Fiat Kobelco EX355 Tier2 User manual

EX355 Tier2
TECHNICAL MANUAL - OPERATIONAL PRINCIPLE
TECHNICAL MANUAL - TROUBLESHOOTING
WORKSHOP MANUAL
WORKSHOP MANUAL - ENGINE

FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. - ENGINEERING -
FORM No. 604.13.206 - Edition - July 2002
EXCAVATOR
TECHNICAL MANUAL
OPERATIONAL PRINCIPLE
(Tier 2)
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.

EX355 IN-1
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 KOBELCO CONSTRUCTION
MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALY
PRODUCT SUPPORT
Fax. ++39 011 6877357
BOOK PRINT NUMBER
- Technical Manual - Operational Principle 604.13.206
- Technical Manual - Troubleshooting 604.13.211
- Workshop Manual 604.13.216
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 in-
cludes 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, mainte-
nance standards, removal/installation and assem-
bly/disassembly procedures.
• The Service Manual for EX355 Excavator consists
of the following book/print numbers:
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition
to this service manual:
-Operation and Maintenance Instruction
Manual
-Parts Catalog

IN-2 EX355
INTRODUCTION
To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.039 37 Pressure MPa kgf/cm210.197
mm ft 0.003 281 MPa psi 145.0
L US gal 0.264 2 Power kW CV-PS 1.360
Volume L US qt 1.057 kW HP 1.341
m3yd31.308 Temperature °C °F °C x 1.8 + 32
Weight Kg lb 2.205 Velocity Km/h mph 0.621 4
Force N kgf 0.101 97 min-1 rpm 1.0
N lbf 0.224 8 Flow rate L/min US gpm 0.264 2
Torque N.m Kgf.m 0.10197 ML/rev Cc/rev 1.0
N.m lbf.ft 0.737 5
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.

Section 3 - COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Other components (Upperstructure)
Group 7 Other components (Undercarriage)
TECHNICAL MANUAL EX355
OPERATIONAL PRINCIPLE
SECTION AND GROUP CONTENTS
Section 1 - GENERAL
Group 1 Specifications
Group 2 Component Layout
Section 2 - SYSTEM
Group 1 Control System
Group 2 Hydraulic System
Group 3 Electrical System

SECTION 1 EX355
GENERAL
CONTENTS
Group 1 - Specifications
Excavator Dimensions
(Monoblock version) ............................. T1-1-1
Escavator Dimensions
(BEH version) ...................................... T1-1-2
Excavator Dimensions
(Triple articulation version) ................... T1-1-3
Excavator performance ........................ T1-1-4
Engine ................................................. T1-1-4
Engine accessory ................................ T1-1-5
Hydraulic Devices ................................ T1-1-5
Electrical Equipment ............................ T1-1-6
Group 2 - Component layout
Main components ................................ T1-2-1
Electrical system
(Overall system) .................................. T1-2-2
Electrical system
(Cab) .................................................... T1-2-3
Electrical system
(Monitor and Switch panels) ................. T1-2-5
Electrical system
(Batteries compartment) ...................... T1-2-6
Electrical system (Fuses) .................... T1-2-7
Other components ............................... T1-2-8

