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Fiat Hitachi Excavator EX255 Troubleshooting Technical Manual – PDF DOWNLOAD
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Description
Fiat Hitachi Excavator EX255 Troubleshooting Technical Manual – PDF DOWNLOAD
FILE DETAILS:
Fiat Hitachi Excavator EX255 Troubleshooting Technical Manual – PDF DOWNLOAD
Language : English
Pages : 224
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Fiat Hitachi Excavator EX255 Troubleshooting Technical Manual – PDF DOWNLOAD
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
FOLLOW SAFETY PRECAUTIONS
• Carefully read and observe all safety signs on the machine and read all safety precautions in this Manual.
• Safety signs should be installed, maintained, and replaced when necessary
If a safety sign or this Manual are damaged or missing, obtain a replacement from your FIATHITACHI Dealer in the same way you order a spare part (be sure to detail machine model and serial number upon ordering).
Learn how to operate the machine and its controls correctly and safely. • Allow only trained, qualified, authorised personnel to operate the machine.
• Keep the machine in proper working conditions. – Unauthorised changes to the machine may impair function and/or safety and affect machine life.
• Safety messages in this Chapter “SAFETY PRECAUTIONS”, are intended to illustrate basic safety procedures of the machine. However, it is impossible for these safety messages to cover every hazardous situation you may encounter.
If you have any doubts, consult your direct supervisor prior to operating or servicing the machine
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Fiat Hitachi Excavator EX255 Troubleshooting Technical Manual – PDF DOWNLOAD
TROUBLESHOOTING................................................................... 1 INTRODUCTION...................................................................... 2 SAFETY PRECAUTIONS................................................................ 4 SECTION AND GROUP CONTENTS........................................................ 28 SECTION 4 - OPERATIONAL PERFORMANCE TEST...................................... 28 GROUP 1 - Introduction.................................................... 29 OPERATIONAL PERFORMANCE TEST.......................................... 30 PREPARATION FOR PERFORMANCE TESTS..................................... 31 GROUP 2 - Standard........................................................ 29 OPERATIONAL PERFORMANCE STANDARD TABLES............................... 32 MAIN PUMP P-Q DIAGRAM................................................. 36 GROUP 3 - Engine test..................................................... 29 ENGINE SPEED.......................................................... 38 GROUP 4 - Excavator test.................................................. 29 TRAVEL SPEED.......................................................... 40 TRACK REVOLUTION SPEED................................................ 41 MISTRACK CHECK........................................................ 42 TRAVEL PARKING FUNCTION CHECK......................................... 43 SWING SPEED........................................................... 44 SWING FUNCTION DRIFT CHECK............................................ 45 SWING MOTOR LEAKAGE................................................... 46 SWING BEARING PLAY.................................................... 47 MAXIMUM SWINGABLE SLANT ANGLE......................................... 48 HYDRAULIC CYLINDER CYCLE TIME......................................... 49 DIG FUNCTION DRIFT CHECK.............................................. 51 CONTROL LEVER OPERATING FORCE......................................... 52 CONTROL LEVER STROKE.................................................. 53 COMBINED BOOM RAISE/SWING FUNCTION CHECK.............................. 54 GROUP 5 - Component test.................................................. 29 PRIMARY PILOT PRESSURE................................................ 56 SECONDARY PILOT PRESSURE.............................................. 58 SOLENOID VALVE SET PRESSURE........................................... 59 MAIN PUMP DELIVERY PRESSURE........................................... 61 MAIN RELIEF VALVE SET PRESSURE........................................ 62 OVERLOAD RELIEF VALVE SET PRESSURE.................................... 66 MAIN PUMP FLOW TEST................................................... 69 SWING MOTOR DRAINAGE.................................................. 73 TRAVEL MOTOR DRAINAGE................................................. 75 SECTION 5 - TROUBLESHOOTING................................................... 28 GROUP 1 - Diagnosing Procedure............................................ 78 INTRODUCTION.......................................................... 80 DIAGNOSING PROCEDURE.................................................. 