EXCAVATOR -

TECHNICAL MANUAL
OPERATIONAL PRINCIPLE

All information, illustrations and specifications in this manual are based on the latest product information avail-
able at the time of publication.
The right is reserved to make changes at any time without notice.

FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. - ENGINEERING -

FORM No. 604.13.191 - Edition - July 2002
COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.
Documentation Centre
Strada di Settimo, 323 - S. MAURO T.SE ( TO ) ITALY

Reproduction of text or illustrations,

in whole or in part, is strictly prohibited

Print No. 604.13.191 - VII - 2002

Printed by Satiz - Turin (Italy)

Coordinamento Editoriale Satiz - Torino
 EX255-EX285 Tier2

TECHNICAL MANUAL - OPERATIONAL PRINCIPLE

TECHNICAL MANUAL- TROUBLESHOOTING

WORKSHOP MANUAL EXCAVATOR

WORKSHOP MANUAL ENGINE

EX255-EX285 IN-1

INTRODUCTION

TO THE READER

• This manual is written for an experienced techni- - If you have any questions or comments, or if you
cian to provide technical information needed to found any errors regarding the contents of this
maintain and repair this machine. manual, please contact:

- Be sure to thoroughly read this manual for correct FIAT KOBELCO CONSTRUCTION
information concerning the service procedures. MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALY
PRODUCT SUPPORT
Fax. ++39 011 6877357

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition

to this service manual:

- Operation and Maintenance Instruction

Manual
- Parts Catalog

SERVICE MANUAL COMPOSITION

• The complete service manual consists of three
books:
- Technical Manual - Operational Principle
- Technical Manual - Troubleshooting
- Workshop Manual
- 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 Technical Manual-Operational Principle in- • The Service Manual for EX255 and EX285 Excava-
cludes the technical information concerning the tors consists of the following book/print numbers:
operation of main devices and systems.

- The Technical Manual -Troubleshooting includes

the technical information needed for operational
performance tests, and troubleshooting proce-
dures.

BOOK PRINT NUMBER

- Technical Manual - Operational Principle 604.13.191
- Technical Manual - Troubleshooting 604.13.196
- Workshop Manual 604.13.201
IN-2 EX255-EX285

INTRODUCTION

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.

To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW CV-PS 1.360
Volume L US qt 1.057 kW HP 1.341
m3 yd 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N.m kgf.m 0.10197 mL/rev Cc/rev 1.0
N.m lbf.ft 0.7375
TECHNICAL MANUAL EX255-EX285

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 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)
SECTION 1
GENERAL
CONTENTS
Group 1 - Specification
EX255 Excavator Dimensions ............. T1-1-1
EX285 Excavator Dimensions ............. T1-1-3
EX255 Excavator performance ............ T1-1-5
- Engine Data ....................................... T1-1-5
- Engine Accessory .............................. T1-1-6
- Hydraulic Devices .............................. T1-1-6
- Electrical Equipment .......................... T1-1-7
EX285 Excavator performance ............ T1-1-8
- Engine Data ....................................... T1-1-8
- Engine Accessory .............................. T1-1-9
- Hydraulic Devices .............................. T1-1-9
- Electrical Equipment .......................... T1-1-10
EX255-EX285
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
Pump and related parts ........................ T1-2-8
Other Components ............................... T1-2-9
EX255-EX285
EX255 T1-1-1

SPECIFICATIONS

EX255 EXCAVATOR DIMENSIONS

(Monoblock Version)
E
G D/D'

H F

I C
L
M A
N B

OM0253

VERSIONS A B C D D’ (*) E F G H I L
(**)
EX255 3 463 4 260 1 090 2 950 2 937 10 170 1) 3 206 2 815 2 940 960 460
(mm)
2) 3 237
EX255 EL (mm) 3 845 4 642 1 090 2 950 2 937 10 170 2 815 2 940 960 460
3) 2 991
EX255 LC 3 845 4 642 1 090 2 950 2 937 10 170 4) 3 204 2 815 2 940 960 460
(mm)
(*) Rear swing radius (**) Arm: 1) 2158 mm, 2) 2480 mm, 3) 2950 mm, 4) 3600 mm

EX255 EX255 EL EX255 LC

M-Track shoe width (mm)
600 700 800 900 600 700 800 900 600 700 800 900

N-Maximum width (mm) 2 990 3 090 3 190 3 290 2 990 3 090 3 190 3 290 3 190 3 290 3 390 3 490

Working weight (kg) 24 500 24 750 25 000 25 250 25 000 25 300 25 600 25 900 25 100 25 400 25 700 26 000

Spec. Ground Press. 0.54 0.47 0.41 0.36 0.51 0.44 0.39 0.35 0.51 0.44 0.39 0.35
(bar)

DIGGING DATA

6 000 mm Boom
Arm mm 2 158 2 480 2 950 3 600

A mm 9 650 9 865 10 277 10 903

A’ mm 9 462 9 681 10 100 10 737

B mm 6 172 6 485 6 948 7 597

B’ mm 5 940 6 253 6 737 7 429

C mm 9 551 9 460 9 635 9 988

D mm 6 770 6 759 6 946 7 279

E mm 3 789 3 952 3 865 3 892

OM0254
T1-1-2 EX255-EX285
EX255

SPECIFICATIONS

EX255 EXCAVATOR DIMENSIONS

(Triple Articulation Version)

E G

D/D'

F H

C I
L

A M

B N

OM0255

VERSIONS A B C D D’ (*) E F G H I L
(**)
EX255 3 463 4 260 1 090 2 950 2 937 10 145 1) 3 083 2 815 2 940 960 460
(mm)
2) 3 137
EX255 EL (mm) 3 845 4 642 1 090 2 950 2 937 10 145 2 815 2 940 960 460
3) 3 019
EX255 LC 3 845 4 642 1 090 2 950 2 937 10 145 4) 3 290 2 815 2 940 960 460
(mm)
(*) Rear swing radius (**) Arm: 1) 2 158 mm, 2) 2 480 mm, 3) 2 950 mm, 4) 3 600 mm

EX255 EX255 EL EX255 LC

M-Track shoe width (mm)
600 700 800 900 600 700 800 900 600 700 800 900

N-Maximum width (mm) 2 990 3 090 3 190 3 290 2 990 3 090 3 190 3 290 3 190 3 290 3 390 3 490

Working weight (kg) 25 100 25 350 25 600 25 850 25 600 25 900 26 200 26 500 25 700 26 000 26 300 26 600

Spec. Ground Press. 0.56 0.48 0.43 0.38 0.52 0.45 0.40 0.34 0.52 0.45 0.40 0.34
(bar)

DIGGING DATA

3 100 mm Boom
Arm mm 2 158 2 480 2 950 3 600

A mm 9 756 9 993 10 420 11 058

A’ mm 9 570 9 812 10 246 10 895

B mm 5 791 6 067 6 517 7 170

B’ mm 5 678 5 958 6 414 7 077

C mm 11 099 11 237 11 379 12 128

D mm 6 306 8 146 5 840 5 248

E mm 2 868 2 896 2 568 2 808

OM0256
EX255-EX285
EX285 T1-1-3

SPECIFICATIONS

EX285 EXCAVATOR DIMENSIONS

(Monoblock Version)
E / E'
G D / D'

H F

I C
L
M A
N B OM0540

VERSIONS A B C D D’ (*) E E’ (***) F (**) G H I L

1) 3 531
EX285 (mm) 3 706 4 574 1 208 2 937 2 950 10 293 10 282 2) 3 350 2 815 3 028 1 012 525.5
3) 3 166
EX285 LC (mm) 4 011 4 879 1 210 2 937 2 950 10 293 10 282 4) 3 295 2 815 3 028 1 012 525.5

(*) Rear swing radius (**) Arm: 1) 2 120 mm, 2) 2 400 mm, 3) 3 100 mm, 4) 3 750 mm (***) Arm: 2 120 mm

EX285 EX285 LC
M-Track shoe width (mm) 600 700 800 900 600 700 800 900
N-Maximum width (mm) 3 000 3 100 3 200 3 300 3 190 3 290 3 390 3 490
Working weight (kg) 26 700 27 066 27 432 27 800 27 442 27 830 28 220 28 608
Spec. Ground Press.
(bar) 0.65 0.57 0.50 0.45 0.62 0.54 0.48 0.43

DIGGING DATA

6 200 mm Boom
Arm mm 2 120 2 400 3100 3750

A mm 9 834 10 062 10 705 11 299

A’ mm 9 620 9 864 10 519 11 124

B mm 6 120 6 538 7 230 7 878

B’ mm 5 998 6 319 7 052 7 725

C mm 9 802 9 638 9 978 10 242

D mm 6 857 6 906 7 215 7 472

E mm 4 269 4 307 4 146 4 124

OM0254
T1-1-4 EX255-EX285
EX285

SPECIFICATIONS

EX285 EXCAVATOR DIMENSIONS

(Triple Articulation Version)

G
E / E'
D / D'

H F

I C
L
M A

N B OM0255

VERSIONS A B C D D’ (*) E E’ (***) F (**) G H I L

1) 3 139
EX285 (mm) 3 706 4 574 1 208 2 937 2 950 10 081 10 199 2) 3 166 2 815 3 028 1 012 525.5
3) 3 094
EX285 LC (mm) 4 011 4 879 1 210 2 937 2 950 10 081 10 199 4) 3 376 2 815 3 028 1 012 525.5

(*) Rear swing radius (**) Arm: 1) 2100 mm, 2) 2400 mm, 3) 3100 mm, 4) 3750 mm (***) Arm: 2 120 mm

EX285 EX285 LC
M-Track shoe width (mm) 600 700 800 900 600 700 800 900
N-Maximum width (mm) 3 000 3 100 3 200 3 300 3 190 3 290 3 390 3 490
Working weight (kg) 27 400 27 766 28 132 28 498 28 140 28 506 28 872 29 238
Spec. Ground Press.
(bar) 0.67 0.58 0.52 0.46 0.69 0.60 0.53 0.48

DIGGING DATA

3 200 mm Boom
Arm mm 2 120 2 400 3 100 3 750

A mm 9 882 10 072 10 733 11 345

A’ mm 9 680 9 875 10 548 11 170

B mm 5 784 6 014 6 699 7 335

B’ mm 5 671 5 905 6 600 7 244

C mm 11 285 11 370 11 924 12 413

D mm 8 175 8 264 8 813 9 302

E mm 3 038 3 009 2 726 2 867

OM0256
EX255-EX285
EX255 T1-1-5

SPECIFICATIONS

EX255 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)

EX255 ENGINE DATA

MAIN SPECIFICATIONS
- Manufacturer ........................................................................................................................................ ISUZU
- Model ................................................................................................................................. CC-6BG1 TRA-05
- Type .......................................................................... Diesel, 4 cycle, vertical, 6-cylinder inline, water-cooled,
direct injection type turbocharged, with intercooler
- Cyl. No.-bore x stroke .......................................................................... 6-105 mm x 125 mm (4.13 in x 4.92 in)
- Piston displacement ............................................................................................................ 6494 cm3 (475 in3)
- Rated output ........................................................................................ 118 kW/2000 min-1 (158 HP/2000 rpm)
HP Mode: 125 kW/2100 min-1 (168 HP/2100 rpm)
- Compression ratio .........................................................................................................................................18
- Dry weight ............................................................................................................................... 490 kg (1080 lb)
- Firing order ....................................................................................................................................... 1-5-3-6-2-4
- Rotation direction .............................................................................................. Clockwise (view from fan side)

COOLING SYSTEM
- Cooling fan ............................................................................................. Dia. 670 mm, 6 blades, draw-in type
- Fan pulley ratio .................................................................................................................... Engine rpm x 0.95
- 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 - 4.5 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
T1-1-6 EX255-EX285
EX255

SPECIFICATIONS

EX255 ENGINE ACCESSORY

RADIATOR ASSEMBLY
- Type ...................................................................... Radiator/Oil Cooler tandem type and intercooler assembly
- Mass .......................................................................................................................................... 85 kg (187 lb)
- Radiator Capacity ....................................................................................................................................... 8 L
- Oil Cooler Capacity ................................................................................................................................. 6.3 L

BATTERY
- Capacity ........................................................................................................................................ 160 Ah x 2
- Voltage ............................................................................................................................................... 12V x 2

HYDRAULIC DEVICES EX255

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/cm2) @ 140 L/min
Power Boost: 36.3 MPa (370 kgf/cm2) @ 140 L/min
- Overload relief pressure ........................................................................ 37.3 MPa (380 kgf/cm2) @ 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/cm2)

TRAVEL DEVICE
- Type ..................................................................................................... Three-stage planetary reduction gear

TRAVEL MOTOR
- Model ............................................................................................................................................... HMV116
- Type ............................................................................. Bent-axis type, variable displacement plunger motor
EX255-EX285
EX255 T1-1-7

SPECIFICATIONS

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)

CYLINDERS

Boom Arm Bucket Positioning (*)

Rod diameter 90 mm 100 mm 85 mm 90 mm
Cylinder inner diameter 125 mm 135 mm 125 mm 145 mm
Stroke 1350 mm 1610 mm 1075 mm 1205 mm
Fully retracted
length 1950 mm 2235 mm 1665 mm 1799 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

EX255 ELECTRICAL EQUIPMENT

BATTERY RELAY
- Voltage - Current ........................................................................................................................ 24 V - 100 A

GLOW RELAY
- Voltage - Current .......................................................................................................................... 24 V - 30 A

HORN
- Specifications ........................................................................................................... 24 V - 1.5 A, 113 dB (A)

LIGHT
- Specifications ............................................................................................ Work lights: Halogen 24 V - 70 W
Dome light: 24 V - 10 W
AIR CONDITIONER
- Refrigerant .............................................................................................................................................. 134 a
- Temperature control .............................................................................................................. electronic control
T1-1-8 EX285
EX255-EX285

SPECIFICATIONS

EX285 EXCAVATOR PERFORMANCE

GRADEABILITY .......................................................................................................... 35° (70%) in continuous

TRAVEL SPEED ................................................................................................... 1.9 / 3.2 mph (3.0/5.1 km/h)

- Slow ................................................................................................................... 0 to 1.9 mph (0 to 3.0 km/h)
- Fast .................................................................................................................... 0 to 3.2 mph (0 to 5.1 km/h)

EX285 ENGINE DATA

MAIN SPECIFICATIONS
- Manufacturer ........................................................................................................................................ ISUZU
- Model ................................................................................................................................. CC-6BG1 TRA-06
- Type .......................................................................... Diesel, 4 cycle, vertical, 6-cylinder inline, water-cooled,
direct injection type turbocharged, with intercooler
- Cyl. No.-bore x stroke .......................................................................... 6-105 mm x 125 mm (4.13 in x 4.92 in)
- Piston displacement ............................................................................................................ 6494 cm3 (475 in3)
- Rated output ........................................................................................ 125 kW/2050 min-1 (168 HP/2050 rpm)
HP Mode: 132 kW/2150 min-1 (177 HP/2150 rpm)
- Compression ratio .........................................................................................................................................18
- Dry weight ............................................................................................................................... 490 kg (1080 lb)
- Firing order ....................................................................................................................................... 1-5-3-6-2-4
- Rotation direction .............................................................................................. Clockwise (view from fan side)

COOLING SYSTEM
- Cooling fan ............................................................................................. Dia. 670 mm, 6 blades, draw-in type
- Fan pulley ratio ................................................................................................................... Engine rpm x 0.95
- 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 - 4.5 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
EX285
EX255-EX285 T1-1-9

SPECIFICATIONS

EX285 ENGINE ACCESSORY

RADIATOR ASSEMBLY
- Type ...................................................................... Radiator/Oil Cooler tandem type and intercooler assembly
- Weight ....................................................................................................................................... 85 kg (187 lb)
- Radiator Capacity ....................................................................................................................................... 8 L
- Oil Cooler Capacity ................................................................................................................................. 6.3 L

BATTERY
- Capacity ........................................................................................................................................ 160 Ah x 2
- Voltage .............................................................................................................................................. 12 V x 2

EX285 HYDRAULIC DEVICES

MAIN PUMP
- Model .......................................................................................................................................... HPV102FW
- Type ............................................................... Variable displacement plunger pump: regulator attached type
- Max. flow (Theoretical value) .................................................................................................... 209 L/min x 2

PILOT PUMP
- Model ................................................................................................................................... HY/ZFS 11/16.8
- Type ....................................................................................................... Fixed displacement type gear pump
- Max. flow (Theoretical value) ..................................................................... 34.4 L/min; HP Mode: 36.1 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/cm2) @ 140 L/min
Power Boost: 36.3 MPa (370 kgf/cm2) @ 140 L/min
- Overload relief pressure ........................................................................ 37.3 MPa (380 kgf/cm2) @ 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 ........................................................................................................................................ M2X210CHB
- Type ............................................................................. Swash-plate type, fixed-displacement plunger motor

SWING BRAKE VALVE

- Type ............................................................................................................. Non counter balance valve type
- Relief pressure ......................................................................... 27.7±0.3 MPa (282±3 kgf/cm2) @ 140 L/min

SWING PARKING BRAKE

- Type ............................................................................................................. Multiple-wet-plate negative type
- Cracking pressure for release ................................................................ 2.25 to 2.84 MPa (23 to 29 kgf/cm2)

TRAVEL DEVICE
- Type ..................................................................................................... Three-stage planetary reduction gear

TRAVEL MOTOR
- Model ............................................................................................................................................... HMV145
- Type ............................................................................. Bent-axis type, variable displacement plunger motor
T1-1-10 EX255-EX285
EX285

SPECIFICATIONS

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)

CYLINDERS

Boom Arm Bucket Positioning (*)

Rod diameter 90 mm 100 mm 90 mm 90 mm
Cylinder inner diameter 135 mm 145 mm 135 mm 145 mm
Stroke 1340 mm 1555 mm 1070 mm 1205 mm
Fully retracted
length 1920 mm 2155 mm 1660 mm 1799 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

EX285 ELECTRICAL EQUIPMENT

BATTERY RELAY
- Voltage - Current ........................................................................................................................ 24 V - 100 A

GLOW RELAY
- Voltage - Current .......................................................................................................................... 24 V - 30 A

HORN
- Specifications ................................................................................................................. 24 V - 1.5 A, 113 dB

LIGHT
- Specifications ............................................................................................ Work lights: Halogen 24 V - 70 W
Dome light: 24 V - 10 W

AIR CONDITIONER
- Refrigerant .............................................................................................................................................. 134 a
- Temperature control ............................................................................................................. Electronic control
EX255-EX285 T1-2-1

COMPONENT LAYOUT

MAIN COMPONENTS

SM5601

1 - Bucket Cylinder 12 - Engine

2 - Arm Cylinder 13 - Radiator
3 - Boom Cylinder 14 - Oil Cooler
4 - Center Joint 15 - Intercooler
5 - Swing Bearing 16 - Battery
6 - Swing Device 17 - Travel Device
7 - Fuel Tank 18 - Shockless Valve
8 - Hydraulic Oil Tank 19 - Pilot Shut-Off Valve
9 - Control Valve 20 - Travel Pilot Valve
10 - Pilot Filter, Pilot Relief Valve 21 - Front/Swing Pilot Valve
11 - Pump Device
T1-2-2 EX255-EX285

COMPONENT LAYOUT

ELECTRICAL SYSTEM (overall system)

SM5402

1 - Wiper Motor 19 - Engine Oil Pressure Switch

2 - Monitor Panel 20 - Coolant Temperature Switch (Engine Preheat Circuit)
3 - Relays, Relays box 21 - Engine Oil Level Switch (on oil pan)
4 - Windshield 22 - Overheat Switch
5 - Horn 23 - Coolant Temperature Sensor
6 - Work Light 24 - Battery Relay
7,8 - Fuel Sensor with Low Fuel Level Switch 25 - Coolant Level Switch
9 - Solenoid Valve Unit 26 - Battery
10 - Pressure Switch (Travel) 27 - Starter Relay
11 - Hydraulic Oil Level Switch 28 - Air Cleaner Restriction Switch
12 - PC Pressure Sensor (Upper: 4-Spool Side) 29 - Pressure Switch (Boom Raise), Pressure Sensor (Arm
13 - PC Pressure Sensor(Lower: 5-Spool Side) Roll-In)
14 - EC Motor 30 - Pressure Switch (Front)
15 - EC Sensor 31 - Fuse Box
16 - Pump Delivery Pressure Sensor 1 32 - MC (Main Controller)
17 - Pump Delivery Pressure Sensor 2 33 - QOS Controller
18 - N (Engine Speed) Sensor
EX255-EX285 T1-2-3

COMPONENT LAYOUT

ELECTRICAL SYSTEM (cab)

SM5603

1 - Relay box 13 - Breaker relay (R2) variant provision

2 - Air conditioner relays (if installed) 14 - R.H. Rotation bucket relay (R3) variant provision
3 - Connection for cab light (ceiling) 15 - L.H. Rotation bucket relay (R4) variant provision
4 - WWES connection for wiper cut-off microswitch 16 - Cab light relay (R5)
5 - Heater connection 17 - Rear cab light relay (R6)
6 - Air conditoner connection 18 - A, B, K junction connector
7 - Loudspeakers connection 19 - C, D juncton connector
8 - Cab ground 20 - E, F junction connector
9 - Main controller (MC) 21 - G, H junction connector
10 - Q.O.S. controller 22 - Dr. EX. connector
11 - Load momentum alarm buzzer provision 23 - Engine learning switch
12 - Load momentum alarm relay provision (R1) 24 - Fuse box
T1-2-4 EX255-EX285

COMPONENT LAYOUT

ELECTRICAL SYSTEM (cab)

1 2

8 7 5

SM5604

1 - Connectors for monitor and switch panels 7 - Connector not used

2 - Cigarette lighter 8 - Connector
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
EX255-EX285 T1-2-5

COMPONENT LAYOUT

ELECTRICAL SYSTEM (monitor and switch panels)

10

24
11
1 12
23 13
22 14

21 15
16
2 20
17
19
3
18
T157-07-02-001
SM0610

5
25
6
32
4
7

8 26
31

9 27

28
30

T157-01-01-009
29 T157-01-01-018
SM0611 SM0612

1 - Monitor Panel 17 - Fuel Level Indicator

2 - Switch Panel 18 - Overheat Indicator
3 - Power Boost Switch 19 - Alternator Indicator
4 - Key Switch 20 - Engine Oil Pressure Indicator
5 - Cigar Lighter 21 - Engine Oil Level Indicator
6 - HP Mode Switch 22 - Coolant Level Indicator
7 - E Mode Switch 23 - HP Mode Indicator
8 - Engine Control Dial 24 - Coolant Temperature Gauge
9 - Air Conditioner Panel 25 - Work Light Switch
10 - Warm Up Complete Indicator 26 - Wiper Switch
11 - Fuel Gauge 27 - Travel Mode Switch
12 - E Mode Indicator 28 - Work Mode Switch
13 - Auto-Idle Indicator 29 - Buzzer Stop Switch
14 - Hydraulic Oil Level Indicator 30 - Auto-Idle Switch
15 - Preheat Indicator 31 - Washer Switch
16 - Air Filter Restriction Indicator 32 - Level Check Switch
T1-2-6 EX255-EX285

COMPONENT LAYOUT

ELECTRICAL SYSTEM (batteries compartment)

1
8

6
4

5 SM5605

1 - Battery relay 5 - Safety relay

2 - Fuse link (Box B - Fuse 3-60A) 6 - Engine coolant level switch
3 - Fuse link (Box A - Fuse 1-40A, Fuse 2-40A) 7 - Ground joint connector
4 - Connection box 8 - Glow relay
EX255-EX285 T1-2-7

COMPONENT LAYOUT

ELECTRICAL SYSTEM (fuses)

FUSES IN THE BOX

Fuse PROTECTED Rating
No. LABEL CIRCUIT (A)
Backup power
1 SW. BACK UP source 5

MC
2 ENGINE C/U (Power Source) 10

EC
3 E.C. MOTOR Motor 10

Auxiliary
4 AUXILIARY Power supply 5

REAR CAB Rear cab light

5 LIGHT power supply 10 OM0231

6 HAMMER Breaker 10

ROTARY Bucket 1 2 3 4 5 6 7 8 9 10
7 BUCKET rotation 10

Solenoid valve
8 SOLENOID power supply 5
11 12 13 14 15 16 17 18 19 20
Switches
9 SW. BOX panel 5

HEATING
10 SEAT Heating seat 10
OM1150
11 WIPER Windshield wiper 10
12 HEATER Heater 20 Fuses in the fuse box

13 LIGHT Light 15
14 CAB LIGHT Cab light 15
15 RADIO Radio 5
16 LIGHTER Cigar light 15

17 HORN Horn 10

GLOW Glow relay

18 RELAY power supply 5

19 POWER ON Power supply on 5

AIR Air
20 CONDITION conditoner 10

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
OM1304
supply
Charge Fuses in the batteries compartment
FUSE 3 BOX B circuit 60
supply
BOX B – –
T1-2-8 EX255-EX285

COMPONENT LAYOUT

PUMP AND RELATED PARTS

5 6 7

3-4
8

1 12 11 10 9
SM3004

1 - Pilot Filter 7 - N Sensor

2 - Pilot Relief Valve 8 - Regulator (Pump 1)
3 - EC Motor 9 - Pump Delivery Pressure Sensor (Pump 1)
4 - EC Sensor 10 - Pump 1
5 - Pilot Pump 11 - Pump Delivery Pressure Sensor (Pump 2)
6 - Regulator (Pump 2) 12 - Pump 2
EX255-EX285 T1-2-9

COMPONENT LAYOUT

OTHER COMPONENTS

Swing Device Shockless Valve

4
1
5

8
6

SM0626
T157-01-01-011 SM0627
T157-07-03-018

Travel Device Solenoid Valve Unit

FRONT

10

11
12
2
13
3

SM0628
T157-01-01-012 SM0629
W157-02-11-020

1 - Swing Relief Valve 8 - Check Valve

2 - Counterbalance Valve 9 - Pilot Pressure Sensor (Arm Roll-In)
3 - Travel Relief Valve 10 - Solenoid Valve Unit (SC)
4 - Shockless Valve 11 - Solenoid Valve Unit (SD)
5 - Pilot Pressure Switch (Boom Raise) 12 - Solenoid Valve Unit (SI)
6 - Check Valve 13 - Solenoid Valve Unit (SG)
7 - Shockless Valve
T1-2-10 EX255-EX285

COMPONENT LAYOUT

NOTES
SECTION 2
SYSTEM
CONTENTS
Group 1 - Control system
Outline .................................................... T2-1-1
Engine control ........................................ T2-1-2
Pump control .......................................... T2-1-8
Valve control ..........................................T2-1-10
Other control functions ......................... T2-1-14
Group 2 - Hydraulic system
Main circuit .......................................... T2-2-1
Pilot circuit ........................................... T2-2-2
Neutral circuit ...................................... T2-2-3
Single actuator operation .................... T2-2-3
Combined operation ............................ T2-2-4
EX255-EX285
Group 3 - Electrical system
Outline ................................................... T2-3-1
Electric power circuit
(Key Switch: OFF) ................................. T2-3-2
Bulb Check Circuit (Key Switch: ON) ..... T2-3-4
Accessory Circuit (Key Switch: ACC) .... T2-3-6
Preheat Circuit
(Key Switch: ON or START) .................. T2-3-8
Starting Circuit
(Key Switch: START) ........................... T2-3-10
Charging Circuit
(Key Switch: ON) ................................. T2-3-12
Surge Voltage Prevention Circuit ......... T2-3-16
Engine Stop Circuit
(Key Switch: OFF) ............................... T2-3-18
Engine and pump control circuit .......... T2-3-20
Monitor circuit ...................................... T2-3-24
EX255-EX285 T2-1-1

CONTROL SYSTEM

OUTLINE

Microcomputer built-in main controller (MC) is pro- After processing the sensing signals in the logic
vided to control machine operation. Electronic sens- circuits, the MC sends out the control signals to the
ing signals from the engine control dial, various EC motor and solenoid valve unit to control the
sensors and switches are sent to the MC. engine, pump, and valve operations.

