool)
-Main relief pressure..................................................................Normal: 31.4
Boost: 34.3
(320 kgf/cm 2), 260 L/min
(350 kgf/cm2), 200
-Overload relief pressure..........................................................................33.3 MPa (340 kgf/cm2), 50 L/min (Boom raise / lower, Arm roll-in, Bucket roll-in) 35.3 MPa (360 kgf/cm2), 50 L/min (Arm roll-out, Bucket roll-out)
SWING DEVICE
-Type .........................................................................................................Two-stage planetary reduction type
SWING MOTOR
-Model .......................................................................................................................................... M2X210CHB
-Type ...............................................................................Swash-plate type, fixed-displacement plunger motor
SWING BRAKE VALVE
-Type ..............................................................................................................Non counter balance valve type
-Relief pressure........................................................................................28.4 MPa (290 kgf/cm2), 236 L/min
SWING PARKING BRAKE
-Type ..............................................................................................................Multiple-wet-plate negative type
-Cracking pressure for release.......................................................................................2.45 MPa (25 kgf/cm2)
TRAVEL DEVICE
-Type ......................................................................................................Three-stage planetary reduction gear
TRAVEL MOTOR
-Model ................................................................................................................................................. HMV145
-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/cm2)
T1-1-4
-Weight ......155 kg (342
-Radiator Capacity......................................................................................................................................18 L -Oil Cooler Capacity........................................................................................................... .....................11.1 L BATTERY -Capacity .........160 Ah x 2 -Voltage ...............................................................................................................................................12V x 2
-Max. flow (Theoretical value)..........................................................................................................31.9 L/min CONTROL VALVE
MPa
Power
MPa
L/min
BYPASS CHECK VALVE
SPECIFICATIONS
T1-1-5
CYLINDERS BoomArm BucketPositioning (*) Rod diameter105 mm115 mm95 mm105 mm Cylinder bore150 mm170 mm145 mm170 mm Stroke1507 mm1795 mm1250 mm1335 mm Fully retracted length2150 mm2480 mm1835 mm2020 mm (*)Triple articulation version
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 - 100A STARTER RELAY -Voltage ......................24V GLOW RELAY -Voltage.....................................................................................................................................................24V HORN -Specifications.....................................................................................................................24V - 1.5A, 113dB LIGHT -Specifications............................................................................................Work lights:Halogen 24V - 70W Dome light:24V - 10W AIR CONDITIONER -Refrigerant............................................................................................................................................134 a -Temperature control........................................................................................................... Electronic control
FRONT
VALVE
SOLENOID
SD:Speed
SG:Power
SI:Travel
OIL
T1-1-6
SPECIFICATIONS NOTES
MAIN COMPONENTS
COMPONENT LAYOUT
T1-2-1
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-Pilot Filter, Pilot Relief Valve 11-Pump Device 12-Engine 13-Radiator 14-Oil Cooler 15-Battery 16-Travel Device 17-Shockless Valve 18-Pilot Shut-Off Valve 19-Travel Pilot Valve 20-Front/Swing Pilot Valve SM6001
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Overall system)
T1-2-2
1-Wiper Motor
Light
Low Fuel Level Switch
2-Monitor Panel 3-Relays 4-Horn 5-Work
6,7-Fuel Sensor with
Unit
8-Solenoid Valve
Preheat Circuit)
9-Pressure Switch (Engine
4-Spool Side)
Side) 14-EC Motor 15-EC Sensor 16-Pump Delivery Pressure Sensor 1 17-Pump Delivery Pressure Sensor 2
(Engine Speed) Sensor
Oil Pressure Switch
Oil Level Switch
Switch
Temperature Sensor
Temperature Switch (Engine Preheat Circuit)
Relay
Level Switch
Relay
Cleaner Restriction Switch
Switch (Boom Raise), Pressure Sensor (Arm Roll-In) 30 -Pressure Switch (Front) 31 -Fuse Box 32 -MC (Main Controller) 33 -QOS Controller SM6002
10-Pressure Switch (Travel) 11-Hydraulic Oil Level Switch 12-PC Pressure Sensor (Upper:
13-PC Pressure Sensor(Lower: 5-Spool
18-N
19-Engine
20-Engine
21-Overheat
22-Coolant
23-Coolant
24-Battery
25-Coolant
26-Battery 27-Starter
28-Air
29-Pressure
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Monitor and Switch panels)
T1-2-3
1-Monitor Panel 2-Switch Panel 3-Power Boost Switch 4-Key Switch 5-Cigar Lighter 6-HP Mode Switch 7-E Mode Switch 8-Engine Control Dial 9-Air Conditioner Panel 10-Warm Up Complete Indicator 11-Fuel Gauge 12-E Mode Indicator 13-Auto-Idle Indicator 14-Hydraulic Oil Level Indicator 15-Preheat Indicator 16-Air Filter Restriction Indicator 17-Fuel Level Indicator 18-Overheat Indicator 19-Alternator Indicator 20-Engine Oil Pressure Indicator 21-Engine Oil Level Indicator 22-Coolant Level Indicator 23-HP Mode Indicator 24-Coolant Temperature Gauge 25-Work Light Switch 26-Wiper Switch 27-Travel Mode Switch 28-Work Mode Switch 29-Buzzer Stop Switch 30-Auto-Idle Switch 31-Washer Switch 32-Level Check Switch 5 6 7 8 9 1 2 3 4 10 24 23 22 21 20 19 18 11 12 13 14 15 16 17 25 26 27 28 32 31 30 29 T157-01-01-009 T157-01-01-018 T157-07-02-001 SM0611 SM0612 SM0610
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Relays, Diodes, etc.)