EX355 T1-1-1
SPECIFICATIONS
EXCAVATOR DIMENSIONS
(Monoblock version)
VERSION A B C D D'(*) E F (**) G H I L
EX355 EL (mm) 4052 4952 1250 3280 3300 11040 3000 3020 1020 530
EX355 LC (mm) 4052 4952 1250 3280 3300 11040 3000 3020 1020 530
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) 600 700 800 900 600 700 800 900
N-Maximum width (mm) 3000 3100 3200 3300 3190 3290 3390 3490
Working weight (kg) 33400 33825 34250 34675 33650 34075 34500 34925
Spec. Ground Press (bar) 0.66 0.57 0.50 0.45 0.66 0.57 0.50 0.45
EX355 EL EX355 LC
OM0554
DIGGING DATA
6400 mm Boom
Arm mm 2300 2650 3190 3990
Amm 10320 1058011100 11870
A' mm 10100 1036010900 11680
Bmm 6490 6830 7360 8160
B' mm 6290 6650 7210 8030
Cmm 9920 9910 10270 10660
Dmm 7030 7030 7270 7620
Emm 4560 4650 4490 4540
OM0553
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T1-1-2 EX355
SPECIFICATIONS
EXCAVATOR DIMENSIONS
(BEH version)
VERSION A B C D D'(*) E (**) F (**) G H I L
EX355 BEH (mm) 4052 4952 1250 3280 3300 10680 3640 3000 3020 1020 530
(*) Rear swing radius (**) These dimensions without bucket will be: F = 3485; E = 10640.
M-Track shoe width (mm) 600 700 800 900
N-Maximum width (mm) 3000 3100 3200 3300
Working weight (kg) 34000 34425 34850 35275
Spec. Ground Press (bar) 0.67 0.58 0.51 0.46
EX355 BEH
OM0554
DIGGING DATA
5775 mm Boom
Arm mm 2070
Amm 9360
A' mm 9120
Bmm 5640
B' mm 5400
Cmm 9080
Dmm 6400
Emm 4200
E
OM0660
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EX355 T1-1-3
SPECIFICATIONS
EXCAVATOR DIMENSIONS
(Triple articulation version)
VERSIONS A B C D D'(*) E F (**) G H I L
EX355 EL (mm) 4052 4952 1250 3280 3300 10980 3000 3020 1020 530
EX355 LC (mm) 4052 4952 1250 3280 3300 10980 3000 3020 1020 530
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) 600 700 800 900 600 700 800 900
N-Maximum width (mm) 3000 3100 3200 3300 3190 3290 3390 3490
Working weight (kg) 34000 34425 34850 35275 34250 34675 35100 35525
Spec. Ground Press (bar) 0.67 0.58 0.51 0.46 0.67 0.58 0.51 0.46
EX355 EL EX355 LC
DIGGING DATA
3400 mm Boom
Arm mm 2300 2650 3190 3990
Amm 10430 10720 11260 12040
A' mm 10210 10510 11060 11850
Bmm 6010 6320 6870 7660
B' mm 5900 6220 6770 7580
Cmm 11940 12140 12630 13310
Dmm 8620 8820 9330 10020
Emm 3220 3150 2940 3290
OM0555
N
OM0556
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T1-1-4 EX355
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 .................................................................................................................................... AA 6HK1XQA-01
- Type ........................................................................... Diesel, 4 cycle, vertical, 6-cylinder inline, water-cooled,
direct injection type turbocharged, with intercooler
- Cyl. No.-bore x stroke .......................................................................... 6-115 mm x 125 mm (4.52 in x 4.92 in)
- Piston displacement ....................................................................................................... 7790 cm3(475.34 in3)
- Rated output ..................................................................................... 176.5 kW/1900 min-1 (240 PS/1900 rpm)
HP Mode: 183.9 kW/2000 min-1 (250 PS/2000 rpm)
- Compression ratio ......................................................................................................................................17.3
- Dry weight............................................................................................................................... 644 kg (1420 lb)
- Firing order....................................................................................................................................... 1-5-3-6-2-4
- Rotation direction .............................................................................................. Clockwise (view from fan side)
COOLING SYSTEM
- Cooling fan ............................................................................................... Dia. 850 mm, 6 blades, draw-in type
- Fan pulley ratio ...................................................................................................................... Engine rpm x 0.8
- Thermostat ....................................................... Cracking temp. : 82 °C (180 °F) (under atmospheric pressure)
Full open (Stroke: 10 mm or larger) temp. : 95 °C (203 °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-5 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-50 A (Brush-less type)
SUPERCHARGING SYSTEM
- Type .............................................................................................................. Exhaust-gas-turbo type IHI RG6
FUEL SYSTEM
- Injection pump model ......................................................................................................................Bosch type
- Governor ....................................................................................................... Centrifugal all speed control RSV
- Injection nozzle ....................................................................................................................... Multihole nozzle