Sensing signals (Input signals) Control signals (Output signals)

Engine control
• EC sensor →
• Engine control dial →
• Normal control
• HP mode control
• Pump control pressure sensor → → EC motor: • E mode control
• Pump delivery pressure sensor → • Auto-Idle control
• N sensor →
• Engine learning control
• Pressure switches
• (Travel - Front - Boom raise) → Pump control
• Pilot pressure sensor → Solenoid valve (SD): • Speed sensing control
• (Arm roll-in) → MC
• Auto-idle switch →
• Learning switch →
Valve control
• Power boost switch →
• Power Boost control
• HP mode switch → → Solenoid valve (SC, SG, SI): • Arm regenerative control
• E mode switch → • Travel motor swash
angle control
• Travel mode switch →
• Work mode switch →
• Key switch → Work Mode Control
→ EC Motor • General Purpose Mode
→ Solenoid Valve Unit • Grading Mode
(SC, SG) • Precision Mode
• Attachment Mode
T2-1-2 EX255-EX285

CONTROL SYSTEM

ENGINE CONTROL

The engine control system has the following control

functions:

• Normal control
• HP mode control
• E mode control
• Auto-Idle control
• Engine learning control.

Layout of engine control system

Pilot pressure sensor

(Arm Roll-in)

Pressure
Pressure switch (Travel) switch
(Front)
Learning switch

P/V
Key switch

Engine control dial EC sensor

ENGINE
M
Auto-Idle switch MC
A/I EC motor
HP mode switch
H/P
E mode switch
E

Pump delivery pressure sensor

(Pump 1, 2)

SM0101
EX255-EX285 T2-1-3

CONTROL SYSTEM

Normal Control

Purpose: To control engine speed in response to the

operation angle of the engine control dial on the NOTE - Normally, the governor lever does not come
switch panel. into contact with the full side stopper even if the
engine control dial is turned to the full speed position.
Operation: In response to the operation angle of the (Refer to HP Mode Control).
engine control dial, the MC drives the EC motor,
causing the governor lever to move to control engine
speed.

The EC sensor feedbacks the position of the EC

motor to the MC.
This confirms that the EC motor moves according to
commands from the MC.

P/V

Engine control dial

EC sensor

ENGINE
M Stop Full

MC
A/I Governor lever
EC motor

H/P

SM0102
T2-1-4 EX255-EX285

CONTROL SYSTEM

HP Mode Control

Purpose: To instantaneously increase the engine

speed only when a little more hydraulic power is
required for arm roll-in operation. For example, to Engine speed
increase the arm roll-in power while conducting a HP mode operation line
deep ditching work.
100 min-1 (rpm)
Operation: Only when the following conditions are
satisfied, the MC drives the EC motor to operate the
engine faster than normal operation.
1800 min-1 (rpm)
• Engine Control Dial Setting: 1600 min-1 or faster
• HP Mode Switch: ON 1600 min-1 (rpm)
• Operation: Arm Roll-In
• Average Delivery Pressures of Pump 1 and 2:
Higher Range

Slow Idle Fast Idle (Max. Speed)

NOTE - The engine governor stopper position is
adjusted in accordance with the HP mode operation. Slow Idle Fast Idle
Therefore, the governor lever does not come into (Max. Speed)
contact with the stopper in the Normal Control mode.
SM0103

Pilot pressure sensor

(Arm Roll-in)

P/V

Engine control dial

ENGINE
M Min. Max.

MC
A/I Governor lever
EC motor
HP mode switch
H/P

E Pump delivery pressure sensor

SM0104
EX255-EX285 T2-1-5

CONTROL SYSTEM

E Mode Control
Engine speed
Purpose: To decrease the engine speed at a fixed
rate.
When the E mode switch
Operation: When the E mode switch is ON, the MC is not depressed
instructs the EC motor to run the engine in the speed
range slower than normal operation in proportion to
the engine control dial set angle.

When the E mode

switch is depressed
Slow Idle Fast Idle (Max. Speed)
Slow Idle Fast Idle
(Max. Speed)

SM0105

P/V

Engine control dial

ENGINE
M

MC
A/I EC motor Governor lever

H/P
E mode switch
E

SM0106
T2-1-6 EX255-EX285

CONTROL SYSTEM

Auto-Idle Control

Purpose: To slow the engine speed when all control
levers are in neutral to reduce fuel consumption and
noise.
Operation: When the auto-idle switch is ON and all
control levers are kept in neutral (the pressure
switches for travel and front operations are off) for
more than four seconds, the MC instructs the EC
motor to reduce the engine speed to the auto-idle
speed.

Pressure switch (Travel) Pressure switch

(Front)

P/V

Engine control dial

ENGINE
M
Auto-Idle switch MC
A/I EC motor Governor lever

H/P

SM0107
EX255-EX285 T2-1-7

CONTROL SYSTEM

Engine Learning Control

Purpose: To check the governor lever stopper posi-

tions to run the engine at full-speed or to stop as
engine control standard data.

Operation: When the learning switch in the rear

console is turned to the engine learning side, the EC
motor is driven by the signal from the MC. Then, the
EC motor moves the governor lever to the Idle,
FULL, and STOP positions in that order.
Thereby, the EC sensor checks the stopper positions Rear Console
for the FULL and STOP operation. The signals
corresponding to each stopper position are sent to
the MC from the EC sensor, and the MC stores the Fuse Box
data.

Learning Switch
Engine Learning
IMPORTANT - Be sure to operate the engine learn-
ing control system after replacing the engine, engine
control cable, EC motor, or MC. The procedure is
listed in the Technical Manual "Troubleshooting" on
page T5-4-60. Neutral (OFF)

SM0108
NOTE - The replacement of batteries does not re-
quire operation of the engine learning control system.

Learning switch

P/
Key switch V

EC Sensor

ENGINE
M Stop Full

MC
A/I EC Motor
Governor Lever

H/P

SM0109
T2-1-8 EX255-EX285

CONTROL SYSTEM

PUMP CONTROL

The pump operation is regulated by the speed sens- The pump control valve is provided in the control
ing system and the pump control valve. valve. (Refer to the Control Valve Group in the
The speed sensing system works via the MC. COMPONENT OPERATION Section).
EX255-EX285
CONTROL SYSTEM
Speed Sensing Control
Purpose: To control the pump drive torque in re-
sponse to the variation of loads to the engine or the
output of the hydraulic pumps to utilize the engine
output more efficiently.
Operation: The target engine speed is selected by
setting the engine speed with the engine control dial.
The MC receives signals for the target engine speed,
and actual engine running speed from the N sensor.
After processing these input data, the MC sends out
the control signals to the solenoid valve unit (SD).
Engine control dial
Solenoid Valve
unit
S D
MC
T2-1-9
According to the control signals from the MC, the
solenoid valve unit (SD) supplies pilot oil pressure to
the pump regulators to control the pump flow rate.
When poor quality fuel is used or if the machine is
operated at high altitudes, the engine output torque
may decrease, causing the engine to run slower than
the target speed. As the MC in the speed sensing
control system instructs the solenoid valve unit (SD)
to reduce the pump flow rate, the pump drive torque
is reduced. Thereby, engine speed reduction or
engine stall is avoided.
N sensor
ENGINE
REG REG
SM0110
T2-1-10 EX255-EX285

CONTROL SYSTEM

VALVE CONTROL

The valve control consists of the power boost control,

arm regenerative control, and travel motor swash
angle control.

Pump control pressure sensor

(5-Spool Side)
Pilot pressure sensor (Arm Roll-In)
Pressure switch (Boom Raise)

Travel motor swash angle

selector valve

Power Boost switch Pressure switch

Travel motor (Front)

Pressure switch
Travel mode switch (Travel)

Relief valve

P/V

Arm cylinder

MC

To MC
S G

Pump delivery
pressure sensor

Solenoid SI S C
valve unit

Arm regenerative
valve

Swing motor REG REG

From pump control Pump control pressure

pressure sensor sensor (4- Spool Side)
(4-Spool Side)

SM0111
EX255-EX285 T2-1-11

CONTROL SYSTEM

Power Boost Control

Purpose: To increase hydraulic power by temporar- ON, the MC magnetizes solenoid valve unit (SG) for
ily increasing the main relief pressure. 8 seconds. When magnetized, solenoid valve unit
(SG) supplies pilot oil pressure to the relief valve to
Operation: When the power boost switch is turned increase the relief set pressure.

Relief Valve

Power Boost switch

MC

Solenoid
Valve Unit

SM0112
T2-1-12 EX255-EX285

CONTROL SYSTEM

Arm Regenerative Control

Purpose: To increase arm roll-in speed and prevent
the arm roll-in hesitation.
Operation: When the signals to the MC from the
pump delivery pressure sensor (pump 2), pilot pres-
sure sensor (arm roll-in), and pressure switch (boom
raise) fall into the following conditions, the MC mag-
netizes the solenoid valve unit (SC). Then, the sole-
noid valve (SC) starts to deliver the pilot pressure to
actuate the arm regenerative valve, closing the return
circuit to the hydraulic oil tank from the arm cylinder
rod side.
Thereby, the return oil from the arm cylinder rod side
is combined with the pump delivery oil and supplied
to the arm cylinder bottom side, increasing the arm
roll-in speed and preventing arm roll-in hesitation.
Operation Conditions:
- Pump Delivery Pressure Sensor (Pump 2): Deliv-
ery pressure from pump 2 is low (requiring less arm
operating force).
- Pilot Pressure Sensor (Arm Roll-In): Output is large
(operating the arm control lever with a great
stroke).
- Pressure Switch (Boom Raise): ON

Pilot pressure sensor (Arm Roll-In)

Pressure Switch (Boom Raise)

Bucket
Arm cylinder

MC

Arm 1
Bucket
cylinder

Pump delivery
Solenoid pressure sensor (Pump 2)
valve unit
Arm regenerative
valve

SM0113
EX255-EX285 T2-1-13

CONTROL SYSTEM

Travel Motor Swash Angle Control

Purpose: To change fast/slow travel speed. Operation Conditions:

Operation: When the travel mode switch is in
position, the travel motor swash angle is held at a
large angle, causing the machine to travel at a slow
speed.
When the travel mode switch is in position and the
signals to the MC from the pressure switch (travel),
pump delivery pressure sensors (pump 1 and 2) fall
into the following conditions, the MC magnetizes
solenoid valve (SI), allowing pilot oil pressure to
change the travel motor swash angle control valve
port. Thereby, the travel motor swash angle is re-
duced to cause the machine to travel at a fast speed.
- Pressure Switch (Travel): ON
- Pressure Switch (Front): OFF
- Pump Delivery Pressure Sensors (Pump 1 and 2):
Pump delivery pressure is low.
- Pump Displacement Target Angle (controlled by
the MC according to signals from sensors and
switches): Large
NOTE - Even if the track is revolved with the track
raised, one side pump displacement target angle
remains small so that the travel motor speed does not
increase.
The pump displacement target angle is different from
the travel motor displacement target angle.

Travel motor swash angle

Pump control Pressure Sensor control valve
(5-Spool Side) Travel motor
Pressure switch (Front):
OFF signal
Pressure switch (Travel):
ON signal
Left side travel

Travel mode Right side

switch travel

MC

To MC

Pump control
Pump delivery Pressure Sensor
Pressure Sensors (4-Spool side)
Solenoid (Pump 1 and 2)
valve unit

Front pump control

Pressure Sensor
(4-Spool side)

SM0114
T2-1-14 EX255-EX285

CONTROL SYSTEM

OTHER CONTROL FUNCTION

Work Mode Control

The work mode includes the four modes of GEN- of the full speed to be set when the engine control dial
ERAL PURPOSE, GRADING, PRECISION, and is placed in the full position.
ATTACHMENT, which can be selected by the work The main relief pressure is increased in boom raise
mode switch. operation. (Refer to T2-1-11)

GENERAL PURPOSE MODE NOTE - Operating speed is reduced but operating

Normal control is applied. force is unchanged.

GRADING MODE ATTACHMENT MODE

To decrease the arm leveling speed, the arm regen-
erative control is deactivated.
(Refer to T2-1-12)
PRECISION MODE
In all work modes, engine speed is reduced to 70 %
Only when the attachment option kit is installed, this
function works. In proportion to the auxiliary pilot
valve lever stroke, the engine speed is controlled by
the MC so as to meet the installed attachment
operation. The engine speed setting for the attach-
ment mode is made by the Dr.EX.
EX255-EX285 T2-2-1

HYDRAULIC SYSTEM

MAIN CIRCUIT

The main pumps (pump 1 and pump 2) draw hydrau-
lic oil from the hydraulic oil tank. Pump 1 delivers oil
to the 4-spool control valve while pump 2 delivers oil
to the 5-spool control valve.
Pressure oil from the main pumps are routed to the
motors and cylinders in response to respective con-
trol valve spool shifts.
Return oil from the motors and cylinders flows back
to the hydraulic oil tank via the control valves and the
oil cooler. When oil temperature is low (viscosity is
high), return oil flowing through the oil cooler will be
hampered because of the increased flow resistance
in the oil cooler. If that happens, the bypass check
valve opens, allowing the return oil to directly flow
back to the hydraulic oil tank.

Boom Cylinder
Arm cylinder

Positioning cylinder (*)

Bucket cylinder

Center joint

Swing motor
Travel (R)
Travel (L) Bucket

Boom 1
Aux.
Hydraulic oil tank

Boom 2 Full-flow filter

Arm 1
Suction filter

Bypass check valve

Swing

Arm 2

Pump 1
Engine
Pump 2

Oil cooler

Pressure oil

Return oil

(*) Triple articulation

Center joint version

Left travel motor Right travel motor

SM3005
T2-2-2 EX255-EX285

HYDRAULIC SYSTEM

PILOT CIRCUIT

Pressure oil from the pilot pump acts as working control circuit, and in the swing parking brake release
pressure in pilot operating circuit, in the pump/valve line.

Posit. Left pilot Travel pilot Right pilot

pilot valve valve valve valve

(*)
Pilot operating circuit

Pilot shut-off Manifold for shockless valves, pressure Hydraulic oil

valve sensor, and for pressure switch tank

Swing parking brake

Swing motor release Suction filter

Solenoid valve unit

Main pump
SG Pump / Valve regulator
control circuit
SI 2
Control valve
SD
1

SC

Pilot pump

Relief valve Pilot filter

Travel motor Travel motor

(*) Triple articulation version

SM3006
EX255-EX285 T2-2-3

HYDRAULIC SYSTEM

NEUTRAL CIRCUIT SINGLE ACTUATOR OPERATION

When the control levers are in neutral, pressure oil
from the main pumps returns to the hydraulic oil tank
via the control valves. (Refer to the Control Valve
Group in the COMPONENT OPERATION Section).
Pressure oil from pump 1 flows to the spools (Travel
(R), Bucket, Boom 1, and Arm 2) in the 4-spool side
section in the control valve. Pressure oil from pump
2 flows to the spools (Swing, Arm 1, Boom 2 , Aux.,
and Travel (L)) in the 5-spool side section in the
control valve.
When arm or boom is operated, pressure oil from
both pumps is combined and flows together into the
respective cylinder.

Left travel motor Right travel motor

Pump control valve

Travel (R)

Travel (L)

Bucket Bucket cylinder

Aux.

Boom 2

Boom cylinder

Arm cylinder
Boom 1

Arm 1
Arm 2
Swing

Pump control
valve

5-Spool side 4-Spool side

Hydraulic oil tank

Swing motor Pump 2 Pump 1

SM0117
T2-2-4 EX255-EX285

HYDRAULIC SYSTEM

COMBINED OPERATION

Swing and Boom Raise Operation

When swing and boom raise operations are per-
formed at the same time, pilot pressure shifts the
swing, boom 1, and boom 2 spools in the control
valves.
Then, pressure oil from pump 1 flows into the boom
cylinder via the parallel passage in the 4-spool side
section in the control valve to raise the boom. Pres-
sure oil from pump 2 flows into the swing motor to
swing the upperstructure. A portion of the pressure oil
from pump 2 is detoured to the boom cylinder.
The detoured oil flow is combined with the oil flow
from pump 1 after flowing through the parallel pas-
sage and boom 2 spool in the 5-spool side section in
the control valve. The boom is raised by combined oil
flow from pump 1 and pump 2.

Parallel passage

Boom cylinder
Boom 2

Boom 1

Swing

Parallel Passage

5-Spool Side 4-Spool Side

Swing motor Pump 2 Pump 1

SM0118
EX255-EX285 T2-2-5

HYDRAULIC SYSTEM

Travel and Arm Roll-In Operation

When travel and arm roll-in operations are performed
at the same time, pilot pressure shifts the travel, arm
1, and arm 2 spools. Pressure in the non-travel signal
pilot pressure circuit rises due to arm spool move-
ment, shifting flow combiner valve.
Then, pressure oil from pump 1 flows into the right
travel motor via the travel (R) spool, actuating it.
A portion of the pressure oil from pump 1 is detoured
to the left travel motor via the flow combiner valve and
travel (L) spool, actuating it. For this reason, the
machine can travel straight even when the arm roll-
in operation is performed at the same time, blocking
oil flow from pump 2 to the left travel motor.
Pressure oil from pump 2 flows into the arm cylinder
via the arm 1 spool, actuating it.

Flow combiner
Left travel motor valve Right travel motor

Pilot pump

Travel (R)

Travel (L)

Signal Pilot
Pressure Circuit

Arm Cylinder

Arm 1 Arm 2

Pump 2 Pump 1

SM0119
T2-2-6 EX255-EX285

HYDRAULIC SYSTEM

NOTES
EX255-EX285 T2-3-1

ELECTRICAL SYSTEM

OUTLINE

The electrical system is roughly classified into the • Preheat Circuit:

main circuit, control circuit, and monitor circuit. Helps start the engine in cold weather.
(Key Switch, QOS Controller, Glow relay, Glow
• Main circuit: plugs)
Related to circuit for the engine and accessories.
• Starting Circuit:
• Control circuit: Starts the engine.
The control circuit of the engine, hydraulic pump, (Key Switch, Starter, Starter Relay)
and valves (including actuators such as solenoid
valves, MC (Main Controller), switch box, sensors, • Charging Circuit:
and pressure switches, and so on). Recharges batteries and supplies electricity to the
system.
• Monitor circuit: (Alternator, Regulator)
This circuits indicates machine operating condi-
tions. (The circuits consisting of the monitors, sen- • Surge Voltage Prevention Circuit:
sors, and switches, and soon). Prevents surge voltage from occurring when the
engine is stopped.
(Anti Load Dump Relay)
In this group, the main functions and construction of
the main circuit and some functions of control and • Engine Stop Circuit:
monitor circuit are explaned. Stops the engine with the EC motor
(MC, EC Motor).
• Electric Power Circuit:
Supplies electric power to all electric system on this • Engine and pump control circuit:
machine. Operates the EC motor in order to control the
(Key Switch, Batteries, Fuses (Fuse Box and Fu- engine speed.
sible links), Battery Relay) Control the pump displacement (Main Controller
(MC).
• Bulb Check Circuit: EC motor, Engine control dial, E and HP mode
Checks for blown warning lights and indicator bulbs switch, pressure switches, pressure sensors, sole-
on monitor. noid valve unit).

• Accessory Circuit: • Monitor control circuit:

Works with the key switch placed in the ACC Shows the operation conditions of the excavator.
position. (Monitor panel, pressure switches and sensors).
T2-3-2 EX255-EX285

ELECTRICAL SYSTEM

ELECTRIC POWER CIRCUIT

(Key switch: OFF)

The battery negative terminal is grounded to the

vehicle. Current from the positive terminal flows as
follows with the key switch OFF.

→ Fuse
link 2 (40 A) → Glow relay (Power Source)

Terminal 1 - Radio (Backup Power Source)

Monitor (Backup Power Source)

Battery → → Terminal 2 - MC (Power Source)

Terminal 3 - MC (EC Motor)

Terminal 4 - Auxiliary source

(relay box)

→ Fuse
link 1 (40 A) → Fuse box
→ Relay box (terminal 14 - Relay R1 -
Anti Load Dump)

→ Terminal B - Key switch

 to Monitor (43)
Q.O.S. Controller

Coolant Key switch

temperature
switch To fuel transfer
pump motor (opt)
EX255-EX285

Glow relay

Glow plugs Fuse link

Fuse
box

Batteries

Battery relay

Starter
motor

Safety relay
ELECTRICAL SYSTEM

to Monitor (42)
to monitor (18)
Alternator

Relay box
EC motor
Auxiliary power

MC pow. supply
Radio (pow. b.u.)

SM5607
T2-3-3
T2-3-4 EX255-EX285

ELECTRICAL SYSTEM

BULB CHECK CIRCUIT

(Key switch: ON)

When the key switch is turned to the ON position, key
switch terminal B connects with key switch terminals
M and ACC.
The current from terminal M flows throught the diode
D2, located inner the relay box, and excites the
battery relay.
Then, the battery power is routed to the monitor
through the battery relay, the fuse box and the wiper
box, turning the warning lights and indicators on (for
bulb check).
 QOS Controller To monitor (43)
Coolant
temperature switch

Key switch
EX255-EX285

To fuel transfer
pump motor (opt)

Glow relay

Fuse link
Glow plugs

Fuse
box

Batteries

Battery relay

Starter motor
ELECTRICAL SYSTEM

To motor (18)
Safety relay

To monitor (42)
Alternator

Wiper
box

Monitor

Relay box

SM5608
T2-3-5
T2-3-6 EX255-EX285

ELECTRICAL SYSTEM

ACCESSORY CIRCUIT
(Key Switch: ACC)

When the key switch is turned to the ACC position, Then, the battery current flows through the fuse box
terminal ACC is connected to terminal B in the key terminal 15, 16 and 17, to each accessory circuits
switch. (horn, radio, cigar lighter, power outlet, room lamp.
 Key switch
EX255-EX285

Fuse link

Batteries
Room light

Radio
ELECTRICAL SYSTEM

Cigar lighter
Power outlet

To monitor (30)

Horn

SM5609
T2-3-7
T2-3-8 EX255-EX285

ELECTRICAL SYSTEM

PREHEAT CIRCUIT
(Key switch: ON or START)

When the key switch is turned to the ON or START Terminal #6 of QOS controller grounds to vehicle for
position, the key switch terminal B is connected to 8 seconds while preheat, therefore glow signal is ON.
terminal M in the key switch. The current from terminal (When preheat is not done, glow signal is ON for 0.3
M flows to terminal #1 of QOS controller via the fuse seconds to check the blown bulb.)
#18 and supply power to glow relay. Throught the
relay box.
NOTE - Coolant temperature switch becomes OFF
When the coolant temperature switch is OFF, QOS when coolant temperature is less than 10 °C (50 °F).
controller allows to preheat the engine for approx. 30
seconds. When QOS controller terminal #4 is
grounded, glow plug relay comes ON, so that the glow
plugs are heated.
 Coolant QOS Controller
temperature switch
Key switch
EX255-EX285

Monitor panel

N.C. ≥ 10 °C

Glow relay

Fuse link
Glow plugs

Fuse box

Batteries
ELECTRICAL SYSTEM

To monitor (18)

Relay box

SM5610
T2-3-9
T2-3-10 EX255-EX285

ELECTRICAL SYSTEM

STARTING CIRCUIT
(Key Switch: START)

When the key switch is turned to the START position,
terminal B on the key switch is connected to terminals,
M, and ST. The current from terminal M magnetizes
the battery relay, leading the battery current to termi-
nals B on the starter and starter relay via the battery
relay.
Terminal ST of the key switch is connected to terminal
S on the starter relay so that the battery current flows
through the coil in the starter relay, allowing the relay
to close the circuit. Then, the battery current can flow
to terminal C on the starter, closing the inner starter
relay.
Thereby, the starter begins to rotate.
The current from terminal M flows to the MC,
instructing that the key switch is positioned at ON or
START. When this signal arrives at the MC, the MC
actuates the EC motor which moves the governor
lever.
Starter Relay Operation
• When the key switch is turned to the START
position, key switch terminal B and ST have conti-
nuity in the key switch. Then, the current flows to the
base of transistor (Q2) via resistance R4 in the
starter relay, switching transistor (Q2) ON.
Thereby, the current flows through coil (L) of relay,
closing the circuit between starter terminals B and
C. Then, the starter begins to rotate.
• Once the engine is started, the alternator begins
to charge the batteries so that the voltage at
starter relay terminal R rises. When the voltage at
terminal R reaches 21 to 22 V, zener diode (Z)
comes ON. Accordingly, transistor (Q1) is switched
ON so that the base current to transistor (Q2) is cut,
switching transistor (Q2) OFF. At this time, continu-
ity between starter terminal B and C is opened.
Then, the starter is switched OFF.