1-Cigar lighter
2-Wiper relay BM (R11)
3-Wiper relay B-2 (R10)
4-Diode 5
5-Wiper relay B-1 (R9)
6-Wiper relay A (R8)
7-Diodes 6-7
8-Washer relay (R4)
9-Connectors for option switches
10-Air conditioner relays (if installed)
11-MC (Main Controller)
12-QOS Controller
13-Horn relay (R7)
14-Light relay 1 (R6)
15-Light relay 2 (R5)
16-Anti Load Dump relay (R3)
17-Provision for hammer relay (R19)
18-Provision for Load momentum alarm relay (R17)
19-Provision for rotary bucket relay (R16)
20-Provision for Nordic kit relay (R15)
21-Diodes 8-9
22-Diode 2-12
23-Provision for Load momentum alarm buzzer 24-Dr. EX connector 25-Engine Learning switch 26-Fuse
T1-2-4
box
plug relay
A 29-Battery relay
Cab
Battery
27-Glow
28-Diode
SM6003
compartment
compartment
ELECTRICAL SYSTEM (Fuses)
COMPONENT LAYOUT
T1-2-5
FUSES IN THE BOX Fuse LABEL PROTECTEDRating No.CIRCUIT(AMP) 1SW. BACK UP Backup power 5 source 2ENG. CONTR MC 10 (Power Source) 3E.C. MOTOREC Motor10 4POWER ONPower supply5 5 SOLENOID Solenoid power 5 supply valves 6SW. BOXSwitch panel5 7 HEAT SEAT AND Heated 10 HAMMERseat/breaker 8–––Bucket rot. 9 ROT. BUCKET& Load 10 AND TBGMoment alarm (opt) 10NORDIC KIT Kit for Northern 10 Countries 11LIGHTLights20 12WIPERWiper10 13HEATERHeater20 14 15HORNHorn10 16RADIORadio5 17LIGHTERCigar lighter10 18 POWERPower supply 10 OUTLEToutlet 19 AIRAir 10 CONDITIONconditioner Controller 20 CONTROLLER (Quick on start)5 QOS Power Supply FUSES IN THE BATTERIES COMPARTMENT FUSE 1BOX A Main power 40 supply with key – BOX A FUSE 3BOX B Engine start-up 60 line protection –BOX B–
batteries
8 6 4 3 5 2 1 7 9 19 18 20 16 17 14 13 15 12 11 10 OM0232 Fuses in the fuse box OM0231
Fuses in the
compartment
OM0532
OTHER COMPONENTS
Pump device
COMPONENT LAYOUT
Travel device
Pilot filter
1-Regulator (Pump 2)
2-Pilot Pump
3-Regulator (Pump 1)
4-Pump 2
5-Pump Delivery Pressure Sensor (Pump 2)
6-Pump 1
7-Pump Delivery Pressure Sensor (Pump 1)
8-N (Engine Speed) Sensor
9-Counterbalance Valve
10-Travel Relief Valve
11-Pilot filter
12-Pilot relief valve
SM6004
T1-2-6
COMPONENT LAYOUT
T1-2-7
1-Swing Relief Valve
2-Pilot Pressure Sensor(Arm Roll-In)
3-Shockless Valve
4-Check Valve
5-Check Valve
6-Pilot Pressure Switch (Boom Raise)
Swing Device Shockless Valve
1 T157-01-01-011 T157-07-03-018
Solenoid Valve Unit
T157-01-01-012
7-Check Valve
8-Solenoid Valve Unit (SC)
9-Solenoid Valve Unit (SD)
10-Solenoid Valve Unit (SI)
11-Solenoid Valve Unit (SG)
SM0626 SM6005 SM6006 5 6 2 7 4 3 11 10 9 8 12
12-Pressure Switch (Engine Preheat Circuit)
• 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