81 Dr.EX................................................................. 83 Dr.EX START-UP PROCEDURE.............................................. 83 Dr.EX FAULT CODE...................................................... 84 Dr.EX MONITORING FUNCTION............................................. 85 Dr.EX SPECIAL FUNCTION (SERVICE MODE)................................. 86 ADJUSTABLE DATA LIST.................................................. 93 GROUP 2 - Component Layout................................................ 78 MAIN COMPONENTS....................................................... 94 ELECTRICAL SYSTEM (Overall System).................................... 95 ELECTRICAL SYSTEM (Relays, Diodes, etc)............................... 96 ELECTRICAL SYSTEM (Monitor and Switch Panels)......................... 97 PUMP AND RELATED PARTS................................................ 98 CONTROL VALVE......................................................... 99 OTHER COMPONENTS......................................................104 GROUP 3 - Troubleshooting A............................................... 78 TROUBLESHOOTING A PROCEDURE...........................................105 FAULT CODES...........................................................106 FAULT CODE 01 (EC SENSOR FAILURE).....................................108 FAULT CODE 02, 03.....................................................109 FAULT CODE 04, 05.....................................................110 FAULT CODE 06.........................................................111 FAULT CODE 07.........................................................112 SENSOR OPERATING RANGE LIST...........................................113 GROUP 4 - Troubleshooting B............................................... 78 TROUBLESHOOTING B PROCEDURE...........................................115 RELATIONSHIP BETWEEN MACHINE TROUBLE SYMPTOMS AND PARTS IN TROUBLE....116 CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES................126 ENGINE TROUBLESHOOTING................................................132 ACTUATOR CONTROL SYSTEM TROUBLESHOOTING...............................146 FRONT ATTACHMENT CONTROL SYSTEM TROUBLESHOOTING.......................152 SWING SYSTEM TROUBLESHOOTING..........................................164 TRAVEL SYSTEM TROUBLESHOOTING.........................................167 TROUBLESHOOTING FOR OTHER FUNCTIONS...................................172 ENGINE SPEED ADJUSTMENT AND ENGINE LEARNING...........................174 EXCHANGE INSPECTION METHOD............................................175 GROUP 5 - Troubleshooting C............................................... 78 TROUBLESHOOTING C PROCEDURE...........................................177 MALFUNCTION OF COOLANT TEMPERATURE GAUGE..............................178 MALFUNCTION FUEL GAUGE................................................180 MALFUNCTION OF FUEL LEVEL INDICATOR (RESERVE).........................182 MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM...........................184 MALFUNCTION OF LEVEL CHECK SWITCH.....................................184 MALFUNCTION OF ENGINE OIL LEVEL INDICATOR.............................186 MALFUNCTION OF COOLANT LEVEL INDICATOR................................188 MALFUNCTION OF HYDRAULIC OIL LEVEL INDICATOR..........................190 MALFUNCTION OF ALTERNATOR INDICATOR...................................192 MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR..........................194 MALFUNCTION OF OVERHEAT INDICATOR.....................................196 MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR.......................198 MALFUNCTION OF BUZZER.................................................200 MALFUNCTION OF HOUR METER.............................................202 GROUP 6 - Electrical System Inspection.................................... 79 PRECAUTIONS FOR INSPECTION AND MAINTENANCE............................203 INSTRUCTIONS FOR DISCONNECTING CONNECTORS.............................205 FUSE CONTINUITY TEST..................................................206 INSPECTION AND REPLACEMENT OF MAXI FUSIBLE LINKS......................207 INSPECTION AND REPLACEMENT OF MEGA FUSIBLE............................208 BATTERY VOLTAGE CHECK.................................................209 HOW TO TROUBLESHOOT ALTERNATOR MALFUNCTIONS...........................210 CONTINUITY CHECK......................................................211 VOLTAGE AND CURRENT CHECK.............................................212 REPLACEMENT OF RELAY..................................................216 REPLACEMENT OF DIODE..................................................218 REPLACEMENT OF POWER OUTLET...........................................220 GROUP 7 - Harness Check................................................... 79 CIRCUIT CHECK.........................................................221
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