Capacitor C1 shown in the figure is used to stabilize

the operating voltage. Diode D4 protects the circuit
from damage when the batteries are inversely
connected.

Starter Relay

S B
R4 D3
(1) L

C
R3 (2)
(1)
C
R2 Z D2
To Alternator R Q2 M B
Terminal L Q1
(2)
C1 C
Starter
E
D4

12V
B
ST Batteries

Key Switch 12V

SM4015A
 Key switch
EX255-EX285

Fuse link

Fuse box

Batteries

Battery relay

Starter motor
ELECTRICAL SYSTEM

Safety relay

To monitor (42)
To monitor (18)
Alternator

Main controller
(MC)

Relay box

SM5611
T2-3-11
T2-3-12 EX255-EX285

ELECTRICAL SYSTEM

CHARGING CIRCUIT
(Key Switch: ON)

After the engine starts and the key switch is released,
the key switch is returned to the ON position. With the
key switch kept ON, key switch terminal B is con-
nected to terminals ACC and M.
After the engine starts, the alternator begins power
generation. Current from terminal B on the alternator
flows to the batteries through the battery relay re-
charging the batteries.
In addition, this current from Alternator terminal L
flows to the monitor to turn off the charge lamp.
 Key switch
EX255-EX285

Fuse box

Batteries

Battery relay

Starter motor
ELECTRICAL SYSTEM

Alternator

Relay box

Monitor panel

SM5612
T2-3-13
T2-3-14 EX255-EX285

ELECTRICAL SYSTEM

Power Generation

The alternator consists of field coil FC, stator coil SC,
and diodes D.
The regulator consists of transistors T1 and T2, zener
diode ZD, and resistors R1 and R2.
Alternator terminal B is connected to:
B→R→RF→(R)→R1→Base B for Transistor T1
When the key switch BS is turned ON, the battery
voltage flows to base B for transistor T1 in the regu-
lator, allowing current to flow from collector C to
emitter E.
Accordingly, field coil FC is grounded through transis-
tor T1.
At first, the current does not flow to field coil FC.
When the rotor starts to rotate, alternating voltage is
generated in stator coil SC due to residual magnetism
in the rotor.
Thereby, the current starts to flow through field coil
FC, magnetizing the rotor further and increasing
generating voltage.
As generating voltage increases, the flowing current
through field coil FC is increased further, causing the
generating voltage to increase more. Thus, the batter-
ies are recharged.

Alternator Regulator
B R L

RF R3 R4 R5
(R)
BS
R6
D

ZD Monitor
R2
Batteries SC B

E
R1 C
T2
FC B
D1
C E

T1
(F)

(E)
E

SM4056A
EX255-EX285 T2-3-15

ELECTRICAL SYSTEM

Regulator Operation

When the generating voltage increases higher than
the set voltage of zener diode ZD, the current from the
alternator flows through the zener diode to base B for
transistor T2, connecting collector C to emitter E.
Accordingly, the current flowing through base B for
transistor T1 is cut so that transistor T1 is turned OFF.
Thereby, the current flowing through field coil FC is
cut, causing the SC generating voltage to decrease.
Then, when the voltage to be applied to zener diode
ZD becomes lower than the set voltage of zener diode
ZD, transistor T2 is turned OFF, turning transistor T1
ON again. Thus, the current is allowed to flow through
field coil FC to increase the generating voltage by
stator coil SC. As this operation is repeated, the
alternator generating voltage is maintained at the
specified level.

RF R3 R4 R5
BS

R6
ZD
R2
SC B
A E
C
T2
FC B
R1
C E

D1 T1
(F)

(E)
E

SM4057
T2-3-16
ELECTRICAL SYSTEM
SURGE VOLTAGE PREVENTION CIRCUIT
When the engine is stopped (key switch is OFF), the
current from key switch terminal M is cut so that
battery relay is turned OFF.
The engine does not stop immediately by the key
switch OFF, due to inertia and the alternator contin-
ues to generate electricity. Because the alternator
generating current dose not flow to the batteries, the
surge voltage (Voltage rise) is developed in the cir-
cuit. This is the cause of failure of electrical parts and
components.
On account of this, the surge voltage prevention
circuit has been provided.
EX255-EX285
While the batteries are being recharged, the generat-
ing current from terminal L on the alternator is led to
terminal #42 on the monitor, turning the output tran-
sistor ON for terminal #18 on the monitor.
In the conditions, the batteries current holds the Anti
Load Dump relay R1, located in the relay box, ener-
gised.
Accordingly, even if the key switch is turned OFF
while the engine is running, the battery current can be
supplied through the anti load dump relay (R1) to
magnetize the battery relay, holding the battery relay
ON until the alternator stops generating.
 Key switch
EX255-EX285

Fuse link

Fuse box

Batteries

Battery relay

Starter motor
ELECTRICAL SYSTEM

Safety relay

Alternator

Relay box

Monitor panel

SM5613
T2-3-17
T2-3-18 EX255-EX285

ELECTRICAL SYSTEM

ENGINE STOP CIRCUIT

(Key Switch: OFF)

When the key switch is turned from the ON position to Then, the MC moves the EC motor to the stop position
the OFF position, the signal instructing the MC that causing the engine to stop.
the key switch is ON is cut.
 Key switch
EX255-EX285

Fuse link

Fuse box

Batteries
ELECTRICAL SYSTEM

EC EC
Sensor Motor
To monitor (39)/
To Radio

Main Controller (MC)

T2-3-19

SM5614
T2-3-20 EX255-EX285

ELECTRICAL SYSTEM

ENGINE AND PUMP CONTROL CIRCUIT

The main controller (MC) monitors all digging func-
tions, travel functions, and hydraulic pump functions
Further the main controller stores possible malfunc-
tion conditions of hydraulic and electrical system
generating faults codes that can be detected from
the diagnostic instrument (Dr.EX).
The main controller(MC) receives as input signals:
- from panel switch the signals related to the travel
speed, the auto idle position and work mode selec-
tion;
- from the R.H. control lever hand grip the input signal
of power boost;
- from engine speed control dial panel the engine
speed signal and mode switches E and HP signals.
The EC angle sensor detects the position of EC
motor and supplies signals to the main controller to
indicate the position of the governor lever. (This
signal can be detected from Dr.EX with monitor
function by selecting: EC angle).
The main controller (MC) compares and processes
the input signals and if the engine requires engine
speed changes, it supplies power to the EC motor
in order to change the position of governor lever.

To provide the required functions, the main controller

(MC), compares these input signals with instant con-
ditions detect from various pressure switches and
sensors and provide output signals for the engine
speed control (by means of the operation of EC
motor), and for the pump control circuit (by means of
solenoid valves operation).

• Engine speed control circuit

The engine speed control circuit consists of engine

control dial, E and HP mode switches Auto Idle
switch, N sensor and EC motor and angle sensor
assembly.

The engine control dial adjusts the engine revolu-

tions independently of positions of E mode, HP
mode switches.

The engine control dial sends an electrical signal to

the main controller proportionally to the engine
control dial angle. (This signal can be detected from
Dr.EX with monitor function by selecting: Target
engine speed).

The N sensor supply signal to the main controller

indicating the engine speed. (This signal can be
detected from Dr.EX with monitor function by se-
lecting: Actual engine speed).

In order to change the engine speed, the main

controller sends signals to the EC motor, that re-
volves and controls the governor lever. (This signal
can be detected from Dr.EX with monitor function by
selecting: EC motor position).
 Key switch
EX255-EX285

From fuse link 1 40 A

From fuse link 3 60 A

to monitor
Fuse box panel
From relay box
(R14)

To/from
monitor

Main Controller (MC)

ELECTRICAL SYSTEM

Solenoid valve group Pressure switch N Sensor EC Pressure sensor

Motor

SM5615
T2-3-21
T2-3-22
ELECTRICAL SYSTEM
• Pump control circuit
The pump control circuit consists of pilot pressure
switches related to boom up, Front attachment and
travel, Pump 1 and 2 delivery pressure sensors,
Arm roll-in pilot pressure sensor , Pump 1 and 2
control pressure sensors, work mode selector,
travel mode selector and solenoid valve group.
The pilot pressure switches related to the boom up
(located on the shockless valve), front attachment
and travel (located on control valve), when receive
the actuating pressure, send a ground signal to the
MC controller. (The operation of each pressure
switch can be detected from Dr.EX with monitor
function by selecting: Pressure switch. The Dr EX
will detect the pressure switch ON or OFF condition
showing or deleting the related pressures switch
abbreviation BmH, Fr, Tr ).
The Pump 1 and 2 delivery and control pressure
sensors located on the pump device) and the Arm
Roll-in pilot pressure sensor (located on shockless
valve) send to controller MC an electrical signal that
is proportional to related pressure to be controlled.
EX255-EX285
(The operation of each pressure sensor can be
detected from Dr.EX with monitor function by select-
ing: Pump 1 or 2 Delivery pressure, Pump 1 or 2
Control pressure, Arm Roll-in pilot pressure. The Dr
EX will detect the electrical signal and will show as
pressure value of the related Sensors)
As result of the position of the Work mode selector,
travel mode selector and the actual condition de-
tected from various pressure switches and sen-
sors, the MC controller processes the output signal
to operate the pump regulator solenoid valve (SD),
the travel motor swash angle solenoid valve (SI),
the arm regenerative solenoid valve (SC), and the
relief pressure solenoid valve (SG). (The operation
of each solenoid valve can be detected from Dr.EX
with monitor function by selecting the individual
solenoid valve. The Dr EX will detect the control
electrical signal and will show as controlled pres-
sure value from each related solenoid valve).
 Key switch
EX255-EX285

From fuse link 1 40 A

From fuse link 3 60 A

to monitor
Fuse box panel
From relay box
(R14)

To/from
monitor

Main Controller (MC)

ELECTRICAL SYSTEM

Solenoid valve group Pressure switch N Sensor EC Pressure sensor

Motor

SM5615
T2-3-23
T2-3-24
ELECTRICAL SYSTEM
MONITOR CIRCUIT
The monitor circuit consists of circuits to operate the
hour meter, coolant temperature gauge, fuel gauge,
engine oil level indicator, engine oil pressure indica-
tor, coolant level indicator, engine overheat indicator,
alternator charging indicator, fuel low level indicator,
air cleaner restriction indicator, hydraulic oil level
indicator and engine pre-heat indicator.
Hour meter operates when alternator is charging and
anti load dump relay is energized.
Monitor gauges receive signal from sensors to indi-
cate fuel level and engine coolant temperature.
The monitor controller contains a logic circuit and
transistors to control ground signals for monitor indi-
cator lights.
Monitor controller receives signals from engine oil
level switch, coolant level switch, hydraulic oil level
switch, engine overheating switch, engine oil pres-
sure switch, fuel low level switch, air filter restriction
switch, Q.O.S. controller and alternator.
EX255-EX285
Monitor controller provides voltages to transistors if
temperature, pressures or levels are outside normal
limits to illuminate indicator lights.
Engine oil level switch is closed when oil level in the
oil pan is OK.
Coolant level switch is closed when coolant level in
the recovery tank is OK.
Hydraulic oil level switch is closed when level in the
hydraulic oil tank is OK.
Fuel low level switch is open when the fuel level in the
fuel tank is above the reserve
Engine overheat switch is open when coolant tem-
perature is within normal operating range.
Engine oil pressure switch opens above 98 kPa
(14.2 psi) and closes when the oil pressure is below.
Engine air filter restriction switch closes when vacuum
is above approx. 635 mm (25 in.) water , and opens
when vacuum is below.
The pre-heating temperature switch is closed when
engine coolant temperature is lower to 10°C (50 °F).
 EX255-EX285

Key switch
Alternator
Relay box

From fuse
link 1 (40 A)

From fuse
link 3 (60 A)

Relay box

Monitor panel
Fuse box
ELECTRICAL SYSTEM

Wiper box

NOTE: Shown with engine

stopped and correct
liquid level.
}

to wiper box

SM5616
T2-3-25
T2-3-26 EX255-EX285

ELECTRICAL SYSTEM

NOTES:
SECTION 3 EX255-EX285

COMPONENT OPERATION

CONTENTS

Group 1 - Pump device

Group 5 - Travel device
Outline ................................................. T3-1-1
Main pump .......................................... T3-1-2 Outline ................................................. T3-5-1
Regulator ............................................. T3-1-5 Travel reduction gear ............................ T3-5-3
Pilot pump ........................................... T3-1-13 Travel motor ......................................... T3-5-5
N sensor (Engine speed sensor) ......... T3-1-13 Travel brake valve ................................ T3-5-10
Pump pressure sensor ........................ T3-1-13 Parking brake ....................................... T3-5-13

Group 2 - Swing device

Group 6 - Other components
Outline ................................................. T3-2-1 (Upperstructure)
Swing motor ........................................ T3-2-3
Pilot shut-off valve ............................... T3-6-1
Swing parking brake ............................ T3-2-6
Shockless valve ................................... T3-6-2
Valve unit ............................................. T3-2-7
Solenoid valve unit .............................. T3-6-4
Swing reduction gear ........................... T3-2-9
Pilot relief valve ................................... T3-6-6
EC motor ............................................. T3-6-6

Group 3 - Control valve

Outline ................................................. T3-3-1

Hydraulic circuit ................................... T3-3-6 Group 7 - Other components
Flow combiner valve ............................ T3-3-8 (Undercarriage)
Pump control valve .............................. T3-3-10
Swing bearing ...................................... T3-7-1
Main relief valve .................................. T3-3-12
Center joint .......................................... T3-7-2
Overload relief valve ............................ T3-3-13
Track adjuster ...................................... T3-7-3
Arm regenerative valve ........................ T3-3-14
Boom anti-drift valve,
arm anti-drift valve ............................... T3-3-16
Bucket flow control valve ..................... T3-3-16
Travel flow control valve ....................... T3-3-18
Travel/boom lower
selector valve ...................................... T3-3-18
Boom regenerative valve ..................... T3-3-20

Group 4 - Pilot valve

Outline ................................................. T3-4-1

Operation ............................................ T3-4-3
EX255-EX285 T3-1-1

PUMP DEVICE

OUTLINE

The pump device consists of a transmission, main
pump, and pilot pump. The transmission receives
engine power via coupling, then divides and trans-
mits the power to pump 1 (1), pump 2 (2) and pilot
pump (3) via gears. Gear ratios on the main pump
drive side and the pilot pump side are 1.
Main pumps (1 and 2) are variable displacement,
bent-axis plunger-type pumps equipped with pump
delivery pressure sensors (5) and engine speed
sensor (4) for controlling of the pumps and valves.
These main pumps are incorporated into a single
housing.
Pilot pump (3) is a gear-type pump.

2 1
3 Transmission

SM3016

Transmission

SM3017 SM3018

1 - Pump 1 4 - Engine Speed Sensor (N Sensor)

2 - Pump 2 5 - Pump Delivery Pressure Sensor
3 - Pilot Pump
T3-1-2 EX255-EX285

PUMP DEVICE

MAIN PUMP

Operation

Main pump consists of pump 1 and pump 2, and
supplies hydraulic oil to actuate main components
such as motors and/or cylinders.
Shaft (3) is connected to cylinder block (6) via seven
plungers (4).
Therefore, the rotation of shaft (3) is transmitted to
cylinder block (6), causing cylinder block (6) to slide
along the surface of valve plate (5). Plungers (4)
reciprocate in the cylinder bores, thus discharging
hydraulic oil to the hydraulic circuits.

SM0005

6 2
3

4
5

SM0004 SM0006

1 - Regulator 4 - Plunger
2 - Housing 5 - Valve Plate
3 - Shaft 6 - Cylinder Block
EX255-EX285 T3-1-3

PUMP DEVICE

SM0007
T3-1-4 EX255-EX285

PUMP DEVICE

Increasing and Decreasing Main Pump Oil

Flow Rate

When the displacement angle of cylinder block (3) is
changed, the stroke length of plunger (2) changes.
Thus, oil flow rate of the main pump is controlled by
changing the displacement angle of cylinder block
(3). Servo piston (6) is jointed to valve plate (4) with
pin (5).
When servo piston (6) is moved up or down, valve
plate (4) moves too, changing the displacement
angle of cylinder block (3); cylinder block (3) is kept
in contact with the surface of valve plate (4) and slides
along it.

Maximum displacement angle

2 3

2
6 4
3
SM0008 SM0006

Minimum displacement angle

SM0009

2 - Plunger 5 - Pin
3 - Cylinder Block 6 - Servo Piston
4 - Valve Plate
EX255-EX285 T3-1-5

PUMP DEVICE

REGULATOR

Regulator Construction

Both main pumps (1 and 2) are equipped with a
regulator. Upon receiving various signal pressures,
the regulator controls main pump oil flow rate not to
exceed the engine horsepower.
Regulator mainly consists of spring (1), sleeve B (2),
spool B (3), piston (4), load piston (5), spool A (6),
sleeve A (7), outer spring (8), and inner spring (9).
The pump control pressure is routed to section 1 and
the applicable main pump pressure, the other main
pump pressure and the pilot pressure from the sole-
noid valve unit (SD) are routed to the section 2 of the
regulator. (Note that, viewed from a regulator, two
main pumps are said to be the applicable main pump
and the other main pump). Upon receiving various
signal pressures stated above, the regulator outputs
a pilot pressure to servo piston (10) to change the
displacement angle of cylinder block (11), thus con-
trolling the pump oil flow rate.

1 2 3 4

} Section I

} Section II

5 6 7 8 9

SM0010

12
11

10

SM0006

1 - Spring 5 - Load Piston 9 - Inner Spring

2 - Sleeve B 6 - Spool A 10 - Servo Piston
3 - Spool B 7 - Sleeve A 11 - Cylinder Block
4 - Piston 8 - Outer Spring 12 - Link
T3-1-6 EX255-EX285

PUMP DEVICE

Regulator Functions

The regulator functions to control pump oil flow rate

as follows:

• Control by Pump Control Pressure Q

The pump control valve attached on the control
Flow rate
valve regulates the pump control pressure. Upon
receiving the pump control pressure from the pump
control valve, the regulator increases or decreases
the pump flow rate accordingly.
When the control valve spool is moved to increase
the pump control pressure, the regulator increases
the pump flow rate. When the control valve spool is
returned to neutral, the pump control pressure
decreases. 0 Pump control pressure Pi
Accordingly, the regulator reduces the pump flow
rate to the minimum flow. (Refer to the Control
Valve Group).

• Summation Control (Control by monitoring both

main pump pressures) Pressure increase
If the delivery oil pressure of either of two main Q
pumps increases so that the average pressure of Flow rate
two main pumps exceeds the values set by the Flow rate decrease
P-Q line, the regulator functions to reduce pump oil
flow rate of both main pumps to match the P-Q
value to the one on the set P-Q line, preventing
engine overloading. Since the P-Q line is set using
the average pressure of two main pump pressures,
delivery rates of both pumps are approximately
equal to each other. For this reason, a larger load
is applied to the pump delivering high pressure oil 0 Pressure P
while a smaller load is applied to the pump deliver-
ing low pressure oil, keeping the total load applied
to the pumps equal with the engine horsepower
output. (Total Horsepower Control)

Q
• Control by Pilot Pressure Guided from Solenoid
Flow rate
Valve Unit (SD)
Processing the target engine speed, and the actual
engine speed, the main controller MC sends signal
to solenoid valve unit (SD). Solenoid valve unit, in
turn, routes a pilot pressure to the regulator. Then,
the regulator reduces pump delivery rate accord-
ingly. (Speed Sensing (Horsepower Reducing)
Control) (Refer to the control system Group in the
SYSTEM Section). 0 Pressure P

SM0011
EX255-EX285 T3-1-7

PUMP DEVICE

Regulator operation

3 6 2 1

Pi

12

10

Pps
11
9 13
Pd1 Pd2

5
SM0012
7 4

3 2 6 1

Pi

Pd1

11-12
Pps

Pd2

5
9 13
10

7 4 8 SM0013

1 - Piston 8 - Small Chamber

2 - Spool B 9 - Load Piston
3 - Spring 10 - Spool A
4 - Servo Piston 11 - Inner Spring
5 - Link 12 - Outer Spring
6 - Sleeve B 13 - Sleeve A
7 - Large Chamber
T3-1-8 EX255-EX285

PUMP DEVICE

• Flow Rate Control by Pump Control Pressure

Flow rate increase:

1. Pump control pressure Pi increases when a con-
trol valve spool is moved.
2. Piston (1) pushes spool B (2) and spring (3) to
move spool B (2) to the direction indicated by the
arrow.
3. Large chamber (7) at the end of servo piston (4)
is connected to the hydraulic oil tank line.
4. As a result, servo piston (4) moves to the direction
indicated by the arrow.
5. The displacement angle of the cylinder block is
changed by the movement of the servo piston,
increasing the pump flow rate.
6. The movement of servo piston (4) is transmitted
to sleeve B (6) via link (5), moving sleeve B (6) in
the direction that spool B (2) has moved. When
sleeve B (6) moves for the same distance spool B
(2) has moved, large chamber (7) is closed to the
hydraulic oil tank line, stopping the servo piston
movement, thus stopping the increase of pump
flow rate at that point.

3 6 2 1

Pi Pressure increase

Pps

Q
Pd1 Pd2
Flow rate

0 Pump control pressure Pi

5
SM0014
7 4
SM0015

1- Piston 5- Link
2- Spool B 6- Sleeve B
3- Spring 7- Large Chamber
4- Servo Piston 8- Small Chamber
EX255-EX285 T3-1-9

PUMP DEVICE

Flow rate decrease:

1. When the control valve spool is returned to neu-
tral, the pump control pressure Pi decreases.
2. Spring (3) pushes back piston (1) and spool B (2),
returning spool B (2) to the direction indicated by
the arrow.
3. As a result, the servo pressure acting on small
chamber (8) is also routed to large chamber (7).
4. Servo piston (4) moves in the direction indicated
by the arrow, due to the size difference of the
pressure receiving area between both chambers.
5. The displacement angle of the pump decreases.
6. The movement of servo piston (4) is transmitted
to sleeve B (6) via link (5), moving sleeve B (6) in
the direction that spool B (2) has moved. When
sleeve B (6) moves for the same distance spool B
(2) has moved, large chamber (7) is closed to the
hydraulic oil tank line, stopping the servo piston
movement, thus stopping the decrease of pump
flow rate at that point.

3 6 2 1

Pi Pressure decrease

Pps

Q
Pd1 Pd2
Flow rate

0 Pump control pressure Pi

5
SM0016
7 4
SM0017

1- Piston 5- Link
2- Spool B 6- Sleeve B
3- Spring 7- Large Chamber
4- Servo Piston 8- Small Chamber
T3-1-10 EX255-EX285

PUMP DEVICE

• Summation Control (Flow Rate Control by Monitor-

ing Both Main Pump Pressures)

Flow Rate Increase:

(Note that, viewed from a regulator, two main pumps
are said to be the applicable main pump and the other
main pump)
1. The pressure from the applicable main pump
(Pressure Pd1) or from the other main pump
(Pressure Pd2) decreases.
2. Inner spring (11) and outer spring (12) pushes
load piston (9) and spool A (10), moving them in
the direction indicated by the arrow.
3. Large chamber (7) at the end of servo piston (4) is
connected to the hydraulic oil tank line.
4. As a result, servo piston (4) moves in the direction
indicated by the arrow.
5. As the servo piston moves, the displacement
angle of the cylinder block changes, increasing
the pump flow rate.
6. The movement of servo piston (4) is transmitted
to sleeve A (13) via link (5), moving sleeve A (13)
in the direction spool A (10) has moved. When
sleeve A (13) moves for the same distance spool
A (10) has moved, large chamber (7) is closed to
the hydraulic oil tank line, stopping the servo
piston movement, thus stopping the increase of
pump flow rate at that point.

9 13 10

Pi

11

Pps
Q
12
Flow rate Pd1 Pd2
Pressure decrease

0 (Summation of two main Pd

pump pressures)

5
SM0018

7 4
SM0015

4 - Servo Piston 10 - Spool A

5 - Link 11 - Inner Spring
7 - Large Chamber 12 - Outer Spring
8 - Small Chamber 13 - Sleeve A
9 - Load Piston
EX255-EX285 T3-1-11

PUMP DEVICE

Flow rate decrease:

1. The pressure from the applicable main pump
(Pressure Pd1) or from the other main pump
(Pressure Pd2) increases.
2. Load piston (9) pushes spool A (10), inner spring
(11), and outer spring (12), moving spool A (10) in
the direction indicated by the arrow.
3. As a result, the servo pressure acting on small
chamber (8) is also routed to large chamber (7).
4. Servo piston (4) moves in the direction indicated
by the arrow, due to the size difference of the
pressure receiving area between both chambers.
5. The displacement angle of the pump decreases.
6. When sleeve A (13) moves for the same distance
spool A (10) has moved, servo pressure routed to
large chamber (7) is shut out, stopping the servo
piston movement, thus stopping the decrease of
pump flow rate at that point.

9 13 10

Pi

Flow rate 11

Q Pps
12
Pd1 Pd2
Pressure increase

0 (Summation of two main Pd

pump pressures) 5
7
SM0019

4
SM0020

4 - Servo Piston 10 - Spool A

5 - Link 11 - Inner Spring
7 - Large Chamber 12 - Outer Spring
8 - Small Chamber 13 - Sleeve A
9 - Load Piston
T3-1-12 EX255-EX285

PUMP DEVICE

• Flow Rate Control by Pilot Pressure Guided from

Solenoid Valve Unit (SD).