EX355 T1-1-5
SPECIFICATIONS
ENGINE ACCESSORY
RADIATOR ASSEMBLY
- Type ..............................................................................................Radiator/Oil Cooler tandem type assembly
- Weight ..................................................................................................................................... 155 kg (342 lb)
- Radiator Capacity......................................................................................................................................15 L
- Oil Cooler Capacity .................................................................................................................................... 8 L
BATTERY
- Capacity ........................................................................................................................................ 160 Ah x 2
- Voltage ............................................................................................................................................... 12V x 2
HYDRAULIC DEVICES
MAIN PUMP
- Model ............................................................................................................................................. PF300E5M
- 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
- Max. flow (Theoretical value) .......................................................................................................... 31.9 L/min
CONTROL VALVE
- Model ................................................................................................................................................ KMX15H
- Type .................................................................................................................... Pilot pressure operated type
(4-spool + 5-spool)
- Main relief pressure .................................................................. Normal: 31.4 MPa (320 kgf/cm2), 260 L/min
Power Boost: 34.3 MPa (350 kgf/cm2), 200 L/min
- 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)

T1-1-6 EX355
SPECIFICATIONS
CYLINDERS
Boom Arm Bucket Positioning (*)
Standard BEH
Rod diameter 105 mm 115 mm 95 mm 105 mm 105 mm
Cylinder bore 150 mm 170 mm 145 mm 150 mm 170 mm
Stroke 1507 mm 1795 mm 1250 mm 1250 mm 1335 mm
Fully retracted length 2150 mm 2480 mm 1835 mm 1864 mm 2020 mm
(*) Triple articulation version
FRONT ATTACHMENT PILOT VALVE
- Model .................................................................................................................................. HVP04S-040-101
TRAVEL PILOT VALVE
- Model ................................................................................................................................... HVP05D-040-101
SOLENOID VALVE UNIT
- Functions ............................................................................................... SC: Arm regenerative control
SD: Speed sensing control
SG: Power boost control
SI: Travel motor swash angle control
OIL COOLER BYPASS CHECK VALVE
- Cracking pressure ........................................................................................... 392 KPa (4 kgf/cm2) 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 (A)
LIGHT
- Specifications ............................................................................................ Work lights: Halogen 24V - 70W
Dome light: 24V - 10W
AIR CONDITIONER
- Refrigerant ............................................................................................................................................ 134 a
- Temperature control ........................................................................................................... Electronic control

EX355 T1-2-1
COMPONENT LAYOUT
MAIN COMPONENTS
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 - Intercooler
16 - Battery
17 - Travel Device
18 - Shockless Valve
19 - Pilot Shut-Off Valve
20 - Travel Pilot Valve
21 - Front/Swing Pilot Valve
SM5601

T1-2-2 EX355
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Overall system)
1 - Wiper Motor
2 - Monitor Panel
3 - Relays, Relays box
4 - Windshield
5 - Horn
6 - Work Light
7,8 - Fuel Sensor with Low Fuel Level Switch
9 - Solenoid Valve Unit
10 - Pressure Switch (Travel)
11 - Hydraulic Oil Level Switch
12 - PC Pressure Sensor (Upper: 4-Spool Side)
13 - PC Pressure Sensor(Lower: 5-Spool Side)
14 - EC Motor
15 - EC Sensor
16 - Pump Delivery Pressure Sensor 1
17 - Pump Delivery Pressure Sensor 2
18 - N (Engine Speed) Sensor
19 - Engine Oil Pressure Switch
20 - Coolant Temperature Switch (Engine Preheat Circuit)
21 - Engine Oil Level Switch (on oil pan)
22 - Overheat Switch
23 - Coolant Temperature Sensor
24 - Battery Relay
25 - Coolant Level Switch
26 - Battery
27 - Starter Relay
28 - Air Cleaner Restriction Switch
29 - Pressure Switch (Boom Raise), Pressure Sensor (Arm Roll-In)
30 - Pressure Switch (Front)
31 - Fuse Box
32 - MC (Main Controller)
33 - QOS Controller
SM5602