Flow rate decrease:

1. Solenoid valve unit (SD) is activated by signals
from the main controller MC, guiding pilot pres-
sure Pps.
2. Pilot pressure Pps, together with the applicable
main pump pressure or with the other main pump
pressure, acts on load piston (9).
3. Load piston (9) pushes spool A (10), inner spring
(11), and outer spring (12), moving spool A (10) in
the direction indicated by the arrow.
4. As a result, the servo pressure acting on small
chamber (8) is also routed to large chamber (7).
5. Servo piston (4) moves in the direction indicated
by the arrow, due to the size difference of the
pressure receiving area between both chambers.
6. The displacement angle of the pump decreases.
7. When sleeve A (13) moves for the same distance
spool A (10) has moved, servo pressure routed to
large chamber (7) is shut out, stopping the servo
piston movement, thus stopping the decrease of
pump flow rate at that point.

9 13 10

Pi

11

Pps
Pressure increase 12
Q Pd1 Pd2
Flow rate

0 P 7
(Summation of two main
pump pressures)
4
SM0021
SM0020

4 - Servo Piston 10 - Spool A

7 - Large Chamber 11 - Inner Spring
8 - Small Chamber 12 - Outer Spring
9 - Load Piston 13 - Sleeve A
EX255-EX285 T3-1-13

PUMP DEVICE

PILOT PUMP Suction port

2 1
Drive gear (1) is rotated via the transmission to driven
gear (2).

1 - Drive gear
2 - Driven gear

Delivery port

SM0022

N SENSOR (ENGINE SPEED SENSOR)

The N sensor detects engine speed. Engine speed is

a necessary signal for various controls of the ma-
chine. The N sensor is installed close to the top of the
4
transmission gear; when the gear rotates, gear tooth
tops pass by the top of the N sensor. Then numbers 5
of gear teeth passing by are converted to electrical 6
pulse signals which are sent to the EC.
Thereby, engine speed is detected.

4 - Coil 7 8
5 - Magnet
6 - Gear
7 - Signal output terminal SM0023
8 - Power supply (5 V) SM0024

PUMP PRESSURE SENSOR

The pump pressure sensor detects oil pressure. Oil

pressure is a necessary signal for various controls of
the machine.
Oil pressure is received by diaphragm (12).
Depending on the extent of deformation of the dia-
phragm, oil pressure is detected as an electrical
signal. 9 10 11 12

9 - Grounding terminal
10 - Output terminal
11 - Power supply (5V) terminal
12 - Pressure receiving section (diaphragm) SM0025
T3-1-14 EX255-EX285

PUMP DEVICE

NOTE
EX255-EX285 T3-2-1

SWING DEVICE

OUTLINE

The swing device consists of the valve unit, the swing
motor, and the swing reduction gear.
The valve unit prevents cavitation and overload of the
swing circuit.
The swing motor is a swash-plate-type axial plunger
motor (with a built-in parking brake for swing), and is
driven by the pressure oil from the pump to rotate the
swing reduction gear.
The swing reduction gear rotates the upperstructure
by rotating the shaft by slow speed and large torque.

NOTE- The figure shows the swing device installed on

EX255
Valve unit

Swing motor

Swing reduction
gear

SM3019
T3-2-2 EX255-EX285

SWING DEVICE

NOTE - The figure shows the swing device installed on

EX285.

Valve unit

Swing motor

Swing reduction
gear

SM5001
EX255-EX285 T3-2-3

SWING DEVICE

SWING MOTOR

The swing motor consists of the swashplate, rotor,
plungers, valve plate, housing and swing parking
brake (consists of spring, brake piston, plate, friction
plate and switch valve).
The rotor is installed onto shaft with a spline coupling,
and the plungers are inserted in rotor.
The pressure oil is fed from the pump so that the
plungers are pushed.
The shoe of the plunger slides along swash plate, and
rotation occurs in rotor. The shaft end is connected to
first stage sun gear of the swing reduction gear by a
spline coupling. Therfore the rotation of shaft is
transmitted to the swing reduction gear.

NOTA - The figure shows the swing motor instal-

led on EX255.

9 3

1-2

4 6

5 7

1 - Valve Plate 7 - Swash Plate

8 - Switch valve SM0027
2 - Rotor
3 - Housing 9 - Plate and Friction Plate
4 - Plunger 10 - Brake piston
5 - Shoe 11 - Spring
6 - Shaft
T3-2-4 EX255-EX285

SWING DEVICE

NOTE - The figure shows the swing motor instal-

led on EX285.

11

10
2

9
4
8

5
7

SM5007

1 - Valve Plate 7 - Swash Plate

2 - Rotor 8 - Switch valve
3 - Housing 9 - Plate and Friction Plate
4 - Plunger 10 - Brake piston
5 - Shoe 11 - Spring
6 - Shaft
EX255-EX285 T3-2-5

SWING DEVICE

Swing speed varies depending on the amount of oil
delivered from the pump. From port A, high pressure
oil is fed so that plunger (3) is pushed from the top to
the bottom.
Shoe (4) then slides along swash plate (5),
developing turning force.
Turning force is transmitted to the swing reduction
gear unit via shaft (6). The return oil flows to outlet
port B and returns to the hydraulic oil tank.
When pressure oil is fed to port B, the motor rotates
in the opposite direction.

SM0028

1 - Valve Plate 4 - Shoe

2 - Rotor 5 - Swash Plate
3 - Plunger 6 - Shaft
T3-2-6 EX255-EX285

SWING DEVICE

SWING PARKING BRAKE 1

The parking brake is a wet-type multiple disc brake.

The brake is released only when brake release
pressure enters into brake piston chamber (b),
(negative type brake). When swing and/or front at-
tachment operation is made brake release pressure 2
is supplied from the pilot pump.
During operations other than swing and/or front, or b
while the engine is stopped, brake release pressure
is routed to the hydraulic oil tank and the parking
3
brake is automatically applied by spring (1). 4
5
• When the swing and/or front function is operated,
the brake is released: 6 SM0032
When the swing and/or front control lever is oper-
1 - Spring 4 - Friction Plate
ated, the control valve spool for swing and/or front 2 - Brake Piston 5 - Motor Housing
function is moved from the neutral position, closing 3 - Plate 6 - Rotor
the spool passage for the signal pilot pressure
circuit. Then, the pilot oil pressure increases, and
the increased pressure pilot oil is sent to the pilot
port of the switch valve in the brake release circuit. When the brake is released (OFF):
Therefore, the switch valve is opened, allowing the
Oil pressure timer
brake release pilot oil pressure from the pilot pump
to act on brake piston (2) via the oil pressure timer Signal pilot pressure
Brake release
circuit
check valve. Accordingly, brake piston (2) is moved pressure
up against spring (1), breaking contact between
friction plates (4) and plates (3). Then, the brake is OFF
released.

• When the swing and/or front function is not oper-

ated, the brake is applied: Swing motor
When the swing and/or front control lever is not
operated, the control valve spool for swing and/or Spool Switch valve
front function is in the neutral position, holding the
spool passage for the signal pilot pressure circuit
SM0033
open. Then, the pilot oil pressure does not in-
crease. Therefore, the switch valve in the brake
circuit is kept closed, allowing the brake release
pilot oil pressure on brake piston (2) to flow out to
the hydraulic oil tank via the oil pressure timer
orifice. Accordingly, brake piston (2) is moved When the brake is applied (ON):
down by spring (1) force so that friction plates (4)
come into contact with plates (3). As friction plates Oil pressure timer
(4) engage the inner circumference of motor hous- Signal pilot pressure
ing (5) and plates (3) engage the outer circumfer- circuit Brake release
pressure
ence of rotor (6), rotor (6) is braked by friction
force developed between plates (3) and friction ON
plates (4).

Swing motor

Switch valve
Spool

SM0034
EX255-EX285 T3-2-7

SWING DEVICE

VALVE UNIT Relief valve

The valve unit consists of the make-up valve and the

relief valve.
The make-up valve prevents cavitation in the circuit,
and the relief valve prevents surge pressure and
overloads in the circuit.

Make-Up Valve Make-up valve

When swing is stopped, if the upperstructure tends to
keep rotating due to inertia force, causing the swing
motor to continue rotating further, and to begin suck-
Port M
ing oil from the pump, developing cavitation in the
motor. A B
The make-up valve sucks hydraulic oil through the
return circuit (port M) to compensate for the lack of oil, Control valve
and prevent cavitation.

SM0029

Relief valve

Port M

Make-up valve

Control valve

SM5008
T3-2-8 EX255-EX285

SWING DEVICE

Relief Valve Relief valve

When starting or stopping swing operation, oil
pressure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the specified pressure. Plunger (1) is pushed to
the left by pressure Pp at port (P) and pressure-
receiving area A2. PA PB
However, plunger (1) is also pushed back to the right
by spring (2) force and pressure Pg at chamber (g)
and pressure-receiving area A1.
Chamber (g) is routed to port (P) through orifice (m).
When force acting on the right is higher than that on
Port M
the left, the relief valve operates.
A B
Control valve

SM0029

g 2 1

A1 A2

SM0031
EX255-EX285 T3-2-9

SWING DEVICE

SWING REDUCTION GEAR

The swing reduction gear is a two-stage planetary
gear type. Ring gears (2 and 4) in the first and second
stages are provided on the inside of the housing.
The housing is bolted to the main frame so that ring
gears (2 and 4) are held stationary.
The motor output shaft of the swing motor drives first
stage sun gear (9).
Then, rotary power is transmitted to second stage
sun gear (7) via first stage planetary gear (1) and first
stage carrier (8). Second stage sun gear (7) rotates
shaft (5) via second stage planetary gear (3) and
carrier (6).
As shaft (5) meshes with the internal gear of the
swing bearing bolted to the undercarriage, the
upperstruc- ture is rotated.

NOTE - The figure shows the swing reduction gear

installed on EX255.

9
1
8

7 3
4
6

SM3020

1 - First Stage Planetary Gear 6 - Second Stage Carrier

2 - First Stage Ring Gear 7 - Second Stage Sun Gear
3 - Second Stage Planetary Gear 8 - First Stage Carrier
4 - Second Stage Ring Gear 9 - First Stage Sun Gear
5 - Shaft (Output Shaft)
T3-2-10 EX255-EX285

SWING DEVICE

NOTE - The figure shows the swing reduction gear

installed on EX 285.

8 1
2

7 3
4
6

SM5002

1 - First Stage Planetary Gear 6 - Second Stage Carrier

2 - First Stage Ring Gear 7 - Second Stage Sun Gear
3 - Second Stage Planetary Gear 8 - First Stage Carrier
4 - Second Stage Ring Gear 9 - First Stage Sun Gear
5 - Shaft (Output Shaft)
EX255-EX285 T3-3-1

CONTROL VALVE

OUTLINE

The control valve controls oil pressure, flow rate, and
flow direction in the hydraulic circuit. A 4-spool side
section and a 5-spool side section are bolted to-
gether.
The control valve is a pilot-pressure-operated type
which mainly consists of the main relief valve, pump
control valves, flow combiner valve, and main spools.
In the 4-spool side section, the Right Travel, Bucket,
Boom 1, and Arm 2 spool sections are arranged in
that order as viewed from the machine front.
In the 5-spool side section, the Left Travel, Auxiliary,
Boom 2, Arm 1, and Swing spool sections are ar-
ranged in that order as viewed from the machine
front.

Machine Front Right travel

Bucket

Left travel Boom 1

Main relief valve

Arm 2

Auxiliary

4-spool side section

Boom 2

Arm 1

Swing

Pump control valve (5-spool side)

5-spool side section

Machine Rear

SM0036
T3-3-2 EX255-EX285

CONTROL VALVE

Control valve layout

Left travel motor Right travel motor

3 4 5 6 7 8 9 10
2
1
11
41
12
13
14
40
15
16
39
Bucket cylinder
38
37
36
Boom cylinder
35
34

17
Arm cylinder 18
33
32 19
31 20
30 21
29 22
23
26
27
24
28 25

Swing motor SM0037

1 - Hydraulic Timer 15 - Overload Relief Valve (Bucket) 29 - Load Check Valve (Arm Tandem
2 - Travel Flow Control Valve 16 - Overload Relief Valve (Bucket) Circuit)
3 - Load Check Valve (Travel Parallel 17 - Overload Relief Valve (Boom) 30 - Check Valve
Circuit) 18 - Overload Relief Valve (Boom) 31 - Arm Regenerative Valve
4 - Check Valve 19 - Boom Anti-Drift Valve (Check Val- 32 - Check Valve
5 - Main Relief Valve ve) 33 - Overload Relief Valve (Arm)
6 - Check Valve 20 - Boom Anti-Drift Valve (Switch 34 - Overload Relief Valve (Arm)
7 - Check Valve Valve) 35 - Arm Anti-Drift Valve (Check Val-
8 - Flow Combiner Valve 21 - Boom Regenerative Valve ve)
9 - Load Check Valve (Bucket) 22 - Check Valve 36 - Arm Anti-Drift Valve (Switch Val-
10 - Bucket Flow Control Valve 23 - Pump Control Valve (4-Spool ve)
(Switch Valve A) Side) 37 - Load Check Valve (Boom 2
11 - Bucket Flow Control Valve 24 - Check Valve Parallel Circuit)
(Switch Valve B) 25 - Restriction (4-Spool Side Parallel 38 - Travel/Boom Lower Selector Val-
12 - Bucket Flow Control Valve Circuit) ve
(Poppet Valve) 26 - Load Check Valve (Arm Parallel 39 - Check Valve
13 - Load Check Valve (Boom 1 Circuit) 40 - Load Check Valve (Travel
Parallel Circuit) 27 - Restriction (Arm 1 Parallel Tandem Circuit)
14 - Load Check Valve (Boom 1 Circuit) 41 - Pump Control Valve (5-Spool
Tandem Circuit) 28 - Load Check Valve (Swing) Side)
EX255-EX285 T3-3-3

CONTROL VALVE
A Section A
H
B 5
G C
D
E
F

41 8

SM0036 SM0038

Section C Auxiliary Bucket

15

12
39 11

Section D
9
Boom 2

16
Boom 1
Section B SM0040

L. Travel R. Travel
38 20

17 21
19
37
3
2 13

14
10
40
18

SM0039 SM0041
T3-3-4 EX255-EX285

CONTROL VALVE

Control valve layout

Left travel motor Right travel motor

3 4 5 6 7 8 9 10
2
1
11
41
12
13
14
40
15
16
39
Bucket cylinder
38
37
36
35 Boom cylinder
34

17
Arm cylinder
18
33
32 19
31 20
30 21
29 22
23
26
27
24
28 25

Swing motor SM0037

1 - Hydraulic Timer 17 - Overload Relief Valve (Boom) 31 - Arm Regenerative Valve

2 - Travel Flow Control Valve 18 - Overload Relief Valve (Boom) 32 - Check Valve
3 - Load Check Valve (Travel Parallel 19 - Boom Anti-Drift Valve (Check Val- 33 - Overload Relief Valve (Arm)
Circuit) ve) 34 - Overload Relief Valve (Arm)
4 - Check Valve 20 - Boom Anti-Drift Valve (Switch 35 - Arm Anti-Drift Valve (Check Val-
5 - Main Relief Valve Valve) ve)
6 - Check Valve 21 - Boom Regenerative Valve 36 - Arm Anti-Drift Valve (Switch Val-
7 - Check Valve ve)
8 - Flow Combiner Valve 22 - Check Valve 37 - Load Check Valve (Boom 2
9 - Load Check Valve (Bucket) 23 - Pump Control Valve (4-Spool Parallel Circuit)
10 - Bucket Flow Control Valve Side) 38 - Travel/Boom Lower Selector Val-
(Switch Valve A) 24 - Check Valve ve
11 - Bucket Flow Control Valve 25 - Restriction (4-Spool Side Parallel 39 - Check Valve
(Switch Valve B) Circuit) 40 - Load Check Valve (Travel
12 - Bucket Flow Control Valve 26 - Load Check Valve (Arm Parallel Tandem Circuit)
(Poppet Valve) Circuit) 41 - Pump Control Valve (5-Spool
13 - Load Check Valve (Boom 1 27 - Restriction (Arm 1 Parallel Side)
Parallel Circuit) Circuit)
14 - Load Check Valve (Boom 1 28 - Load Check Valve (Swing)
Tandem Circuit) 29 - Load Check Valve (Arm Tandem
15 - Overload Relief Valve (Bucket) Circuit)
16 - Overload Relief Valve (Bucket) 30 - Check Valve
EX255-EX285 T3-3-5

CONTROL VALVE
Section E (2) Arm 1
Arm 2

31

32

Section E (1)
Section F

Arm 1 Arm 2
Swing
SM0042
36

34
35 28
24

26 25

27 23
29 22

33 SM0043 SM0045
30
Section H

Section G

6 7

SM0044 SM0046
T3-3-6 EX255-EX285

CONTROL VALVE

HYDRAULIC CIRCUIT

Main Circuit Signal Pilot Pressure Circuit

Pressure oil from pump 1 and from pump 2 is routed
to the 4-spool side section in the control valve and to
the 5-spool side section in the control valve, respec-
tively.
A parallel passage is provided in both right and left
main circuits, making combined operations possible.
The main circuit pressure is restricted by the main
relief valve. Moreover, two overload relief valves are
provided in each of boom, arm, and bucket circuits.
Also, a pump control valve is provided at the most
downstream position of each of right and left neutral
passages.
The pilot pressure from the pilot pump flows through
the control valve.
When the causes the travel signal pilot pressure circuit
to be restricted, increasing the travel signal pilot pres-
sure, thus turning on the pressure switch (travel) and
shifting the travel/boom lower selector valve.
When a control lever other than the travel levers is
operated, the signal pilot pressure in the front att.
signal pilot pressure circuit increases, thus turning on
the pressure switch (front) and shifting the flow
combiner valve, travel flow control valve, and swing
parking brake shift valve.

Flow combiner valve

Swing parking brake Pressure switch Pressure switch

shift valve (Front) (Travel)
Neutral passage
Main relief valve

Signal pilot pressure

circuit

Left travel motor

Pump control valve
(5-spool side)
Right travel motor

Auxiliary

Bucket
Travel flow control
valve

Travel/Boom lower
selector valve

Boom
Arm
Overload relief valves
Overload relief valves

Parallel Pump control valve

passages (4-spool side)
Swing

Main circuits
Neutral passage

5-spool side 4-spool side

Pilot pump
Pump 2 Pump 1

SM0047
EX255-EX285 T3-3-7

CONTROL VALVE

Pilot Valve Guided Pilot Pressure Circuit

Pilot pressure via the pilot valve exerts on the control
valve spools, shifting them. At the same time, it also
exerts on switch valves. (Arm anti-drift valve, Boom
anti-drift valve, Bucket flow control valve)
Besides shifting of control valve spools (when control
levers are operated), the pilot valve guided pilot
pressure functions as follows:
• When the arm roll-in lever is operated, the pilot
pressure via the pilot valve exerts on the bucket
flow control valve and the anti-drift valve (switch
valve), shifting them.
• When the boom raise lever is operated, the pilot
pressure exerts on the bucket flow control valve as
the valve shift pressure.
• When the boom lower lever is operated, the pilot
pressure exerts on the boom anti-drift valve (switch
valve), shifting it.
In addition, an air bleed circuit is provided in the top
part of the control valve, automatically bleeding air
trapped in the circuit.
Solenoid Valve Guided Pilot Pressure Circuit
The pilot pressure guided via the solenoid valve unit
(SG and SC) shifts the main relief valve and the arm
regenerative valve. (Refer to the Control System
Group in the SYSTEM Section).

Main relief valve

From the solenoid valve unit (SG)
Bucket flow control valve

1 2 11 12
8
5
3 4 13 14

Arm anti-drift valve

5
5

Arm regenerative valve

7 8
From the solenoid valve 8 7 Boom anti-drift valve
unit (SC)

9 Air bleed circuit

10

Pump 2 Pump 1 SM0048

1 - Left Travel Forward 6 - Boom Lower 11 - Right Travel Reverse

2 - Left Travel Reverse 7 - Arm Roll-out 12 - Right Travel Forward
3 - Auxiliary 8 - Arm Roll-in 13 - Bucket Roll-in
4 - Auxiliary 9 - Swing Left 14 - Bucket Roll-out
5 - Boom Raise 10 - Swing Right
T3-3-8 EX255-EX285

CONTROL VALVE

FLOW COMBINER VALVE

When a control lever other than the travel levers is the pilot pressure to shift the flow combiner valve.
operated, the signal movement of the control valve As a result, the pressure oil from the pump 1 is routed
spool restricts the signal pilot pressure in the front to both right and left travel spools, securing straight
attachment signal pilot pressure circuit, increasing travel in travel combined operations.
EX255-EX285 T3-3-9

CONTROL VALVE

Front attachment signal

pilot pressure circuit
Left travel motor Flow combiner valve Right travel motor

Pilot pump

Arm cylinder

Pump 2 Pump 1

SM0049
T3-3-10 EX255-EX285

CONTROL VALVE

PUMP CONTROL VALVE

A pump control valve is provided on the most down- In addition, the pump control pressure sensor detects
stream part of the neutral passage in each of the 4- the pump control pressure, sending signals to MC for
spool and 5-spool side sections. travel motor displacement angle control. (Refer to the
The pump control pressure altered by the pump Control System Group in the SYSTEM Section).
control valve exerts on the regulator, changing the
pump displacement angle. (Refer to the Pump De-
vice Group in this section).

Pump control valve

(5-spool side)
To the pump 2 regulator and
to pump control pressure sensor Neutral passage

Pump control valve

(4-spool side)

To the pump 1 regulator and

to the pump control pressure sensor

4-spool side
5-spool side

Neutral passage

SM0050
EX255-EX285 T3-3-11

CONTROL VALVE

Operation with Control Valve Spool Activated

When a control valve spool is shifted, oil flowing
through the neutral passage and through the pump
control valve decreases.
As oil flowing through the pump control valve
decreases, the pump control valve spool shifts to the
left, increasing the relief valve set pressure, thus
raising the pump control pressure.
This increased pump control pressure exerts on the
regulator and, in return, the regulator increases the
pump displacement angle, increasing the pump
delivery oil flow.

From the pilot pump

Pump control pressure passage

Pump control Hydraulic oil tank

pressure sensor

Pressure
increase
Pump control valve

To the regulator
Neutral passage

Small oil flow

SM0051

Operation with Control Valve Spools in Neutral

Position
When control valve spools are returned to the neutral As the pump control pressure decreases to a
position, the neutral passage is fully opened and all minimum, the regulator decreases the pump
pump oil flow goes through the neutral passage and displacement angle to have the minimum pump
the pump control valve so that the pump control valve delivery flow, contributing to fuel efficiency.
spool moves to the right, decreasing the relief valve
set pressure so as to have the lowest pump control
pressure.

From the pilot pump

Pump control pressure passage

Pump control Hydraulic oil tank

pressure sensor

Pressure
Decrease
Pump control valve

To the regulator
Neutral passage

Large oil flow

SM0052
T3-3-12 EX255-EX285

CONTROL VALVE

MAIN RELIEF VALVE

The main relief valve regulates main circuit pressure.
The set pressure of the main relief valve is shifted by
the pilot pressure guided via the solenoid valve unit
(SG). (Refer to the Control System Group in the
SYSTEM Section).
Valve Operation
When the pilot pressure is not guided to the main
relief valve via the solenoid valve unit (SG):
When oil pressure at port Hp matches the spring set
force, the pilot poppet opens. Oil at port Hp flows to
port Lp through passage A.
As the pilot poppet opens, oil pressure in spring
chamber A decreases, opening the main poppet,
thus directly routing pressure oil at port Hp to port Lp.

Main poppet

Pilot poppet

Lp

Hp Port SG

Lp

Spring A Passage A

SM0053

When the pilot pressure is guided to the main relief
valve via the solenoid valve unit (SG):
When the pilot pressure via the solenoid valve unit
exerts on port (SG), the piston is pushed to the left in
the set position, increasing the compressional force
of spring B, thus requiring higher port Hp pressure to
open the pilot poppet.
For this reason, the main relief valve set pressure
increases.

Pilot poppet

Piston

Lp

Hp Port SG

Lp

Spring B

SM0054
EX255-EX285 T3-3-13

CONTROL VALVE

OVERLOAD RELIEF VALVE

(With Make-Up Function)

Overload relief valves are provided in each port of
the boom, bucket, and arm cylinders, and regulate
oil pressure in the cylinder circuits to protect them
from damage due to excessive high pressure that
might develop if a cylinder is moved by excessive
external force.
Moreover, these relief valves function to suction oil
from the return (hydraulic oil tank) line to prevent the
occurrence of cavitation if negative oil pressure
arises in a cylinder (the make-up function).

1 2 3 4 5

10

9 8 G 7 6

SM0055

1 - Spring 6 - Adjusting Screw

2 - Plug 7 - Plug
3 - Pilot Poppet 8 - Main Poppet
4 - Spring 9 - Sleeve
5 - Spring 10 - Piston
T3-3-14 EX255-EX285

CONTROL VALVE

ARM REGENERATIVE VALVE

The arm regenerative valve is shifted by the pilot
pressure guided via the solenoid valve unit (SC).
When the arm regenerative valve is shifted, the
return oil line from the cylinder rod side is closed.
Then, the return oil is combined with the pump
delivery oil to be supplied to the cylinder bottom side,
increasing the arm roll-in speed, improving the arm
controllability in general, and preventing arm move-
ment hesitation from occurring in arm roll-in opera-
tions. (Refer to the Control System Group in SYS-
TEM Section).

Arm cylinder

From the solenoid valve unit (SC)

Arm regenerative valve

SM0056
EX255-EX285 T3-3-15

CONTROL VALVE

Arm regenerative valve

Arm 1
From the solenoid valve
unit (SC)

Pump 2 Pump 1

SM0057
T3-3-16
CONTROL VALVE
BOOM ANTI-DRIFT VALVE, ARM ANTI-
DRIFT VALVE
An anti-drift valve is provided on the bottom side of
the boom cylinder and on the rod side of the arm
cylinder so as to reduce cylinder drift.
When the control valve spool is in neutral, the switch
valve part of the anti-drift valve is not shifted and the
pressure in the boom cylinder bottom side (the arm
cylinder rod side) exerts on the check valve of the
anti-drift valve via the switch valve, closing the check
valve.
Boom 1
Boom lower
pilot pressure
BUCKET FLOW CONTROL VALVE
The bucket flow control valve restricts the bucket
circuit in the combined operations of the bucket, arm
roll-in, and boom raise, so as to raise the boom
sufficiently.
When the arm is rolled in, the arm roll-in pilot pressure
shifts switch valve (A) of the bucket flow control
valve. If the boom is raised at the same time, the
boom raise pilot pressure is routed through the switch
Arm roll-in pilot pressure
Switch valve A
Boom raise pilot pressure
Switch valve B
Bucket pilot pressure
EX255-EX285
When the arm roll-in or boom lower is operated, the
pilot pressure via the pilot valve shifts the switch valve
of the anti-drift valve. The oil pressure exerted on the
check valve is returned to the hydraulic oil tank via the
restriction in the switch valve.
(The check valve is designed to close by a signal
pressure, which arises when the switch valve is not
shifted, and to open when the signal pressure is not
exerted (when the switch valve is shifted.)).
Boom cylinders
Anti-drift valve (check valve)
Anti-drift valve (switch valve)
SM0058
valve (A), shifting the switch valve (B) of the bucket
flow control valve.
Thus, the back pressure exerting on the poppet
valve rises, applying a force to close the poppet
valve, thus restricting oil flow through the poppet
valve. For this reason, the oil flow to the bucket is
restricted, supplying an oil flow to the higher-load-
applied boom raise side.
Poppet valve
Bucket
Bucket cylinder
SM0059
EX255-EX285 T3-3-17

CONTROL VALVE

Bucket flow control valve

Arm anti-drift valve

Boom anti-drift
valve

Pump 2 Pump 1

SM0048
T3-3-18
CONTROL VALVE
TRAVEL FLOW CONTROL VALVE
When the front attachment is operated while
traveling, the non-travel signal pilot pressure exerts
on the travel flow control valve, which is located in the
parallel circuit, after flowing through the hydraulic
Hydraulic timer
To the travel motor
Left
travel spool
Travel parallel circuit
TRAVEL/BOOM LOWER SELECTOR VALVE
The boom lower operation is actuated by the oil flow
via the boom 1 section. However, in travel-com-
bined operations, the oil flow from pump 1 does not
flow in the downstream boom 1 spool as it goes to
the upstream travel spool. If the boom is positioned
up in the air at the moment, the boom would be
lowered by its own weight. However, if the travel-
combined boom lower operation is performed with
the base machine raised off the ground, the boom
does not lower.
Boom 2
Travel/Boom lower
selector valve
Pump 2
EX255-EX285
timer, so as to gradually restrict the parallel circuit.
As the parallel circuit is gradually restricted, shock
loads, occurring due to the front attachment opera-
tion, are reduced.
Non-travel signal pilot pressure
Travel flow control valve
Non-travel spool
SM0060
To prevent this from occurring, in travel-combined
boom lower operations, the boom 2 spool is shifted to
route the oil flow from pump 2 to the boom lower
section so that the boom lowers to sufficiently per-
form the machine jack-up operation.
When the travel spool is shifted, the travel signal pilot
pressure shifts the travel/boom lower selector valve,
allowing the boom lower pilot pressure to exert on the
boom 2 spool. Thus, the boom lower operation is
sufficiently performed in travel-combined operations.
Right travel spool
Boom 1
To the boom cylinder
SM0061
EX255-EX285 T3-3-19

CONTROL VALVE

Hydraulic timer

Travel flow
control valve Signal pilot pressure circuit

Left travel motor

Right travel motor

Bucket
Travel/Boom lower
selector valve

Boom

Parallel passages

Pilot pump

Pump 2 Pump 1

SM0047
T3-3-20 EX255-EX285

CONTROL VALVE

BOOM REGENERATIVE VALVE

In boom lower operations, the return oil from the
cylinder bottom side is combined with the oil flow from
the pump, supplying an additional oil flow to the
cylinder rod side, via the check valve in the boom
spool.
By this boom regenerative valve operation, the boom
lower operation is improved and cavitation is pre-
vented from occurring.

Boom regenerative
valve

Boom cylinders

Boom 1
Boom lower
pilot pressure

SM0062
EX255-EX285 T3-4-1

PILOT VALVE

OUTLINE

The pilot valve controls pilot pressure oil to move the
control valve spools. There are two types of pilot
valves. One is for front/swing operation; the other is
for travel operation. Both have standard four oil ports.
An optional two-oil-port type is available.
Except for the cam construction to push the pusher
down, the construction of the pilot valve in both the
front/swing pilot valve and the travel pilot valve is the
same.

• Right and left pilot valves (Front/Swing)

Port No. Control

1 Bucket roll-out
Right 2 Boom lower
3 Bucket roll-in
4 Boom raise
1 Swing right
Left 2 Arm roll-out
3 Swing left
4 Arm roll-in T 3 4 P
3 4
T P

P T 2 1

SM0065

1 3 2 4

SM0063
T3-4-2 EX255-EX285

PILOT VALVE

• Travel pilot valve

Port No. Control

1 Left travel forward
2 Left travel reverse
3 Right travel reverse
T
4 Right travel forward T

4
P T 1

2
1 2 3 4
3

SM0064 SM0066

• Positioning pilot valve (triple articulation version)

Port No. Control

1 Positioning raise
(Positioning cylinder retraction)
T
2 Positioning lower
1
(Positioning cylinder extension) 2
T

1 2 P
P

P T

1 2

SM3043 SM3021
EX255-EX285 T3-4-3

PILOT VALVE

OPERATION

• Front and Swing Pilot Valve

The lower face of spool (8) head is suspended by the In neutral

upper face of spacer (4); they are kept in contact by
setting force of balance spring (6). Spacer (4) is
installed between pusher (3) and spring guide (5) and
supported by return spring (7). Piston (9) is located
inside spool (8). The lower end of piston (9) makes
contact with the plate, preventing the piston from
moving further downward.
Above piston (9), a chamber is provided and it is led
to the outside of spool (8) through holes provided in
spool (8).
(Corresponding to A to B in the output diagram):
When control lever (1) is in the neutral position (no
pusher stroke), spool (8) completely blocks pressure
oil from entering port P. Since the delivery port is open
to port T, pressure at the delivery port equals that in
the hydraulic oil tank.
When control lever (1) is slightly moved, cam (2)
moves together, pressing down on pusher (3).
Then, pusher (3), spacer (4), and spring guide (5)
move downward as a unit, compressing return spring
(7).
The lower face of spool (8) is kept in contact with the
upper face of spacer (4) by setting force of balance
spring (6) and moves downward together with spacer
(4). However, even if control lever (1) is moved
further, until clearance (A) at section (a) reaches
zero, the delivery port remains open to port T, keep-
ing pressure at the delivery port equal to that in the
hydraulic oil tank.

Delivery port
pressure
(pilot pressure)
1

2
A B Pusher stroke

3 OUTPUT DIAGRAM

4
5
6

Section (a)
7
(A) 8
Port T
(A)=0
Delivery port

Port P
9

SM0067

1 - Control Lever 6 - Balance Spring

2 - Cam 7 - Return Spring
3 - Pusher 8 - Spool
4 - Spacer 9 - Piston
5 - Spring Guide
T3-4-4
PILOT VALVE
Ready to start operation
(Corresponding to B to C section in the output dia-
gram):
When control lever (1) is tilted slightly further from the
position where clearance (A) in section (a) reaches
zero, and pusher (3) is pushed downward, spool (8)
is moved downward, opening notched section (b) to
allow pressure oil at the port P to flow into the delivery
port.
This oil pressure is also led to the inside of spool (8)
via orifice (10), and acts to push spool (8) upward.
Until this oil pressure force reaches the setting force
of balance spring (6), balance spring (6) will not be
compressed so that spool (8) is not moved upward,
closing the clearance at section (a), keeping the
notch at section (b) opened, and letting the oil pres-
sure to increase at the delivery port.
If the oil pressure at the delivery port increases, and the
upward-pushing force of spool (8) slightly exceeds the
1 (Pilot pressure)
3
Section (a)
Port T
Clearance (A) reaches zero
Delivery port
10
Port P
1 - Control Lever
3 - Pusher
6 - Balance Spring
EX255-EX285
setting force of balance spring (6), spool (8) moves
upward against setting force of balance spring (6).
Once spool (8) moves upward, upper clarance at
section (a) is opened and lower notch section at
section (b) is closed, leading oil pressure at the
delivery port to port T, and decreasing oil pressure at
the delivery port.
When oil pressure at the delivery port decreases, the
force to push up spool (8) is reduced so that balance
spring (6) stretches to move spool (8) downward,
closing both the clearance and the notch at sections
(a and b).
Thus, original position of spool (8) is kept resumed.
The oil pressure will continue to increase until it is
equal to setting force of balance spring (6) (shown by
the point C in the output diagram).
Delivery port
pressure
B Pusher stroke
OUTPUT DIAGRAM
8
Section (b)
SM0068
8 - Spool
9 - Piston
10 - Orifice
EX255-EX285 T3-4-5

PILOT VALVE

Operation corresponding to the control lever stroke

(Corresponding to C to D in the output diagram):

As control lever (1) is moved further to push pusher
(3) downward, spool (8) is pushed down to open the
notch at section (b), increasing oil pressure at the
delivery port.
As pressure increases, the force to push up spool (8)
increases. Then, when force to push up spool (8)
exceeds the setting force of balance spring (6), spool
(8) starts to move upward, compressing balance
spring (6).
When spool (8) moves upward until the clearance at
section (a) opens, the delivery port is opened to port
T, stopping oil pressure increase at the delivery port
and stopping movement of spool (8).
Accordingly, when compressed by pusher (3), spring
force of balance spring (6) increases in proportion to
the pusher stroke, Then, oil pressure increases to
counteract against this spring force.

Delivery port
pressure
(Pilot pressure)
1
D

Pusher stroke

OUTPUT DIAGRAM

Section (a)
8

Port T

Delivery port
Section (b)

Port P

SM0069

1 - Control Lever 6 - Balance Spring

3 - Pusher 8 - Spool
T3-4-6 EX255-EX285

PILOT VALVE

Operation close to pusher stroke end

(Corresponding to D to E in the output diagram):

As pusher (3) is pressed down, balance spring (6) is
compressed, reducing clearance (B) between
pusher (3) and the top of spool (8) (shown at section
(c)), finally to zero.
After that, pusher (3) directly pushes spool (8).
Even if oil pressure at the delivery port increases,
spool (8) cannot move upward, closing the oil pas-
sage from the delivery port to port T, and opening the
oil passage from the delivery port to port P.
Then, oil pressure at the delivery port increases until
it reaches port P pressure.

Delivery port E
pressure
(Pilot pressure)
D

Pusher stroke

3 OUTPUT DIAGRAM

Section (c)

Clearance (B) reaches zero

6

Port T

Delivery port

Port P

SM0070

3 - Pusher 8 - Spool
6 - Balance Spring
EX255-EX285 T3-4-7

PILOT VALVE

Full stroke operation

(Corresponding to E to F section in the output dia-
gram):

Even if control lever (1) is tilted further to push down
pusher (3), spool (8) moves downward along with
pusher (3), only widening the notch at lower section
(b) of spool (8).
Thus, oil pressure at the delivery port is kept same as
at port P. Pusher (3) can be pressed down until spring
guide (5) comes into contact with the shoulder (sec-
tion (d)) of the casing.
This position is the stroke end of pusher (3) (corre-
sponding to F position in the output diagram).
This process corresponds with E to F section in the
output diagram.
The total stroke of the control lever is decided by
dimension C.

Delivery port E F
pressure
1 (Pilot pressure)

Pusher stroke

3 OUTPUT DIAGRAM

Section (d)

C
5

Port T

Delivery port
Section (b)

Port P

SM0071

1 - Control Lever 5 - Spring Guide

3 - Pusher 8 - Spool
T3-4-8 EX255-EX285

PILOT VALVE

• Travel Pilot Valve

In neutral Full stroke operation:

(Corresponding to A to B in the output diagram):
Lever - In Neutral (Pusher Stroke: A to B)
In neutral, spool (6) closes port P (the input port) and
tank port T is connected to delivery port through
clearance (A). Thus, the pressure at delivery port is
the same as that at tank port T.
When the control lever is moved slightly from A to B,
pusher (2) and spring guide (3) together move down
against return spring (5) and balance spring (4). At
this time, as both oil pressures above and below
spool (6) are the same as the tank pressure, spool (6)
moves down together with spring guide (3) until
clearance (A) becomes zero.
Lever - Full Stroke (Pusher Stroke)
When the control lever is moved full stroke, pusher
(2) is moved down until spring guide (3) comes into
contact with the shoulder of the valve casing (Lever
Stroke End), opening notch (B) further to port P.
The output pressure (pilot pressure to the control
valve) remains at the pilot system pressure (the port
P pressure).
Dimension (C) in the figure right shows the control
lever full stroke.

Delivery port
Operation corresponding to the control lever stroke pressure
(Corresponding to C to D in the output diagram): (Pilot pressure)
Lever - Operated D
(Pusher Stroke: C to D — Metering)

When the control lever is moved further to push

pusher (2) down, port P is connected to delivery port C
through notch (B) and passage in spool (6), routing
pilot pump pressure. However, when the pressure
applied into spool (6) overcomes the balance spring A B Pusher stroke
force, spool (6) moves up, closing port P. When
pusher (2) is moved further down, compressing re-
turn spring (5) and balance spring (4), the larger the
balance spring force; thus, the output pressure in- OUTPUT DIAGRAM
creases in proportion to the increase in the balance
spring force.
SM0072
EX255-EX285 T3-4-9

PILOT VALVE

Pusher stroke: A to B

4
5
Port T
(A) Clearance A: 0

Port P

Delivery port

SM0073 SM0075

Pusher stroke: C to D Pusher stroke: full stroke

2
2

(C)
4

5
3
Port T Port T
(B)

Port P 6 Port P

Delivery port Delivery port

SM0074 SM0076

1 - Cam 4 - Balance Spring

2 - Pusher 5 - Return Spring
3 - Spring Guide 6 - Spool
T3-4-10 EX255-EX285

PILOT VALVE

NOTE
EX255-EX285 T3-5-1

TRAVEL DEVICE

OUTLINE

The travel device consists of travel motor (14), plan-

etary reduction gears (1 to 10, 12, 13), and sprocket
(11).

NOTE - The figure shows the travel device installed

on EX255.

3 2 1

7
11
6
9

12

10
13

14

SM3022

1 - Cover 8 - Third Stage Sun Gear

2 - First Stage Sun Gear 9 - Third Stage Planetary Gear
3 - First Stage Planetary Gear 10 - Ring Nut
4 - First Stage Carrier 11 - Sprocket
5 - Second Stage Sun Gear 12 - Housing (Ring Gear)
6 - Second Stage Planetary Gear 13 - Hub (Third Stage Carrier)
7 - Second Stage Carrier 14 - Travel Motor
T3-5-2 EX255-EX285

TRAVEL DEVICE

NOTE - The figure shows the travel device installed

on EX285.

12

13

14

5
6

10

11

SM5003

1 - Ring Gear 8 - Third Stage Sun Gear

2 - Propel Shaft 9 - Third Stage Carrier
3 - First Stage Planetary Gear 10 - Third Stage Planetary Gear
4 - First Stage Carrier 11 - Sprocket
5 - Second Stage Sun Gear 12 - Drum
6 - Second Stage Carrier 13 - Housing
7 - Second Stage Planetary Gear 14 - Travel Motor
EX255-EX285 T3-5-3

TRAVEL DEVICE

TRAVEL REDUCTION GEAR

The travel reduction gear is a third stage planetary Third stage carrier (2) is part of the hub and as the
gear type. The travel motor rotates first stage sun gear housing (1) (ring gear) and sprocket (11) are bolted
(7) and this driving force is transmitted to the housing together, they all rotate.
(1) via first stage planetary gear (8), first stage carrier
(6), second stage sun gear (5), second stage plan-
NOTE - The figure shows the travel reduction gear
etary gear (9), second stage carrier (4), third stage sun
installed on EX255.
gear (3), and third stage planetary gear (10).

2 10 3

5
7

12
1 2 3 4 5 9 6
12
12

11 8
Third Second First
stage stage stage
11 10
SM3023

1 - Ring Gear (housing) 7 - First Stage Sun gear (Propel Shaft)

2 - Third Stage carrier 8 - First Stage Planetary Gear
3 - Third Stage Sun Gear 9 - Second Stage Planetary Gear
4 - Second Stage Carrier 10 - Third Stage Planetary Gear
5 - Second Stage Sun Gear 11 - Sprocket
6 - First Stage Carrier 12 - Hub
T3-5-4 EX255-EX285

TRAVEL DEVICE

NOTE - The figure shows the travel reduction gear

installed on EX285.

1 2 3 4 5

12 10 9
1 2 3 4 5 9 6

11

12 8
Third Second First
stage stage stage
11 10
SM5004

1 - Ring Gear (housing) 7 - Propel Shaft

2 - Third Stage Carrier 8 - First Stage Planetary Gear
3 - Third Stage Sun Gear 9 - Second Stage Planetary Gear
4 - Second Stage Carrier 10 - Third Stage Planetary Gear
5 - Second Stage Sun Gear 11 - Sprocket
6 - First Stage Carrier 12 - Hub
EX255-EX285 T3-5-5

TRAVEL DEVICE

TRAVEL MOTOR

This travel motor is a variable-displacement bent-
axis axial-plunger type that includes a parking brake
(wet-multi-disc negative type).
The main parts of the motor are plate (1), valve plate
(2), rotor (14), plungers (13), center shaft (5), drive
disc (7), servo piston (16), parking brake piston (12),
friction plates (11), and plates (10).
Rotor (14) is pre-loaded against valve plate (2) by
spring (4). As oil pressure in the rotor bores in-
creases, the pressure acts on end faces (A) of the
rotor bores and assists spring (4) to force rotor (14)
against valve plate (2).

NOTE - The figure shows the travel motor installed on

EX255.

1 2 3 4

9
16
10

11

15
12
14
A
13

SM3024
1 - Plate 9 - Roller Bearing
2 - Valve Plate 10 - Plate
3 - Disc Spring 11 - Friction Plate
4 - Spring 12 - Brake Piston
5 - Center Shaft 13 - Plunger
6 - Housing 14 - Rotor
7 - Drive Disc 15 - Link
8 - Roller Bearing 16 - Servo Piston
T3-5-6 EX255-EX285

TRAVEL DEVICE

NOTE - The figure shows the travel motor installed on

EX285.

2 3 4
1
5
6

10 9
11
10
15 14 13 12 11
16
12

SM5005

1 - Plate 9 - Roller Bearing

2 - Valve Plate 10 - Plate
3 - Disc Spring 11 - Friction Plate
4 - Spring 12 - Brake Piston
5 - Center Shaft 13 - Plunger
6 - Housing 14 - Rotor
7 - Drive Disc 15 - Link
8 - Roller Bearing 16 - Servo Piston
EX255-EX285 T3-5-7

TRAVEL DEVICE

Pressure oil supplied to port AM of the valve plate (1)
flows into the rotor bores (2) underneath port AM,
pushing the plungers (3). The vertical component
force (FV) of plunger pushing force (F) rotates the
drive disc (4). As the drive disc (4) rotates, the rotor
(2) also rotates.
When the plungers (3) moves to port BM side, oil is
routed to the hydraulic oil tank.
Whether pressure oil from the pump is supplied to
port AM or BM determines travel direction.

3
BM 4

AM

FR
FV
F

SM0080

1 - Valve plate 3 - Plunger

2 - Rotor 4 - Drive disc
T3-5-8 EX255-EX285

TRAVEL DEVICE

Travel Speed Selection

Servo piston (1) is interconnected to valve plate (6)

via link (5) so that when servo piston (1) is moved,
swash angle of rotor (7) is shifted through valve plate
(6), leading to travel speed change.

• Slow speed

When the slow speed travel mode is selected, the
MC (Main Controller) does not send out an elec-
tronic control signal to the solenoid valve unit (SI).
Therefore, speed change pilot pressure is not
routed to servo piston (1). Thus, spool (3) is held
down by spring (2). Then, pressure oil P from the
motor port is led to both chambers “B” and “C”.
Since the pressure-receiving area in chamber “C” is
larger than that in chamber “B”, servo piston (1)
moves upward, increasing swash angle to the
maximum.
Accordingly, as the stroke of the plungers in the
motor is increased, slower revolution of the travel
motor for low speed mode is obtained.

7 1

Drain

P B

5
4 Pilot pressure

SM0081

1 - Servo Piston 5 - Link

2 - Spring 6 - Valve Plate
3 - Spool 7 - Rotor
4 - Orifice
EX255-EX285 T3-5-9

TRAVEL DEVICE

• Fast speed travel mode

When the fast speed travel mode is selected,
corresponding to travel loads, the MC sends out an
electronic control signal to the solenoid valve unit
(SI). Therefore, speed change pilot pressure is
routed to chamber “D”, moving spool (3) upward.
Then, passage “E” opens and oil in chamber “C” is
drained through the inner passages in spool (3).
As pressure oil P from the motor port is led to
chamber “B”, servo piston (1) is moved down,
reducing the swash angle of rotor (7).
Accordingly, as the stroke of the plungers in the
motor is decreased, faster revolution of the travel
motor for fast speed mode is obtained.
(Refer to the Control System Group in the SYSTEM
Section).

1
6

7 2
Drain

B
3

E
5
Pilot pressure
4 Drain
P

Position of servo piston at initial

stage of fast speed travel operation

Pilot pressure

Position of servo piston during

stage of fast speed travel operation

SM0082

1 - Servo Piston 5 - Link

2 - Spring 6 - Valve Plate
3 - Spool 7 - Rotor
4 - Orifice
T3-5-10 EX255-EX285

TRAVEL DEVICE

TRAVEL BRAKE VALVE

The travel brake valve is located on the travel motor
head and consists of the following valves.
- Check Valve (1):
Ensures smooth starts and stops, and prevents
cavitation from occurring in the motor circuit by
functioning together with counterbalance valve (5).
- Overload Relief Valve (4):
Prevents overloads and surge pressure in the
motor circuit.
- Counterbalance Valve (5):
Ensures smooth starts and stops and prevents
overrunning when traveling down slopes.

- Reducing Valve (2): - Servo-Piston Operating Shuttle Valve (6):

Reduces parking brake release pressure and pre- Leads divided hydraulic oil flow for travel motor
vents sudden operation of the brake. operation to the servo-piston.

- Parking Brake Release Shuttle Valve (3): NOTE - The figure shows the travel brake valve
Leads travel motor drive pressure to the parking installed on EX255.
brake.

Section B-B

1
3
1
A 2

4 B
AM BM

AV BV C

Section A-A
A

Section C-C
6
SM0083

1 - Check Valve 4 - Overload Relief Valve

2 - Reducing Valve 5 - Counterbalance Valve
3 - Parking Brake Release Shuttle Valve 6 - Servo-Piston Operating Shuttle Valve
EX255-EX285 T3-5-11

TRAVEL DEVICE

NOTE - The figure shows the travel brake valve

installed on EX285.

2 4 6

6
3

Section B-B
1
1 3

Section C-C

A
4 4 2

AM BM

C
.
.
.
C

.
AV BV B

A Section A-A SM5010

1 - Check Valve 4 - Overload Relief Valve

2 - Reducing Valve 5 - Counterbalance Valve
3 - Parking Brake Release Shuttle Valve 6 - Servo-Piston Operating Shuttle Valve
T3-5-12
TRAVEL DEVICE
Travel Operation
When supply oil from the control valve is routed to
port BV, supply oil flows around spool CB, opens
check valve BC (9) and is led to motor port BM.
However, return oil from motor port AM is blocked by
check valve AC (8) and spool CB (7).
As supply oil pressure at port BV increases, supply oil
is routed to chamber “G” through orifice “F” in spool
CB (7), moving spool CB (7) to the left against spring
force.
Consequently, return oil from motor port AM starts to
flow into port AV through notch “H” in spool CB (7),
allowing the travel motor to rotate.
When the travel levers are returned to the neutral
position, the oil in both ports AV and BV are routed to
the hydraulic oil tank through the control valve. Thus,
oil pressure in chamber “G” decreases, and spool CB
(7) is moved back to the original position by spring
force. Then, the oil flow circuit is blocked, causing the
travel motors to stop rotating.
Descending Operation
When the machine travels down a slope, the travel
motors are forcibly driven by the machine weight so
that the motor draws oil like a pump. When the motor
7
8
AM
AV
H G
4 - Overload relief valve
7 - Spool CB
EX255-EX285
draws oil, oil pressure at port BV and chamber “G”
decreases, causing spool CB (7) to move to the right.
Then, the return oil flow from the motor is restricted
by the spool, increasing pressure at port AM.
The increased pressure at port AM brakes the motor.
Thus, the restricted return oil flow increases the
pressure at port BV again, moving spool CB (7) back
to the left. This repeat movement of the spool (hy-
draulic brake action) prevents the machine from
overrunning.
Circuit Protectors
If pressure in the circuit increases over the setting
pressure of the overload relief valve (4), this valve
opens to relieve peak pressure to the lower pressure
side to protect the motor from overloading. This valve
also functions to release shock pressure caused by
inertia force developing when the motor stops.
When the motor draws oil because of pumping opera-
tion, check valve BC (9) opens to make up vacuum,
so that cavitation will not develop in the circuit.
4
9
BM
BV
F
SM0084
8 - Check valve AC
9 - Check valve BC
EX255-EX285 T3-5-13

TRAVEL DEVICE

PARKING BRAKE

NOTE - The figure shows the parking brake installed

on EX255.

When the brake is applied: When the brake is released:

M
K
1

2
3
M
4

SM3025

1 - Disc Spring 4 - Plate

2 - Piston 5 - Housing
3 - Friction Plate 6 - Drive Disc
T3-5-14 EX255-EX285

TRAVEL DEVICE

NOTE - The figure shows the parking brake installed

on EX285.