EX355 T1-2-3
COMPONENT LAYOUT
1 - Relay box
2 - Air conditioner relays (if installed)
3 - Connection for cab light (ceiling)
4 - WWES connection for wiper cut-off microswitch
5 - Heater connection
6 - Air conditoner connection
7 - Loudspeakers connection
8 - Cab ground
9 - Main controller (MC)
10 - Q.O.S. controller
11 - Load momentum alarm buzzer provision
12 - Load momentum alarm relay provision
13 - Breaker relay (R2) variant provision
14 - R.H. Rotation bucket relay (R1) variant provision
15 - L.H. Rotation bucket relay (R3) variant provision
16 - Cab light relay (R5)
17 - Rear cab light relay (R6)
18 - A, B, K junction connector
19 - C, D juncton connector
20 - E, F junction connector
21 - G, H junction connector
22 - Dr. EX. connector
23 - Engine learning switch
24 - Fuse box
ELECTRICAL SYSTEM (Cab)
SM5603

T1-2-4 EX355
COMPONENT LAYOUT
1 - Connectors for monitor and switch panels
2 - Cigarette lighter
3 - Connectors to cab harness
4 - Connectors not used
5 - Windshield wiper controller
6 - (1) connector for breaker switch
(2) connector for cab light switch
(3) connector for bucket rotation
(4) connector for load momentum alarm switch
(5) connector for rear cab light
SM5604
ELECTRICAL SYSTEM (Cab)
7 - Connector not used
8 - Connector
3
4
5
6
7
8
12

EX355 T1-2-5
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Monitor and Switch panels)
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

T1-2-6 EX355
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Batteries compartment)
1 - Battery relay
2 - Fuse link (Box B - Fuse 3-60A)
3 - Fuse link (Box A - Fuse 1-40A, Fuse 2-40A)
4 - Connection box
5 - Safety relay
6 - Engine coolant level switch
7 - Ground joint connector
8 - Glow relay
SM5605
8
1
2
3
4
5
6
7

EX355 T1-2-7
COMPONENT LAYOUT
Fuses in the batteries compartment
Fuses in the fuse box
OM0231
ELECTRICAL SYSTEM (Fuses)
OM1304
2 3 4 5 6 798 10
1
20
19
18
171615141312
11
OM1150
FUSES IN THE BOX
Fuse LABEL PROTECTED Rating
No. CIRCUIT (A)
1 SW. BACK UP Backup power 5
source
2 ENGINE C/U MC 10
(Power Source)
3 E.C. MOTOR EC 10
Motor
4 AUXILIARY Auxiliary 5
Power supply
5REAR CAB Rear cab light 10
LIGHT power supply
6 HAMMER Breaker 10
7ROTARY Bucket 10
BUCKET rotation
8 SOLENOID Solenoid valve 5
power supply
9 SW. BOX Switches 5
panel
10 HEATING Heating seat 10
SEAT
11 WIPER Windshield wiper 10
12 HEATER Heater 20
13 LIGHT Light 15
14 CAB LIGHT Cab light 15
15 RADIO Radio 5
16 LIGHTER Cigar light 15
17 HORN Horn 10
18 GLOW Glow relay 5
RELAY power supply
19 POWER ON Power supply on 5
20 AIR Air 10
CONDITION conditoner
FUSES IN THE BATTERIES COMPARTMENT
Main power
FUSE 1 BOX A supply with 40
key
Glow plug
FUSE 2 BOX A and fuel transfer 40
supply
Charge
FUSE 3 BOX B circuit 60
supply
BOX B ––

T1-2-8 EX355
COMPONENT LAYOUT
OTHER COMPONENTS
1 - Regulator (Pump 2)
2 - Pilot Pump
3 - Regulator (Pump 1)
4 - Pump 2
5 - Pump Delivery Pressure Sensor (Pump 2)
6 - Pump 1
SM6004
Pump device
Travel device Pilot filter
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