When the brake is applied: When the brake is released:

SM5006

1 - Disc Spring 4 - Plate

2 - Piston 5 - Housing
3 - Friction Plate 6 - Drive Disc
EX255-EX285
TRAVEL DEVICE
The parking brake is a negative-type brake released
when oil pressure “K” is applied to parking brake
chamber “M”. Whenever the travel control valve
spools are in neutral, the parking brake is automati-
cally applied.
Friction plates (3) are connected to drive disc (6), and
plates (4) to motor housing (5) via spline coupling
respectively. When disc spring (1) pushes piston (2)
to the right, friction plates (3) come into contact with
plates (4), applying the parking brake.
Starting to travel:
When travel lever is pulled reverse, pressurized oil
from the pump flows to port AM via the control valve.
The pressurized oil flows to the travel motor and
AM
G I
7 - Reducing valve
8 - Shuttle valve
T3-5-15
chamber “G” located at the end of spool CB (9).
Parking brake release pressure is blocked by spool
CB (9). When pressure increases, spool CB (9)
moves to the right. Pressurized oil flows to reducing
valve (7) via the orifice “I” of spool CB (9), then flows
to parking brake chamber “M” to release the travel
parking brake.
When the machine is not traveling:
Pressure oil from the travel motor is not routed
through shuttle valve (8), and parking brake chamber
“M” is led to the drain circuit through reducing valve
(7). Piston (2) is gradually forced to the right by disc
spring (1), making friction plates (3) come into con-
tact with plates (4).
Drain
BM
8 9
SM0086
9 - Spool CB
T3-5-16 EX255-EX285

TRAVEL DEVICE

NOTE
EX255-EX285 T3-6-1

OTHER COMPONENTS (Upperstructure)

PILOT SHUT-OFF VALVE To pilot valve

The pilot shut-off valve is a manual-operated switch

valve. The spool in the pilot shut-off valve is rotated To hydrayulic
by moving the pilot control shut-off lever to turn on or oil tank
off the pilot oil flow to the pilot valves.
From pilot
pump

To shockless valve From pilot valve

SM0087

From pilot valve

• Valve Operation with Pilot Control Shut-Off
Lever in LOCK Position
The pilot shut-off valve is set in the neutral position.
Pressure oil from the pilot pump does not flow into
the pilot valves, but it is routed to the shockless To shockless valve
valve. Pilot oil on the pilot valve side is routed to the
hydraulic tank as drain passages in the pilot shut-
off valve open.

To hydraulic From pilot

oil tank pump

SM0088

To pilot valve
• Valve Operation with Pilot Control Shut-Off
Lever in UNLOCK Position
The pilot shut-off valve is set in the operating
position, allowing pressure oil from the pilot pump
to flow into the pilot valves. The pilot pressure can
be and will be routed to the control valve to operate
the respective hydraulic cylinders and/or motors as
the pilot valves are operated, in other words, as the
control levers are operated.

From pilot pump

SM0089
T3-6-2 EX255-EX285

OTHER COMPONENTS (Upperstructure)

SHOCKLESS VALVE 1 2

Check valves, pilot pressure sensor (for arm roll in),

and pilot pressure switch (for boom raise) are built
into the shockless valve block in addition to the
shockless valves.
The shockless valves regulate secondary pilot pres-
sure (pilot pressure between the pilot valves and the
6
control valve spools) for the arm roll-out and for boom
raise functions, preventing abrupt and rapid move- 5
ment of the respective control valve spools.

4 3
SM0090

• When the arm roll out or the boom raise is operated, 7

secondary pilot pressure from the pilot valve is
routed to the side B of the shockless valve. Imme- A B
To control From pilot
diately after operating the control lever, the second- valve spool valve
ary pilot pressure routed to the side B flows to the
control valve spool via orifice (9). As the secondary
pilot pressure increases, check valve (7) opens. 9 8

SM0091

7
• Return oil from the control valve spool flows back to
the hydraulic oil tank via orifice (9). As the pressure
at the side A increases, spool (8) moves in propor-
tion to the pressure increase, regulating the return
To hydraulic
oil flow. oil tank via
A B pilot valve
From control
valve spool

9 8

SM0092

1 - Shockless Valve
2 - Pilot Pressure Switch (Boom Raise)
3 - Check Valve
4 - Check Valve
5 - Shockless Valve
6 - Pilot Pressure Sensor (Arm Roll In)
7 - Check Valve
8 - Spool
9 - Orifice
EX255-EX285 T3-6-3

OTHER COMPONENTS (Upperstructure)

Warm-up circuit

When the pilot shut-off valve is in the LOCK position,
pilot oil via the pilot shut-off valve flows into the
shockless valve. The oil is heated as it flows through
the restriction located at the inlet of the shockless
valve.
For this reason, the pilot circuit is warmed as this
heated oil flows into the shockless valve and into the
pilot valves.

To pilot valve To control valve

To pilot valve To control valve

To pilot valve To control valve

To pilot valve To control valve

Shockless valve

Pilot shut-off valve

From pilot pump

SM0093
T3-6-4 EX255-EX285

OTHER COMPONENTS (Upperstructure)

SOLENOID VALVE UNIT

Front
The solenoid valve unit functions to control the pump
regulator, control valve and travel motor servo piston
upon receiving signals from the main controller MC.
The solenoid valve unit consists of four solenoid
valves (SC), (SD), (SI), and (SG). (Refer to the
Control System Group in the SYSTEM Section).

SC : Controls the arm regenerative valve located in

the control valve.

SD : Controls the pump regulator.

(Speed Sensing)
SC
SI : Controls the travel motor servo piston. SD
(Travel Speed Selection) SG

SG : Functions to increase the main relief valve

pressure setting SI

SM0094
EX255-EX285
OTHER COMPONENTS (Upperstructure)
Proportional Solenoid Valve
Upon receiving an electric current signal from the
MC, the proportional solenoid valve outputs hydraulic
pressure proportional to the degree of the electric
current.
• When not energized (In neutral):
The spring pushes the spool to the right, connect-
ing the output port S to the tank port T.
• When energized:
The solenoid pushes the spool to the left for a
distance proportional to the electric current flowing
through the solenoid. Pilot oil from port (P) flows
S Spring
T P
T3-6-5
into output port S, increasing the pressure at output
port S. The pressure at port S acts on the two banks
of walls on the spool. (See detail “a.”).
Because of the pressure receiving area difference
between the two walls, the pressure at port S acts
as a force to push the spool to the right. As the
pressure at port S increases, the force to push the
spool to the right also increases. When this force
overcomes the force to push the spool to the left by
solenoid, the spool moves back to the right side,
closing the passage between output port S and port
P. As a result, pressure increase at port S stops.
Spool
Solenoid
SM0095
T3-6-6 EX255-EX285

OTHER COMPONENTS (Upperstructure)

PILOT RELIEF VALVE

The pilot relief valve functions to regulate the pilot

pump pressure oil routed to port P to a set constant
pressure.

Pilot relief valve

P A

SM2200

EC MOTOR

The EC motor is used to control engine speed. A motor rotation to calculate the governor lever posi-
worm gear is incorporated into the EC motor to tion. (Refer to the Control System Group in SYSTEM
prevent a loss of synchronism from occurring. The Section).
EC sensor is provided to detect the degrees of the EC

Output shaft Worm gear

Output gear

Sensor gear
Motor

EC sensor
Worm wheel

SM0097
EX255-EX285 T3-7-1

OTHER COMPONENTS (Undercarriage)

SWING BEARING

This bearing is a single-row shear ball-type bearing, The internal gear of inner race (3) engages with the
comprising outer race (1), inner race (3), balls (6), output shaft of the swing reduction gear.
supports (5), and seals (2), (4). Outer race (1) is
bolted to the upperstructure and inner race (3) is
bolted to the undercarriage.

6
4

SM0098

1 - Outer Race 4 - Seal

2 - Seal 5 - Supports
3 - Inner Race 6 - Ball
T3-7-2 EX255-EX285

OTHER COMPONENTS (Undercarriage)

CENTER JOINT

The center joint is a 360° rotating joint. When the
upperstructure is rotated, the center joint avoids
twisting of hoses and allows hydraulic oil to flow
smoothly to or from the travel motors. Spindle (1) is
attached to the main frame, and body (2) is bolted to
the swing center of the undercarriage.
Hydraulic oil flows to the right and left travel motors
via spindle (1) and the oil ports of body (2). Seals (3)
prevent oil leaks between spindle (1) and body (2)
into adjacent passages.

To left travel To right travel To left travel To right travel

motor (Reverse) motor (Forward)
To left travel To right travel
motor (Forward) motor (Reverse)
Pilot pressure for
travel speed selection
motor (Forward) motor (Forward)
To left travel To right travel
motor (Reverse) motor (Reverse)
1
Pilot pressure for
travel speed selection
Drain

Drain

Drain
3

Drain
Forward
Reverse
Pilot pressure for
travel speed selection

SM0099

1 - Spindle 3 - Seal
2 - Body
EX255-EX285 T3-7-3

OTHER COMPONENTS (Undercarriage)

TRACK ADJUSTER

The track adjuster located on the side frame is

composed of spring (5) and adjuster cylinder (6). CAUTION
Spring (5) absorbs loads applied to the front idler.
Do not loosen valve (1) quickly or loosen too much
Adjuster cylinder (6) adjusts track sag.
since high-pressure grease in the adjusting cylin-
der may spout out.
• Grease is applied through grease fitting into cham-
Loosen carefully, keeping body parts and face
ber (A) of adjuster cylinder (6) as illustrated below.
away from valve (1). Never loosen grease fitting.
The pressure of the grease pushes piston rod (8)
out and decreases track sag.

• To increase track sag, loosen valve (1) 1 to 1.5

turns counterclockwise to release grease from the
track adjuster cylinder through the grease dis-
charge hole.
1

Grease fitting

Grease discharge hole

1 2 3 4 A 5 6 7

SM0100

1 - Valve 5 - Spring
2 - Nut 6 - Adjuster Cylinder
3 - Flange 7 - Piston Rod
4 - Spacer
T3-7-4 EX255-EX285

OTHER COMPONENTS (Undercarriage)

NOTE
COPYRIGHT BY FIAT - HITACHI EXCAVATORS S.p.A.
Documentation Centre
Strada di Settimo, 323 - S. MAURO T.SE ( TO ) ITALY

Reproduction of text or illustrations,

in whole or in part, is strictly prohibited

Print No. 604.13.082 - X - 2001

Printed by Satiz - Turin (Italy)

Coordinamento Editoriale Satiz - Torino
EXCAVATOR -

TECHNICAL MANUAL
TROUBLESHOOTING
(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.

FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. - ENGINEERING -

FORM No. 604.13.196 - Edition - July 2002
EX255-EX285 IN-1

INTRODUCTION

TO THE READER

• This manual is written for an experienced technician - If you have any questions or comments, or if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact:

- Be sure to thoroughly read this manual for correct FIAT KOBELCO CONSTRUCTION
information concerning the service procedures. MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALY
PRODUCT SUPPORT
Fax. ++39 011 6877357

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition

to this service manual:

- Operation and Maintenance Instruction

Manual
- Parts Catalog

SERVICE MANUAL COMPOSITION

• The complete service manual consists of three
books:
- Technical Manual - Operational Principle
- Technical Manual - Troubleshooting
- Workshop Manual
- 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 Technical Manual-Operational Principle in- • The Service Manual for EX255-EX285 Excavators
cludes the technical information concerning the consists of the following book/print numbers:
operation of main devices and systems.

- The Technical Manual-Troubleshooting includes the

technical information needed for operational per-
formance tests, and troubleshooting procedures.

BOOK PRINT NUMBER

- Technical Manual - Operational Principle 604.13.191
- Technical Manual - Troubleshooting 604.13.196
- Workshop Manual 604.13.201
IN-2 EX255-EX285

INTRODUCTION

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, 3 560 psi)

A table for conversion from SI units to other system units is shown below for reference purposes.

To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW CV-PS 1.360
Volume L US qt 1.057 kW HP 1.341
3
m yd 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0
N.m lbf.ft 0.7375
EX255-EX285 S-1

SAFETY PRECAUTIONS

RECOGNISE SAFETY INFORMATION

• This is your SAFETY ALERT SYMBOL.

- When you see this symbol on your machine or in

this Manual, be alert of the potential for personal
injury.
- Follow recommended precautions and safe
operating practices.

S0021

UNDERSTAND SIGNAL WORDS

• In this Manual you will find the following words:

- DANGER;
- WARNING;
- CAUTION.
referring to different hazard risks. DANGER
These words are always accompanied by the safety
alert symbol.
WARNING
DANGER: indicates an imminent hazardous
situation which, if not avoided, will result in death or
serious injury. CAUTION
WARNING: indicated a potential hazardous
situation which, if not avoided, could result in death or
serious injury. IMPORTANT
CAUTION: indicates a potential hazardous situation
which, if not avoided, may result in minor or moderate NOTE
injury.

IMPORTANT: indicates a situation which, if not

avoided, may cause damage to the machine.

NOTE: indicates an additional explanation for

information purposes.

ENVIRONMENTAL PROTECTION

• This Manual also contains this symbol

accompanying instructions for correct behaviour
as regards environmental protection.

S0024
S-2 EX255-EX285

SAFETY PRECAUTIONS

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 FIAT
KOBELCO 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 S0022
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.

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or an accident occurs.

- Keep the first-aid kit and fire extinguisher on
hand.
- Thoroughly read and understand the label
attached to the fire extinguisher to use it properly.
- Establish emergency priority procedures to cope
with fires and accidents.
- Keep emergency numbers for doctors,
ambulance service, hospitals and fire
department posted near the telephone.

S0023
EX255-EX285 S-3

SAFETY PRECAUTIONS

WEAR PROTECTIVE CLOTHING

• Wear close-fitting clothing and safety equipment

appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask.
Be sure to correctly wear equipment and clothing
for the job.
- Do not take any chances. S0025

- Avoid wearing loose clothing, jewellery, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
- Wear a suitable hearing protection such as
earmuffs or earplugs to protect objectionable or
uncomfortably loud noise.

S0026

INSPECT THE MACHINE

• Inspect the machine carefully every day or work-

shift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.

- In the walk-around inspection, be sure to cover all

points detailed in the Chapter "MAINTENANCE",
paragraph "EXTERNAL VISUAL INSPECTION"
of the OPERATION AND MAINTENANCE
S0027
INSTRUCTION MANUAL.
S-4 EX255-EX285

SAFETY PRECAUTIONS

USE HAND HOLDS AND STEPS

• Falling is one of the major causes of personal injury.

- When you get on and off the machine, always

face the machine and maintain a three-point
contact with the steps and handrails.

- Do not use any control as a handhold.

- Never jump off the machine. Never get on and

off a moving machine.
S0028
- Be careful of slippery conditions of platforms,
steps, and handrails when leaving the machine.

ADJUST THE OPERATOR'S SEAT

• A seat poorly adjusted for operator or work

requirements may quickly fatigue the operator
leading to improper operations.

- The seat should be adjusted whenever machine

operator changes.

- The operator should be able to fully press the

pedals and correctly move the control levers with
his back resting against the seat back.

- If not, move the seat fore and aft, and check

again.

S0029
EX255-EX285 S-5

SAFETY PRECAUTIONS

FASTEN SEAT BELT

• Should the machine overturn, the operator may

become injured and/or thrown from the cab. Not
only, the operator may be crushed by the
overturning machine resulting in serious injury or
even death.

- Prior to operating the machine, thoroughly

examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
S0030

- Be sure to remain seated with the seat belt

securely fastened at all times when the machine
is in operation to minimise injury hazard in case
of accident.

- After a significant accident, replace the seat belts

even though they do not look damaged.

MOVE AND OPERATE MACHINE

SAFELY

• Bystanders can be run over.

- Pay the utmost attention not to run over

bystanders.

- Be sure and aware of the location of bystanders

before moving, swinging or operating the
machine.

- If fitted, keep the travel alarm and horn sounding

to warn people that the machine is about to move.
S0031

- When operating, swinging, or moving the

machine in a congested area use a signal man.

- Co-ordinate hand signals before starting the

machine.
S-6 EX255-EX285

SAFETY PRECAUTIONS

OPERATE ONLY FROM THE DRIVER'S

SEAT

• Inappropriate engine starting procedures may

cause the machine unexpected movement,
possibly resulting in serious injury and even death.
- Start the engine only from the operator’s seat.

- NEVER start the engine while standing on the

track or on the ground.

- Do not start the engine by shorting across starter

motor terminals.
S0032
- Before starting the engine, ensure that all control
levers are in the neutral position.

KEEP RIDERS OFF THE MACHINE

• Riders on the machine are subject to injuries such

as being struck by foreign objects and being thrown
off the machine.

- Only machine operator is allowed on the

machine. Keep riders off.

- Riders also obstruct the operator’s visibility,

resulting in the machine being operated
unsafely.
S0033

CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN

• Incorrect travel controls operation may result in

serious injury and even death.

- Before driving the machine, be aware of the

undercarriage position relative to the operator’s
position. If travel motors are located at the front
of the cab, the machine will move reverse when
travel controls are moved towards cab front.
S0037
EX255-EX285 S-7

SAFETY PRECAUTIONS

AVOID INJURY FROM BACK-OVER AND

SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.

• To avoid back-over and swing accidents:

- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.

- Keep the travel alarm in working condition (if

equipped).

- ALWAYS BE ALERT FOR BYSTANDERS

S0042
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.

- USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.

- Use hand signals, which conform to your local

regulations, when work conditions require a
signal person.

- No machine motions shall be made unless S0043

signals are clearly understood by both signalman
and operator.

- Learn the meanings of all flags, signs, and

markings used on the job and confirm with the
person in charge of signalling.

- Keep windows, mirrors, and lights clean and in

good condition.

- Dust, heavy rain, fog, etc., can reduce visibility.

As visibility decreases, reduce speed and use
proper lighting.

- Read and understand all operating instructions in

the OPERATION AND MAINTENANCE
INSTRUCTION MANUAL.
S-8 EX255-EX285

SAFETY PRECAUTIONS

DRIVE MACHINE SAFELY

• Before starting the machine carefully read the

OPERATION AND MAINTENANCE INSTRUC-
TION MANUAL. (Refer to the OPERATING IN-
STRUCTIONS chapter).

• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.

- Pushing down on the front of the travel pedals or

S0038
pushing the levers forward moves the machine
towards the idlers. (Refer to the OPERATION
AND MAINTENANCE INSTRUCTION
MANUAL).

• Traveling on a grade may cause the machine to slip

or to overturn, possibly resulting in serious injury or
death.

- When traveling up or down a grade, keep the

bucket in the direction of travel, approximately 20
to 30 cm (A) above the ground.

- If machine starts to skid or becomes unstable,

lower the bucket immediately. S0039

- Traveling across the face of a slope may cause

the machine to skid or to overturn. When
travelling (ascending/descending) on a slope, be
sure to point the tracks uphill/downhill.

S0004

- Turning on an incline may cause the machine to

tip over.
If turning on an incline is absolutely unavoidable,
do so at a place where the slope is gentle and the
surface is firm.

- When operating on a grade and the fuel reserve

indicator light lights, immediately refuel.

WRONG
S0005
EX255-EX285 S-9

SAFETY PRECAUTIONS

AVOID OVERTURNING

• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death.

• To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the bucket low to the ground and close to
the machine.
- Reduce machine operating speed to avoid
tipping or slipping.
- Avoid changing direction when travelling on
grades. S0002
- NEVER attempt to travel across a grade steeper
than 15 degrees.
- Reduce swing speed as necessary when
swinging loads.

• Be careful when working on frozen ground.

- Temperature increases will cause the ground to
become soft and make ground travel unstable.

S0047

PARK MACHINE SAFELY

• To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Turn auto-idle (A/I) switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Pull the safety lever (pilot-control shut-off lever) to
the LOCK position.
- Close windows, roof window, and cab door.
- Lock all access doors and compartments. S0049
S-10 EX255-EX285

SAFETY PRECAUTIONS

AVOID INJURY FROM UNEXPECTED

MACHINE MOVEMENT

• Death or serious injury may result if you attempt to

get on or off a moving machine.

• To avoid roll-aways:
- Select level ground when possible to park
machine.
- Do not park the machine on a grade.
- Lower the bucket and/or other work tools to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
- Turn the auto-idle switch off.
- Run the engine at slow idle speed without load for
S0040
5 minutes to cool down the engine.
- Stop the engine and remove the key from the key
switch.
- Pull the pilot shut-off lever to LOCK position.
- Block both tracks.
- Position the machine to prevent overturning.
- Park a reasonable distance from other machines.

S0041

PROVIDE SIGNALS FOR JOBS

INVOLVING A NUMBER OF MACHINES

• For jobs involving several machines, provide

signals commonly known by all personnel involved.
Also, appoint a signal person to co-ordinate the job
site. Make sure that all personnel obey the signal
person’s directions.

S0036
EX255-EX285 S-11

SAFETY PRECAUTIONS

INVESTIGATE JOB SITE BEFORE HAND

• When working at the edge of an excavation or on

a road shoulder, the machine could overturn,
possibly resulting in serious injury or death.
- Investigate the configuration and ground
conditions of the job site beforehand to prevent
the machine from overturning and prevent the
ground, stockpiles, or banks from collapsing.
- Make a work plan. Use machines appropriate to
the work and job site.
- Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
- When working on an incline or road shoulder,
employ a signal person as required.
Confirm that your machine is equipped with a S0034

F.O.P.S. (Falling Object Protective Structure)

cab before working in areas where there is the
possibility of falling stones or landslides.
- When footing is weak, reinforce the ground
before starting the work.
- When working on frozen ground, be extremely
alert. As ambient temperature rises, footing
becomes loose and slipped.

PROTECT AGAINST FALLING STONES

AND LANDSLIDES

• Confirm that your machine is equipped with a

F.O.P.S. (Falling Object Protective Structure) cab
before working in areas where there is the
possibility of falling stones.

S0035
S-12 EX255-EX285

SAFETY PRECAUTIONS

DIG WITH CAUTION

• Accidental severing of underground cables or gas

lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
- Before digging, check the location of cables, gas
lines, and water lines.
- Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic
cable should be accidentally severed, do not look
into the end. Doing so may result in serious eye
injury.
- Contact local authorities and/or the utility
companies directly (electric power, gas,
telephone, water, sewers, telecommunications,
etc.) to obtain information about underground S0009

utility lines.

OPERATE WITH CAUTION

• If the front attachment or any other part of the

machine hits against an overhead obstacle, such
as a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury may
results as well.

- Take care to avoid hitting overhead obstacles

with the boom or arm.

S0008

AVOID ELECTRIC LINES

• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines. L
- When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m plus twice the line insulator length (L).
- Check and comply with any local regulations that
may apply.
- Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
- Keep all bystanders or co-workers away from the
site.

S0205
EX255-EX285 S-13

SAFETY PRECAUTIONS

KEEP PERSONNEL CLEAR FROM

WORKING AREA

• A person may be hit severely by the swinging front

attachment or counterweight and/or may be
crushed against an other object, resulting in serious
injury or death.

- Keep all persons clear from the area of operation

and machine movement.
- Before operating the machine, set up barriers to
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.

S0044

NEVER MOVE THE BUCKET OVER ANY

ONE

• Never lift, move, or swing bucket above anyone or

a truck cab.
Serious injury or machine damage may result due
to bucket load spill or due to collision with the
bucket.

S0045

AVOID UNDERCUTTING

• In order to retreat from the edge of an excavation if

the footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.

- If the footing starts to collapse and if sufficient

retreat is not possible, do not panic. Often, the
machine can be secured by lowering the front
attachment, in such cases.

S0011
S-14 EX255-EX285

SAFETY PRECAUTIONS

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could

occur causing serious injury or death.

S0048

SAFETY LOADS MOVING

• The excavator is no lifting and transportation

means, therefore it should not be used to position
loads accurately. Should it be exceptionally used to
lift and lay building components, special caution
must be taken as follows:

- The machine must be equipped without failure

with the appropriate variant supplied, upon
request, by FIAT KOBELCO. Also, totally comply
with the safety precautions for the operation of the
excavator as a lifting equipment.

- Secure the loads to be raised using cables or

chains fastened with appropriate hooking
mechanisms.

- Never hook cables or chains to the bucket teeth.

- Nobody should be allowed to remain under the

raised load or within the excavator operating
range for any reason whatever.
S0165

- Never exceed specified loading capacity.

Incorrect fastening of slings or chains may cause
boom/arm failure or failure of the lifting means
with consequent bodily injuries and even death.

- Always ensure that slings and chains used for

lifting are adequate to the load and in good
condition.

- All loading capacities are referred to the

machine on a level surface and should be
disregarded when working on a slope.
EX255-EX285 S-15

SAFETY PRECAUTIONS

SAFETY TRANSPORTING

• The danger of tipping is present when loading/

unloading the machine onto/from a truck or trailer
bed.
- Be sure to observe local regulations when
transporting the machine on public roads.
- Provide an appropriate truck or trailer for
transporting the machine.

• Take the following precautions when loading/

unloading the machine:
1. Select firm level ground.
2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when loading/ S0052

unloading the machine.

4. Always turn the auto-idle (A/I) switch OFF when
loading or unloading the machine, to avoid
unexpected speed increase due to unintentional
operation of a control lever.
5. Always select the slow speed mode with the
travel speed selector. In the high speed mode,
travel speed may automatically increase.
6. Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify travelling direction, and begin to
drive again.
7. Do not operate any levers besides the travel
levers when driving up or down the ramp.
8. The top end of the ramp where it meets the
flatbed is a sudden jolt. Take care when traveling
over it.
9. Prevent possible injury from machine tipping
while the upperstructure is rotating.
10. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11. Securely fasten machine frame using chains or
cables. Refer to “TRANSPORT” chapter in the
OPERATION AND MAINTENANCE
INSTRUCTION MANUAL for details.
S-16 EX255-EX285

SAFETY PRECAUTIONS

SAFE MAINTENANCE
• To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Kepp the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it is
in motion.
- Kepp hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Switch off the Auto-Idle (A/I).
4. Let the engine idle with no load for at least five
minutes until it has cooled down.
5. Move the key-start switch to the OFF position
to stop the engine.
6. Remove the ignition key from the start switch.
S0053
7. Apply the "Maintenance in progress" tag .
This tag can be applied o the left-hand control
lever, safety lever or cab door.
8. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
9. Let the engine cool down.
- Do not leave the machine unattended if servicing
requires the engine running .
- If the machine is to be raised, place boom and arm
at an angle 90 to 110°. Lock machine components
which should be raised for maintenance or repair
using suitable supporting means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary.
Refer to the the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL. S0054
- Keep all components in good condition and
properly install. Immediately repair any fault.
- Immediately repair any damage.Replace worn or
failed components. Remove grease, oil, debris
build-ups.
- Disconnect the negative cable (−) from the battery
before carry out any work on the electrical system
or arc-welding on the machine.
EX255-EX285 S-17

SAFETY PRECAUTIONS

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause

serious injury.

- Before performing any work on the machine,

attach a maintenance in progress tag. This tag
can be applied o the left-hand control lever,
safety lever or cab door.

S0055

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without

securing the machine first.

- Always lower the attachment or tool to the ground

before working on the machine.
- If you must work on a lifted machine or
attachment, securely support the machine or
attachment.
- Do not support the machine on cinder blocks,
bollow tires, or props that may crumble under
continuous load.
- Do not work under a machine that is supported S0054
solely by a jack.

STAY CLEAR OF MOVING PARTS

• Entanglements in moving parts can cause serious

injury.

• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working near
rotating parts.

S0056
S-18 EX255-EX285

SAFETY PRECAUTIONS

DISPOSE OF WASTE IN THE

APPROPRIATE MANNER

• Waste improperly disposed of represents a danger

for the envinronment. Potentially dangerous waste
used on the FIAT KOBELCO excavators includes
lubricants, fuel, coolant, brake fluid, filters and
batteries.

- Used sealed containers when discharging fluids.

Do not use containers for food or beverages
which may induce drinking.

- Do not spill waste over the ground, into drains, or

water beds.
S0064

- Obtain information about the correct methods to

recycle or dispose of waste from local
Authorities, collection centres or your Dealer.

WORK IN A CLEAN AREA

• Before starting an operation, clean the working

area.
Clear the area from all the objects that can be
dangerous for mechanics or people in the working
area.

S0166

PROPERLY LIGHT THE WORKING AREA

• Properly and safely light the working area.

- Use safe portable lamps in order to work inside

and under the machine.

- Make sure that the lamp is shielded by a cage;

the incandescent filament of a lamp, accidentally
broken, can cause fuel or oil fire. F1480

S0167
EX255-EX285 S-19

SAFETY PRECAUTIONS

REGULARLY WASH THE MACHINE

• Remove all the traces of grease, oil and deposits,

in order to avoid people accidents or damages to
things.

- Do not spray water or steam in the cab.

F1462 S0153

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

breakers and blades can fall and cause serious
injury or death.

- Securely store attachments and implements to

prevent falling.

- Keep bystanders away from storage areas.

F1463 S0058

PREVENT ACID SCALDS

• The sulphuric acid, contained in the battery, is
poisonous.
It is strong enough to scald the skin, corrode
clothes and cause blindness, if it is sprayed into
the eyes.
To avoid dangers:
- Fill the batteries in airy areas.
- Wear eye protections and rubber gloves.
- Avoid breathing the electrolyte vapours when
topping up.
- Avoid spilling or dripping the electrolyte.
- Use proper emergency starting techniques.
If you are touched with acid sprays:
- Rinse your skin well with water.
- Put on your skin sodium bicarbonate or clay to F1474 S0168

help the acid neutralization.

- Rinse your eyes with water for 10-15 minutes.
- Immediately see a doctor.
If you have swallowed the acid:
- Drink a big quantity of water or milk, swallow
milk of magnesia, scrabbled eggs or vegetal oil.
- Immediately see a doctor.
S-20 EX255-EX285

SAFETY PRECAUTIONS

STARTING THE ENGINE WITH

BOOSTER BATTERIES

• Battery gas may explode causing serious damages

and injuries.

- If the engine is to be started using booster

batteries, ensure to comply with all procedures
detailed in the chapter “OPERATING
INSTRUCTIONS” of the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL.

- The operator should be sitting in the driver’s seat

to keep the machine under control when the
engine starts. Starting the engine with booster
S0001
batteries is a two man operation.

- Do not use batteries that have been stored in the

cold for a long time.

- Mistakes in following procedures detailed for

starting the engine with slave batteries may
cause the batteries to explode or machine to
move unexpectedly.

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

- Keep sparks, lighted matches, and flames away

from the top of battery.

- Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.

- Do not charge a frozen battery; it may explode.

Warm battery to 16 °C.

• Battery electrolyte is poisonous. If the battery

should explode, battery electrolyte may be S0001

splashed into eyes, possibly resulting in blindness.

- Be sure to wear eye protection when checking

electrolyte specific gravity.
EX255-EX285 S-21

SAFETY PRECAUTIONS

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.

- To prevent possible injury from hot spraying

water. DO NOT remove the radiator cap until the
engine is cool. When opening, turn the cap slowly
to the stop. Allow all pressure to be released
before removing the cap.
- The hydraulic oil tank is pressurized. Again, be S0019

sure to release all pressure before removing the

cap.

Hot fluids and surfaces:

• Engine oil, reduction gear oil and hydraulic oil also

become hot during operation.
The engine, hoses, lines and other parts become
hot as well.

- Wait for the oil and components to cool down

before starting any maintenance or inspection
work.

S0059

KEEP CLEAN THE MACHINE

Keep clean the engine compartment, radiator,

batteries, hydraulic pipes, fuel tank and operator's
position.
The engine compartment temperature can quickly
rise, after stopping the engine.
IN THESE CASES, BE CAREFUL TO POSSIBLE
FIRES.
Open the access doors in order to quicken the engine
cooling process and clean the compartment.

S0177
S-22 EX255-EX285

SAFETY PRECAUTIONS

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.

- Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
SA0016

- Tighten all connections before applying

pressure.

- Search for leaks with a piece of cardboard; take

care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles for
eye protection.
SA0017
- In an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.

SA0018

PREVENT PARTS FROM FLYING OFF

• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result
in serious injury, blindness, or death.

- NEVER attempt to remove GREASE FITTING

or VALVE ASSEMBLY.
- As pieces may fly off, be sure to keep body and
face away from valve.

• Travel reduction gears are under pressure. F3635

S0178
- As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. REDUCTION GEAR OIL is hot. Wait for
gear oil to cool down, then gradually loosen the air
release plug to release pressure.
EX255-EX285 S-23

SAFETY PRECAUTIONS

PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body,

serious injury may result.

- Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.

S0046

HANDLE FLUIDS SAFELY - AVOID FIRES

• Handle fuel with care: it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.

- Do not refuel the machine while smoking or when

near open flame or sparks.
- Always stop the engine before refuelling the
machine.
- Fill the tank outdoors.

S0050
• All fuels, most lubrificants, and some antifreeze
fluids are flammable.

- Store flammable fluids well away from fire

hazards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn
spontaneously.

S0051
S-24 EX255-EX285

SAFETY PRECAUTIONS

PREVENT FIRES

• Check for Oil Leaks:

- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other,
damage to the oil-cooler, and loose oil-cooler
flange bolts which may cause oil leaks.
- Tighten, repair or replace any missing, loose or S0051
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.

• Check for Shorts circuits which could cause fires:

- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..

• Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.

• Check Key-start Switch:

- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF position
to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.

• Check Heat Shields:

- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
EX255-EX285 S-25

SAFETY PRECAUTIONS

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the

following way:

- Stop the engine by turning the key-start switch to

the OFF position if there is time.

- Use a fire extinguisher if there is time.

- Exit the machine.

S0060

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.

- If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.

S0061

USE APPROPRIATE TOOLS

• Use tools appropriate for the job to be performed.

- Inappropriate tools, parts and procedures might

generate dangerous conditions.

- Use tools of correct size to tighten or loosening

securing elements, in order to avoid injuries
caused by a wrench getting out of control.

- Do not use U.S. Standard or British Standard

tools on metric fasteners and vice versa.

• Use only FIAT KOBELCO genuine spare parts

(please refer to the PARTS CATALOG). S0120
S-26 EX255-EX285

SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.

Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable ma-
terials.

Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area. Install tem-
porary fire resistant guards to protect hoses or other
materials when welding, soldering, etc.

S0062

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

- Do not weld or flame cut pipes or tubes that contain

flammable fluids.

- Clean them thoroughly with non-flammable solvent

before welding or flame cutting them.

REMOVE PAINT BEFORE WELDING OR

HEATING

• Hazardous fumes can be generated when paints is

heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.

- Avoid breathing potentially toxic fumes and dust.

- Do all such work outside or in a well-ventilated

area.

- Dispose of paint and solvents properly.

- Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the S0063
dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
TECHNICAL MANUAL EX255-EX285

TROUBLESHOOTING

SECTION AND GROUP CONTENTS

Section 4 - OPERATIONAL PERFORMANCE TEST

Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test

Section 5 - TROUBLESHOOTING

Group 1 Diagnosing Procedure

Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Electrical System Inspection
Group 7 Harness Check
SECTION 4 EX255-EX285

OPERATIONAL PERFORMANCE

CONTENTS

Group 1 - Introduction Group 5 - Component Test

Operational performance test ............... T4-1-1
Preparation for performance tests ........ T4-1-2
Group 2 - Standard
EX255 Operational Performance
standard tables .................................... T4-2-1
EX255 Main pump P-Q diagram ........... T4-2-5
EX285 Operational Performance
standard tables .................................... T4-2-6
EX285 Main pump P-Q diagram ........... T4-2-10
Primary pilot pressure .......................... T4-5-1
Secondary pilot pressure ..................... T4-5-3
Solenoid valve set pressure ................. T4-5-4
Main pump delivery pressure ............... T4-5-6
Main relief valve set pressure .............. T4-5-7
Overload relief valve set
pressure ............................................... T4-5-11
Main pump flow test ............................. T4-5-14
Swing motor drainage ........................... T4-5-18
Travel motor drainage ........................... T4-5-20

Group 3 - Engine Test

Engine speed ....................................... T4-3-1

Engine check and adjustment .............. T4-3-3

Group 4 - Excavator Test

Travel speed ......................................... T4-4-1

Track revolution speed ......................... T4-4-2
Mistrack check .................................... T4-4-3
Travel parking function
check ................................................... T4-4-4
Swing speed ........................................ T4-4-5
Swing function drift check .................... T4-4-6
Swing motor leakage ............................ T4-4-7
Swing bearing play ............................... T4-4-8
Maximum swingable slant
angle .................................................... T4-4-9
Hydraulic cylinder cycle time ............... T4-4-10
Dig function drift check ........................ T4-4-12
Control lever operating force ................ T4-4-13
Control lever stroke .............................. T4-4-14
Combined boom raise/swing
function check ..................................... T4-4-15
EX255-EX285 T4-1-1

INTRODUCTION

OPERATIONAL PERFORMANCE TEST

Use operational performance test procedure to quan-

titatively check all system and functions on the ma-
chine.

Purpose of Performance Tests

1. To comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machine’s performance to the desired
standard.
3. To economically operate the machine under opti-
mal conditions.

Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the
operational performance of each component
such as hydraulic pump, motor, and various kinds
of valves.

Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.

Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.

The machine performance does not always deterio-

rate as the working hours increase. However, the
machine performance is normally considered to re-
duce in proportion to the increase of the operation
hours. Accordingly, restoring the machine perform-
ance by repair, adjustment, or replacement shall
consider the number of the machine’s working hours.

Definition of “Performance Standard”

1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.
T4-1-2 EX255-EX285

INTRODUCTION

PREPARATION FOR PERFORMANCE

TESTS

Observe the following rules in order to carry out

performance tests accurately and safely.

THE MACHINE
1. Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on,
before starting to test.

TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make
a full swing with the front attachment extended.
3. If required, rope off the test area and provide
SM0131
signboards to keep unauthorized personnel
away.

PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among
coworkers. Once the test is started, be sure to
communicate with each other using these signals,
and to follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.

MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance SM3026
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
EX255 T4-2-1

STANDARD

EX255 OPERATIONAL PERFORMANCE

STANDARD TABLES

The standard Performance values related to excava- indicated below as the preconditions of performance
tor test are listed in the table 1 shown below. In table tests unless otherwise instructed in each perform-
2 are listed the standard performance related to ance test procedure:
component test. Engine Control Dial : Fast Idle
Refer to the Group T4-3 to T4-5 for performance test E Mode Switch : OFF
procedures. HP Mode Switch : OFF
Values indicated in parentheses are reference val- Work Mode Switch : General Purpose Mode
ues. Hydraulic Oil Temperature : 50 ± 5 °C (122 ± 9 °F)
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as NOTE - 1 kgf = 9.807 N
Table 1 - Excavator performance (EX255)

Ref. Performance test designation Performance Remarks

pag. standard
EX255

ENGINE SPEED (rpm)

Fast idle speed with E and HP modes

OFF 2180 ± 100

Fast idle speed with E mode ON 1980 ± 50

Fast idle speed with HP mode ON 50 or more higher Extend the arm cylinder to
T4-3-1/2

than fast idle speed relieve the arm roll-in circuit

measured with E
and HP modes
OFF and arm roll-in
circuit relieved

Slow idle speed 850 ± 100

Auto-idle speed (A/I) 1200 ± 100

ENGINE COMPRESSION PRESSURE 3 (31) With the engne hot

MPa (kgf/cm2) (approx. 75 °C)
– Allowable limit: 2.5 (26)
– Difference cylinder pressure
compression exceeding
200 kPa (2.0 kgf/cm2) is
inacceptable
T4-3-3

VALVE CLEARANCE
(IN, EX) (mm) 0.4 With the engine cold

NOZZLE INJECTION PRESSURE 18.1 (185)

MPa (kgf/cm2)

INJECTION TIMING
(Before TDC) (deg.) 8°
T4-2-2 EX255

STANDARD

Ref. Performance test designation Performance Remarks

pag. standard
EX255

TRAVEL SPEED (s/20 m)

T4-4-1

Fast speed 13.2 ± 1

Slow speed 20 ± 2

TRACK REVOLUTION
SPEED (s/3 rev)
T4-4-2

EX255 26.5 ± 2 Travel slow speed only

EX255 LC 28.8 ± 2
T4-4-3

MISTRACK (mm/20 m)
(With fast and slow travel speed modes) 200 or less

TRAVEL PARKING FUNCTION

T4-4-4

CHECK (rev) 1/6 or less

Travel motor
leak (mm/5 min) 0
T4-4-5

SWING SPEED
(s/3 rev) 13.3 ± 1

SWING FUNCTION DRIFT

T4-4-6

CHECK (mm/180°) 1500 or less 2950 arm (Mono) or 2158 arm

(Triple articulation) and 1.1 m3
bucket (SAE heaped)
T4-4-7

SWING MOTOR 2950 arm (Mono) or 2158 arm

LEAKAGE (mm/5 min) 0 (Triple articulation) and 1.1 m3
bucket (SAE heaped)
T4-4-9 T4-4-8

SWING BEARING PLAY

(mm) 1.3 or less Allowable limit: 4.3 mm

MAXIMUM SWINGABLE SLANT 2950 arm (Mono) and 1.1 m3

ANGLE (deg.) 19.2° or more bucket (SAE heaped)

HYDRAULIC CYLINDER (s) 2950 arm (Mono) or 2158 arm

CYCLE TIME (Triple articulation) and 1.1 m3
bucket (SAE heaped)
Boom Raise 3.1 ± 0.3
(Mono version) Lower 2.5 ± 0.3
Boom (Triple Raise 4.1 ± 0.3
articulation version) Lower 3.6 ± 0.3
T4-4-10

Arm Roll-in 3.9 ± 0.3

Roll-out 2.6 ± 0.3
Bucket Roll-in 4.1 ± 0.3
Roll-out 2.5 ± 0.3
Positioning (Triple Roll-in 6.0 ± 0.3
ariticulation version) Roll-out 3.9 ± 0.3
EX255 T4-2-3

STANDARD

Ref. Performance test designation Performance Remarks

pag. standard
EX255

DIG FUNCTION DRIFT 2950 arm (Mono) or 2158 arm

CHECK (mm/5 min) (Triple articulation) and 1.1 m3
bucket (SAE heaped)
Boom cylinder 20 or less
T4-4-12

Positioning cylinder
(Triple articulation version) 20 or less

Arm cylinder 20 or less

Bucket cylinder 20 or less

Total drop Mono 150 or less

Triple articulation 150 or less

CONTROL LEVER OPERATING

FORCE (kgf)

Boom lever 2.0 or less

T4-4-13

Arm lever 2.0 or less

Bucket lever 1.7 or less

Swing lever 1.7 or less

Travel lever 2.5 or less

CONTROL LEVER STROKE (mm)

Boom lever 105 ± 10

T4-4-14

Arm lever 105 ± 10

Bucket lever 83 ± 10

Swing lever 83 ± 10

Travel lever 115 ± 10

BOOM RAISE/SWING (s) 3.7 ± 0.3 2950 arm (mono) and 1.1 m3
(Bucket empty) bucket (SAE heaped)
T4-4-15

Bucket teeth height: H (mm)

Mono 6700 or more

NOTE - 1 kgf = 9.807 N.

T4-2-4 EX255

STANDARD

Table 2 - Component performance standard (EX255)

Ref. Performance test designation Performance Remarks

pag. standard
EX255
T4-5-1

PRIMARY PILOT
PRESSURE (kgf/cm2) 40 +10
–5 (Engine: Fast idle)

SECONDARY PILOT (Engine: Fast idle and slow idle)

T4-5-3

PRESSURE (kgf/cm2) (34 ÷ 40) Value indicated on Dr. EX (Lever:

Full stroke)
T4-5-6 T4-5-4

SOLENOID VALVE SET (kgf/cm2) Value indicated on

PRESSURE Dr. EX ± 2

MAIN PUMP DELIVERY

PRESSURE (kgf/cm2) 25 +15
–7 Value indicated on Dr. EX

MAIN RELIEF VALVE SET

PRESSURE (kgf/cm2)

Boom, Arm and Bucket 350 +20

–5
Value indicated on Dr. EX
T4-5-7

Swing 330 +20

–5 Value indicated on Dr. EX

Travel 350 +20

–5 Value indicated on Dr. EX

Power Boost 370 +20

–10
Value indicated on Dr. EX

OVERLOAD RELIEF VALVE

SET PRESSURE (kgf/cm2) Reference values
at 50 L/min
T4-5-11

Boom (raise/lower), arm roll-in and

bucket roll-in 380 +10
–0

Arm roll-out and

bucket roll-out 400 +10
–0
T4-5-14

MAIN PUMP FLOW

TEST (L/min) –– Refer to page T4-2-5

SWING MOTOR DRAINAGE

T4-5-18

With constant maximum speed (L/min) 0.2 ÷ 1.0 Allowable limit: 2.0

With the motor

relieved (L/min) 8 Allowable limit: 16

TRAVEL MOTOR DRAINAGE

T4-5-20

With the track jacked up (L/min) 1.5 ÷ 2.0 Allowable limit: 3.4

With the motor

relieved (L/min) (1.5 ÷ 4.8) Allowable limit: (5.2)

NOTE - 1 kgf/cm2 = 0.09807 MPa.

EX255 T4-2-5

STANDARD

EX255 MAIN PUMP P-Q DIAGRAM Points on P-Q Line

(Reference: Measured at Test Stand)
Delivery Pressure Flow Rate
• Rated Engine Speed : 2000 min–1 (rpm) kgf/cm2 L/min
• Hydraulic Oil Temperature : 50 ± 5 °C A 144 196+3
–6
B 202 (154)
C 354 84 ± 10
NOTE - Refer to T4-5-14. D 370 –

The value indicated in parentheses is only a refer-

ence value.

NOTE - 1 kgf/cm2 = 0.09807 MPa.

L/min
A
•

▲
B
•

Flow
Rate
(Q1 + Q2) / 2 C
•
D
•

Delivery Pressure (P1 + P2) / 2 kgf/cm2

▲

SM3027
T4-2-6 EX285

STANDARD

EX285 OPERATIONAL PERFORMANCE

STANDARD TABLES
The standard Performance values related to excava- indicated below as the preconditions of performance
tor test are listed in the table 1 shown below. In table tests unless otherwise instructed in each perform-
2 are listed the standard performance related to ance test procedure:
component test. Engine Control Dial : Fast Idle
Refer to the Group T4-3 to T4-5 for performance test E Mode Switch : OFF
procedures. HP Mode Switch : OFF
Values indicated in parentheses are reference val- Work Mode Switch : General Purpose Mode
ues. Hydraulic Oil Temperature : 50 ± 5 °C (122 ± 9 °F)
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as NOTE - 1 kgf = 9.807 N
Table 1 - Excavator performance (EX285)

Ref. Performance test designation Performance Remarks

pag. standard
EX285

ENGINE SPEED (rpm)

Fast idle speed with E and HP modes

OFF 2230 ± 100

Fast idle speed with E mode ON 2030 ± 50

Fast idle speed with HP mode O 50 or more higher Extend the arm cylinder to
T4-3-1/2

than fast idle speed relieve the arm roll-in circuit

measured with E
and HP modes
OFF and arm roll-in
circuit relieved

Slow idle speed 900 ± 100

Auto-idle speed (A/I) 1200 ± 100

ENGINE COMPRESSION PRESSURE 3 (31) With the engne hot

MPa (kgf/cm2) (approx. 75 °C)
– Allowable limit: 2.5 (26)
– Difference cylinder pressure
compression exceeding
200 kPa (2.0 kgf/cm2) is
inacceptable
T4-3-3

VALVE CLEARANCE
(IN, EX) (mm) 0.4 With the engine cold

NOZZLE INJECTION PRESSURE 18.1 (185)

MPa (kgf/cm2)

INJECTION TIMING
(Before TDC) (deg.) 8°
EX285 T4-2-7

STANDARD

Ref. Performance test designation Performance Remarks

pag. standard
EX285

TRAVEL SPEED (s/20 m)

T4-4-1

Fast speed 14.1 ± 1.0

Slow speed 23.2 ± 2.0

TRACK REVOLUTION
SPEED (s/3 rev)
T4-4-2

EX285 32.5 ± 2.0 Travel slow speed only

EX285 LC 34.5 ± 2.0
T4-4-3

MISTRACK (mm/20 m)
(With fast and slow travel speed modes) 200 or less

TRAVEL PARKING FUNCTION

T4-4-4

CHECK (rev) 1/6 or less

Travel motor
leak (mm/5 min) 0
T4-4-5

SWING SPEED
(s/3 rev) 16 ± 1.0

SWING FUNCTION DRIFT

T4-4-6

CHECK (mm/180°) 1300 or less 3100 arm (Mono) or 2120 arm

(Triple articulation) and 1.05 m3
bucket (SAE heaped)

SWING MOTOR 3100 arm (Mono) or 2120 arm

T4-4-9 T4-4-8 T4-4-7

LEAKAGE (mm/5 min) 0 (Triple articulation) and 1.05 m3

bucket (SAE heaped)

SWING BEARING PLAY

(mm) 1.3 or less Allowable limit: 4.3 mm

MAXIMUM SWINGABLE SLANT 18,7° or possibly 3100 arm (Mono) and 1.05 m3
ANGLE (deg.) more bucket (SAE heaped)

HYDRAULIC CYLINDER (s) 3100 arm (Mono) or 2120 arm

CYCLE TIME (Triple articulation) and 1.05 m3
bucket (SAE heaped)
Boom Raise 3.4 ± 0.3
(Mono version) Lower 2.7 ± 0.3
Boom (Triple Raise 5.0 ± 0.3
T4-4-10

(articulation version) Lower 4.1 ± 0.3

Arm Roll-in 3.9 ± 0.3
Roll-out 2.8 ± 0.3
Bucket Roll-in 4.5 ± 0.3
Roll-out 2.7 ± 0.3
Positioning (Triple Roll-in 6.0 ± 0.3
ariticulation version) Roll-out 4.4 ± 0.3
T4-2-8 EX285

STANDARD

Ref. Performance test designation Performance Remarks

pag. standard
EX285

DIG FUNCTION DRIFT 3100 arm (Mono) or 2120 arm

CHECK (mm/5 min) (Triple articulation) and 1.05 m3
bucket (SAE heaped)

Boom cylinder 20 or less

T4-4-12

Positioning cylinder
(Triple articulation version) 15 or less

Arm cylinder 20 or less

Bucket cylinder 15 or less

Total drop Mono 150 or less

Triple articulation 150 or less

CONTROL LEVER OPERATING

FORCE (kgf)

Boom lever 2.0 or less

T4-4-13

Arm lever 2.0 or less

Bucket lever 1.7 or less

Swing lever 1.7 or less

Travel lever 2.5 or less

CONTROL LEVER STROKE (mm)

Boom lever 105 ± 10

T4-4-14

Arm lever 105 ± 10

Bucket lever 83 ± 10

Swing lever 83 ± 10

Travel lever 115 ± 10

BOOM RAISE/SWING (s) 3.8 ± 0.3 3100 arm (mono) and 1.05 m3
(Bucket empty) bucket (SAE heaped)
T4-4-15

Bucket teeth height: H (mm) 7000 or more

NOTE - 1 kgf = 9.807 N.

EX285 T4-2-9

STANDARD

Table 2 - Component performance standard (EX285)

Ref. Performance test designation Performance Remarks

pag. standard
EX285
T4-5-1

PRIMARY PILOT
PRESSURE (kgf/cm2) 40 +10
–5
(Engine: Fast idle)

SECONDARY PILOT Engine: Fast idle and slow idle)

T4-5-3

PRESSURE (kgf/cm2) (34 ÷ 40) Value indicated on Dr. EX

(Lever: Full stroke
T4-5-6 T4-5-4

SOLENOID VALVE SET Value indicated on

PRESSURE (kgf/cm2) Dr. EX ± 2

MAIN PUMP DELIVERY

PRESSURE (kgf/cm2) 25 –+15
7
Value indicated on Dr. EX

MAIN RELIEF VALVE SET

PRESSURE (kgf/cm2)

Boom, Arm and Bucket 350 +20

–5
Value indicated on Dr. EX
T4-5-7

Swing 292 +20

–5 Value indicated on Dr. EX

Travel 350 +20

–5 Value indicated on Dr. EX

+20
Power Boost 370 –10 Value indicated on Dr. EX

OVERLOAD RELIEF VALVE

SET PRESSURE (kgf/cm2) Reference values
at 50 L/min
T4-5-11

Boom (raise/lower), arm roll-in and

bucket roll-in 380 +10
–0

Arm roll-out and

bucket roll-out 400 +10
–0
T4-5-14

MAIN PUMP FLOW

TEST (L/min) –– Refer to page T4-2-5

SWING MOTOR DRAINAGE

T4-5-18

With constant maximum speed (L/min) –– Allowable limit: 2.0

With the motor

relieved (L/min) –– Allowable limit: 31

TRAVEL MOTOR DRAINAGE

T4-5-20

With the track jacked up (L/min) (3.0) Measured at test stand

With the motor

relieved (L/min) (6.0) Measured at test stand

NOTE - 1 kgf/cm2 = 0.09807 MPa.

T4-2-10 EX285

STANDARD

EX285 MAIN PUMP P-Q DIAGRAM Points on P-Q Line

(Reference: Measured at Test Stand)
Delivery Pressure Flow Rate
• Rated Engine Speed : 2050 min–1 (rpm) kgf/cm2 L/min
+3
• Hydraulic Oil Temperature : 50 ± 5 °C A 150 207–6
B 206 (160)
C 354 84 ± 10
NOTE - Refer to T4-5-14. D 370 (76)

The value indicated in parentheses is only a refer-

ence value.

NOTE - 1 kgf/cm2 = 0.09807 MPa.

L/min
A
•

▲
B
•

Flow
Rate
(Q1 + Q2) / 2 C
•
D
•

Delivery Pressure (P1 + P2) / 2 kgf/cm2

▲

SM3027
EX255-EX285 T4-3-1

ENGINE TEST

ENGINE SPEED

Summary:
1. Use Dr.EX. if Dr.EX is not available, use an engine
tachometer.
3
2. Measure the engine speeds in each mode.

NOTE - Measure the engine speed before perform-

ing all other tests to check that the engine speed
meets specification. Because, if the engine speed is
not adjusted correctly, all other performance data will
be unreliable.

Preparation: 2
1. Connect Dr.EX to the diagnosing connector be-
side the fuse box located behind the operator’s
seat, and select the monitor function. When using
an engine tachometer, install speed pickup (2) to
injection pipe (3).

2. Warm up the machine until the engine coolant

temperature reaches 50 °C (122 °F) or more, and
hydraulic oil is 50 ± 5 °C (122 ± 9 °F). 1
SM5401

IMPORTANT - Never attempt to the readjust stopper

(1).
T4-3-2 EX255-EX285

ENGINE TEST

Measurement: E Mode
Switch
1. No Load Engine Speed HP Mode
Switch
1-1. Measure the engine slow idle speed, fast
idle speed (in normal mode), and fast idle
speeds (in both E and HP modes).
1-2. Select the switch positions as shown be-
low.
1-3. Start measurement from the slow idle
speed.
1-4. Measure while changing the engine control
dial, E mode switch, and HP mode switch.

Engine E Mode HP Mode Auto- Work

Control Switch Switch Idle Mode
Dial Switch Switch
Slow Idle OFF OFF OFF General
Purpose
Mode
Fast Idle OFF OFF OFF General
(Normal Purpose
Mode) Mode
Fast Idle ON OFF OFF General
(E Mode) Purpose
Mode
Fast Idle OFF ON OFF General
(HP Mode) Purpose Engine
Control Dial SM0631
Mode

2. No Load Auto-Idle Speed

2-1. Select the switch positions as shown be-
low.

Engine E Mode HP Mode Auto- Work

Control Switch Switch Idle Mode
Dial Switch Switch
Fast OFF OFF ON General
Idle Purpose
Mode

2-2. Start the engine and operate the bucket

lever.
2-3. Return the lever to the neutral position.
Wait approx. 4 seconds until the engine
speed is automatically reduced. Then,
measure the reduced engine speed.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Auto-Idle
Switch Work Mode
Switch

SM0612
EX255-EX285 T4-3-3

ENGINE TEST

ENGINE CHECK AND ADJUSTMENT

To perform the compression pressure measure-

ment, the check and adjustment of valve clearance,
the check of injection nozzle and check and adjust-
ment of injection timing, make reference to the Work-
shop Manual - Section 5.
T4-3-4 EX255-EX285

ENGINE TEST

NOTES
EX255-EX285 T4-4-1

EXCAVATOR TEST

TRAVEL SPEED

Summary:
Measure the time required for the excavator to travel
a 20 m (65.6 ft) test track.

Preparation:
1. Adjust the track sag on both side tracks equally.
2. Prepare a flat and solid test track 20 m (65.6 ft) in Arm Rolled-In, Bucket Rolled-In
End
length with extra length of 3 to 5 m (9.8 to 16 ft) on Bucket Height: 0.3 to 0.5 m
both ends for machine acceleration and decelera-
tion. Start
20 m Deceleration
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the
Zone
ground with the arm and bucket rolled-in. 3 to 5 m
4. Maintain hydraulic oil temperature at 50 ± 5 °C Acceleration
(122 ± 9 °F). Zone
3 to 5 m

SM0138
Measurement:
1. Measure both the slow and fast speeds of the
machine.
2. Select the following switch positions:

Travel Engine E Mode HP Mode Work Auto-Idle

Mode Control Switch Switch Mode Switch
Switch Dial Switch
Slow Fast OFF OFF General OFF
Mode Idle Purpose
Mode
Fast Fast OFF OFF General OFF
Mode Idle Purpose
Mode

3. Start traveling the machine in the acceleration

zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6 ft).
5. After measuring the forward travel speed, turn the
upperstructure 180° and measure the reverse
travel speed.
6. Repeat steps 4. to 5. three times in each direction
and calculate the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-2 EX255-EX285

EXCAVATOR TEST

TRACK REVOLUTION SPEED

Summary:
Measure the track revolution cycle time with the track
raised off ground.

Preparation:
1. Adjust the track sag of both side tracks to be
equal.
2. On the track to be measured, mark one shoe with 90 ÷ 110°
chalk.
3. Swing the upperstructure 90° and lower the
bucket to raise the track off ground. Keep the
boom-arm angle between 90 to 110° as shown.
Place blocks under the machine frame. Mark

SM0139
WARNING
Securely support the raised track using wooden
blocks.

4. Maintain the hydraulic oil temperature at 50 ± 5 °C

(122 ± 9 °F).

Measurement:
1. Select the following switch positions:

Travel Engine E Mode HP Mode Work Auto-Idle

Mode Control Switch Switch Mode Switch
Switch Dial Switch
Slow Fast OFF OFF General OFF
Mode Idle Purpose
Mode
Fast Fast OFF OFF General OFF
Mode Idle Purpose
Mode

2. Operate the travel control lever of the raised track

to full stroke.
3. Measure the time required for 3 revolutions in both
directions after a constant track revolution speed
is obtained.
4. Raise the other side and repeat the above proce-
dures.
5. Repeat steps 2. to 4. three times and calculate the
average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

NOTE - The measurement data obtained through the

raised track revolution test may have wide variations.
Therefore, the evaluation based on the results ob-
tained from the 20 m travel speed check described
before is more recommendable.
EX255-EX285 T4-4-3

EXCAVATOR TEST

MISTRACK CHECK

Summary:
1. Allow the machine to travel 20 m (65.5 ft). Meas-
ure the maximum tread deviation from the tread
chord line drawn between the travel start and end Maximum Distance
points to check the performance equilibrium be-
tween both sides of the travel device systems
(from the main pump to the travel motor). Acceleration
2. If measured on a concrete surface, the tread Zone:
deviation has a trend to decrease. 3 to 5 m
20 m
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.5 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and decel- SM0140
eration.
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the
ground with the arm and bucket rolled in.
4. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

Measurement:
1. Measure the amount of mistracking in both fast,
and slow travel speeds.
2. Select the following switch positions:

Travel Engine E Mode HP Mode Work Auto-Idle

Mode Control Switch Switch Mode Switch
Switch Dial Switch
Slow Fast OFF OFF General OFF
Mode Idle Purpose
Mode
Fast Fast OFF OFF General OFF
Mode Idle Purpose
Mode

3. Start traveling the machine in the acceleration

zone with the travel levers at full stroke.
4. Measure the maximum distance between a
straight 20 m (65.5 ft) tread chord line and the
tread made by the machine.
5. After measuring the tracking in forward travel, turn
the upperstructure 180° and measure in reverse
travel.
6. Repeat steps 3. to 5. three times and calculate the
average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-4 EX255-EX285

EXCAVATOR TEST

TRAVEL PARKING FUNCTION CHECK

Summary:
To measure the parking brake function on a specified
slope.

Preparation:
1. The surface of the test slope shall be even with a
gradient of 20% (11.31°).
0,2 ÷ 0,3 m
2. Mark a white line on the travel device cover.
3. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above the
ground with the arm and bucket fully rolled in.
4. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

SM0141
Measurement:
1. Measure in the fast travel mode.
2. Select the following switch positions:

Travel Engine E Mode HP Mode Work Auto-Idle Position where the machine
comes to a stop Position when the travel
Mode Control Switch Switch Mode Switch levers are in neutral
Switch Dial Switch Displacement
(Revolution Angle)
Fast Fast OFF OFF General OFF
Mark
Mode Idle Purpose
Mode

3. Measure the displacement (revolution angle) of

the travel device cover until the parking brake is
applied.
3-1. Climb the slope and place the travel levers in
SM0142
neutral.
3-2. Measure the displacement from the mark
position on the travel device cover when the
levers are placed in neutral to that position
when the machine stops moving.
4. Measure the travel parking brake slip amount
while parked.
4-1. Climb the slope and place the travel levers in
neutral.
4-2. Stop the engine.
Alignment marks on the track
4-3. After the machine stops, put alignment side frame and shoe when the
marks on a track link or shoe, and the track machine comes to a stop
side frame. Displacement measured
after 5 minutes
4-4. After 5 minutes, measure the distance be-
tween the marks on the track link or shoe and
the track side frame. SM0143

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
EX255-EX285 T4-4-5

EXCAVATOR TEST

SWING SPEED

Summary:
Measure the time required to swing three complete
turns.

Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on
slopes.
3. With the arm rolled out and bucket rolled in, hold
The same height as the
the bucket so that the height of the bucket pin is boom foot pin height
the same as the boom foot pin. The bucket must
be empty.
4. Maintain the hydraulic oil temperature at 50 ± 5 °C
SM0144
(122 ± 9 °F).

WARNING
Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of the
swing area before starting the measurement.

Measurement:
1. Select the following switch positions:

Engine E Mode HP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF OFF General OFF
Idle Purpose
Mode

2. Operate swing control lever fully.

3. Measure the time required to swing 3 turns in one
direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
5. Repeat steps 2. to 4. three times and calculate the
average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-6 EX255-EX285

EXCAVATOR TEST

SWING FUNCTION DRIFT CHECK

Summary:
Measure the swing drift on the bearing outer circum-
ference when stopping after a 180° full-speed swing.

Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on a
slope. Two chalk marks
3. With the arm rolled out and bucket rolled in, hold SM0145
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180°.
6. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

WARNING
Prevent personal injury. Always make sure that SM0146
the area is clear and that coworkers are out of the
swing area before starting the measurement.

Measurement:
1. Select the following switch positions: Measure difference between marks

Engine E Mode HP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF OFF General OFF
Idle Purpose Marking on the Track Frame
Mode
Marking on the Swing Bearing
2. Operate the swing control lever fully and return it SM0147
to the neutral position when the mark on the
upperstructure aligns with that on the track frame
after swinging 180°.
3. Measure the distance between the two marks.
4. Align the marks again, swing 180°, then test in the
opposite direction.
5. Repeat steps 3. to 5. three times each and calcu-
late the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
EX255-EX285 T4-4-7

EXCAVATOR TEST

SWING MOTOR LEAKAGE

Summary:
Check for upperstructure drift while suspending a
load on a slope.

Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 %.
3. Load bucket fully. In lieu of loading the bucket,
weight (W: tons) of the following specification can
be used.
W = M x 1.5
where: M = Bucket heaped capacity (m3) SM0148
1.5 = Soil specific gravity
4. With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as illus-
trated.
6. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

Measurement:
1. Select the following switch position:

E Mode HP Mode Work Auto-

Measure difference between marks
Switch Switch Mode Idle
Switch Switch
OFF OFF General OFF
Purpose
Mode

Marking on the Track Frame

2. Maintain the engine at slow idle. After five min-
utes, measure the difference between the marks
along the swing bearing periphery and the track Marking on the Swing Bearing
frame. SM0147

3. Perform the measurement in both right and left

swing directions.
4. Perform the measurement three times in each
direction and calculate the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-8 EX255-EX285

EXCAVATOR TEST

SWING BEARING PLAY

Summary:
Measure the swing bearing play using a dial gauge to
check the wear of bearing races and balls.

Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
SM0149
3. Install a dial gauge on the track frame as shown,
using a magnetic base.
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.

Measurement:
1. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to raise
the front idler 0.5 m (20 in). Record the dial gauge
reading (h2).
3. Calculate bearing play (H) from this data (h1 and
h2) as follows:
H=h2-h1
SM0150

Measurement: (h1) Measurement: (h2)

The same height as the

boom foot pin height

SM0144 SM0152

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
EX255-EX285 T4-4-9

EXCAVATOR TEST

MAXIMUM SWINGABLE SLANT ANGLE

Summary:
With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.

Preparation:
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket,
weight (W: tons) of the following specification can
be used.
W = M x 1.5
SM0148
where: M = Bucket heaped capacity (m3)
1.5 = Soil specific gravity
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the arm top
pin to the position flush with the boom foot pin
height.
4. Climb a slope and swing the upperstructure 90° to
the slope.
5. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

Measurement:
1. Select the following switch positions:

Engine E Mode HP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF OFF General OFF
Idle Purpose
Mode

2. Operate the swing lever to full stroke to swing the

upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle and repeat steps 2. and
3. Check both clockwise and counterclockwise.
5. Perform the measurement three times.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-10 EX255-EX285

EXCAVATOR TEST

HYDRAULIC CYLINDER CYCLE TIME

Measure the cycle time of the boom, positioning, arm,

and bucket cylinders.

Preparation:
1. To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket
rolled in, lower the bucket to the ground, as
shown.
2. To measure the cycle time of the positioning
cylinder (triple articulation)
With the empty bucket rolled in and arm rolled out,
raise the boom to the maximum height.
3. To measure the cycle time of the arm cylinder:
SM0153
With the empty bucket rolled in, position the arm
so that it is vertical to the ground. Lower the boom
until the bucket is 0.5 m (20 in) above the ground.
4. To measure the cycle time of the bucket cylinder:
The empty bucket should be positioned at mid-
stroke between roll-in and roll-out, so that the
sideplate edges are vertical to the ground.
5. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

0.5 m

Measurement: SM0154
1. Select the following switch positions:

Engine E Mode HP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF OFF General OFF
Idle Purpose
Mode

SM0155
EX255-EX285 T4-4-11

EXCAVATOR TEST

2. To measure cylinder cycle times:

(Cylinder full stroke includes cylinder cushioning
zone)
– Boom cylinders:
Measure the time it takes to raise the boom, and
the time it takes to lower the boom. To do so,
position the boom at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
– Positioning cylinder (triple articulation):
Measure the time it takes to extend and retract
the positioning cylinder. To do so, position the
cylinder at one stroke end, then move the
control pedal to the other stroke end as quickly
as possible.
– Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so,
position the arm at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
– Bucket cylinder:
Measure the time it takes to roll in the bucket,
and the time it takes to roll out the bucket. To do
so, position the bucket at one stroke end, then
move the control lever to the other stroke end as
quickly as possible.

3. Repeat each measurement three times and cal-

culate the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-12 EX255-EX285

EXCAVATOR TEST

DIG FUNCTION DRIFT CHECK

Extended
Summary: Retracted Distance
Distance
Measure dig function drift, which can be caused by oil Retracted
leakage in the control valve and boom, arm, and Distance
bucket cylinders, with the loaded bucket.
Same Height

NOTE - When testing the dig function drift just after

Bucket Bottom
cylinder replacement, slowly operate each cylinder to
its stroke end to purge air.
SM0156

Preparation:
1. Load bucket fully. In lieu of loading the bucket, Arm Cylinder Extension (and positioning cylinder for
weight (W: tons) of the following specification can triple articulation)
be used.
W = M x 1.5
where: M = Bucket heaped capacity (m3)
1.5 = Soil specific gravity
2. Position the arm cylinder with the rod 50 mm (2 in)
extended from the fully retracted position. Mark
3. Position the positioning cylinder (triple articula-
tion) with the rod 50 mm (2 in) extended from the
fully retracted position.
4. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
5. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket pin
is the same as the boom foot pin.
6. Maintain the hydraulic oil temperature at 50 ± 5 °C SM0157

(122 ± 9 °F).

Boom and Bucket Cylinder Retraction

Measurement:
1. Stop the engine. Mark Mark
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, positioning
(triple articulation), arm and bucket cylinders.
3. Repeat step 2. three times and calculate the
average values.

Evalution:
SM0158
Refer to the Performance Standard Table in Group
T4-2.
EX255-EX285 T4-4-13

EXCAVATOR TEST

CONTROL LEVER OPERATING FORCE

Summary:
Use a spring scale to measure the maximum resist-
ance of each control lever as illustrated.

Preparation:
Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

Measurement:
1. Start the engine.
2. Select the following switch positions:

Engine E Mode HP Mode Work Auto-

SM0159
Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF OFF General OFF
Idle Purpose
Mode

WARNING
Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of the
swing area before starting the measurement.

3. Operate each boom, arm, bucket and swing lever

to at full stroke and measure the maximum oper-
ating force for each.
4. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating force
required. When finished, lower the track and then
jack-up the other track.
5. Repeat steps 3. to 4. three times and calculate the
average values.

Evaluation:
Refer to the Performance Standard Table in Group SM0160
T4-2.
T4-4-14 EX255-EX285

EXCAVATOR TEST

CONTROL LEVER STROKE

Summary:
Measure each lever stroke at the lever top using a
ruler.

NOTE - When the lever has play, take a half of this

value and add it to the measured stroke.

Preparation:
Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).
SM0161
Measurement:
1. Stop the engine.

2. Measure each lever stroke at the lever top from

neutral to the stroke end using a ruler.

3. Repeat step 2. three times and calculate the

average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
EX255-EX285 T4-4-15

EXCAVATOR TEST

COMBINED BOOM RAISE/SWING FUNC-

TION CHECK

Summary:
Check boom raise and swing movement and speeds
while operating both functions simultaneously.

Preparation:
1. Start the engine and run it at fast idle. Operate the
boom raise function and check to be sure that the
cylinder movement is smooth, with out sticking. SM0162
2. With the arm fully rolled out and bucket fully rolled
in, lower the bucket to the ground. The bucket
must be empty.
3. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

WARNING
Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of the
swing area before starting the measurement.

Measurement:
1. Select the following switch positions:

Engine E Mode HP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch SM0163

Fast OFF OFF General OFF

Idle Purpose
Mode

2. Raise the boom and swing simultaneously, both

at full stroke.
3. When the upperstructure rotates 90°, release the
control levers to stop both functions. Measure the
time required to swing 90° and the height (H) of the
bucket teeth.
4. Repeat steps 2. to 3. three times and calculate the
average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
SM0164
T4-4-16 EX255-EX285

EXCAVATOR TEST

NOTES
EX255-EX285 T4-5-1

COMPONENT TEST

PRIMARY PILOT PRESSURE

Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the pilot pump delivery
port. Install adapter (75301519) and pressure
gauge (75301518) on the port.

: 6 mm
Plug
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).
SM0165

Measurement:
1. Select the following switch positions:

Engine E Mode HP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF OFF General OFF
Idle Purpose
Mode
Slow OFF OFF General OFF
Idle Purpose
Mode

2. Measure the pilot pressure in each specified

setting above.
3. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-2 EX255-EX285

COMPONENT TEST

Primary Pilot Pressure Adjustment

Adjustment:
Adjust the setting pressure of relief valve (1) (the
primary pilot pressure) as necessary.

: 36 mm 1

SM0166

1. Remove plug (3).

2. Install the estimated necessary number of shims
(2).
3. Tighten plug (3).

: 49 Nm (5 kgf•m, 36 lbf•ft)

4. Check the relief pressure of relief valve (1).

3

Change in Relief Pressure 2

Shim Thickness (mm)
SM2201
kPa kgf/cm2 psi

0.25 78 0.8 11

0.5 157 1.6 23

1.0 304 3.1 44

EX255-EX285 T4-5-3

COMPONENT TEST

SECONDARY PILOT PRESSURE

Preparation:
1. Properly shut down the engine.
1
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Install pressure gauge (75301518) and tee
(75301520) to the end of pilot line (1) at the
respective control valve spool end, as illustrated.

: 14 mm, 17 mm

4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

Measurement:
1. Select the following switch positions:

Engine E Mode HP Mode Work Auto-

Control Switch Switch Mode Idle SM0168
Dial Switch Switch
Fast OFF OFF General OFF
Idle Purpose
Mode
Slow OFF OFF General OFF
Idle Purpose
Mode

2. Measure the pilot pressure in each specified

setting above with the corresponding control lever
operated full stroke.
3. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
Refer to the Performance Standard Table in Group SM0169
T4-2.
T4-5-4 EX255-EX285

COMPONENT TEST

SOLENOID VALVE SET PRESSURE

Measure solenoid valve set pressure with both the

Dr.EX and the pressure gauge.

Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (75301482), tee
(75301521), adapter (75301522), and pressure
gauge (75301518) to the disconnected end at the
solenoid valve side, as illustrated.

: 17 mm, 19 mm, 22 mm 1

Connect Dr.EX to the machine for solenoid valve

set pressure monitoring. SM0629
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).
Solenoid Valve

Pressure Gauge
Measurement:
1. Select the following switch positions:
1
Engine E Mode HP Mode Work Travel
Control Switch Switch Mode Mode
Dial Switch Switch
Fast OFF OFF General Fast
Hose Tee Adapter
Idle Purpose Speed
Mode Mode
SM0171

2. Operate as instructed below for each measuring

solenoid valve:
Solenoid Valve SG: Repeat pressing and releas-
ing of the power boost switch.
Solenoid Valve SD: Perform a combined opera-
tion. Relieve both actuators.
Solenoid Valve SC: Perform a combined opera-
tion of boom raise and arm roll-in.
Solenoid Valve SI: Drive the machine, then stop
the machine.
3. Read the values on both Dr.EX and the pressure
gauge.
4. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
The average value read on the pressure gauge shall
be within ± 0.2 MPa (±2 kgf/cm2, ± 28 psi) of the value
indicated on Dr.EX.
EX255-EX285 T4-5-5

COMPONENT TEST

Solenoid Valve Set Pressure Adjustment Proce-

dure

IMPORTANT - Do not loosen the adjusting screw

excessively.
The O-ring on the threads may come off the sealing
surface, causing oil leakage.

1. Mark the end of the adjusting screw with a white

The distance between the
marker for the record of the original position. lock nut end and screw end
(Take care not to touch any part of the screw should be 4.0 mm (0.157 in)
threads with the white marker). or less.
2. Loosen lock nut (7). Turn adjusting screw (8) to
adjust the set pressure of the solenoid valve. SM0172

3. Retighten lock nut (7).

: 13 mm

: 4 mm

: 8.8 N•m (0.9 kgf•m, 6.5 lbf•ft)

Reference: Standard Change in Pressure

8 7
Turns 1/4 1/2 3/4 1

kPa 98 196 294 392 SM0173

kgf/cm2 1 2 3 4

psi 14 28 43 57
Adjusting Screw

4. Check the set pressure of the solenoid valve.

Pressure Pressure
Increase Decrease

SM0174
T4-5-6 EX255-EX285

COMPONENT TEST

MAIN PUMP DELIVERY PRESSURE

The main pump delivery pressure can also be meas-

ured with Dr.EX.

Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (75301519), hose
(75301523) and pressure gauge (75301524) on
the port.

: 6 mm

Or connect Dr.EX to the machine for main pump

delivery pressure monitoring.
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).
SM0175

Measurement:
1. Select the following switch positions:

Engine E Mode HP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF OFF General OFF
Idle Purpose
Mode

2. Measure the pressure with the control levers in

neutral.
3. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
EX255-EX285 T4-5-7

COMPONENT TEST

MAIN RELIEF VALVE SET PRESSURE

Summary:
Measure the main relief valve setting pressure at the
main pump delivery port.
The main relief pressure can also be measured with
Dr.EX.

Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (75301519), hose
(75301523) and pressure gauge (75301524) on
the port.

: 6 mm

Or connect Dr.EX to monitor the main pump

delivery pressure.
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 ± 5 °C SM0175

(122 ± 9 °F).

Measurement:
1. Select the following switch positions:

Engine E Mode HP Mode Work

Control Switch Switch Mode
Dial Switch
Fast OFF OFF General
Idle Purpose
Mode

2. Relieve each actuator to measure main relief

pressures.
First, slowly operate bucket, arm, and boom con-
trol levers to the stroke end to relieve each func-
tion one at a time.
3. As for the swing function, secure the upperstruc-
ture so it is immovable. Slowly operate the swing
lever to relieve the swing function.
4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
travel levers to relieve the travel function.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

Reference:
If the measure pressures for all functions are lower
than the specified range, the probable cause is a
decrease of the main relief valve setting pressure.
If the relief pressure of a particular function is lower,
the probable cause is other than main relief valve.
T4-5-8 EX255-EX285

COMPONENT TEST

Main Relief Pressure Setting Adjustment Proce-

dure
Main Relief
Valve
Adjustment:
Adjust the pressure setting of the main relief valve
using plug (3) (for the low-side relief pressure setting)
and plug (5) (for the high-side relief pressure setting)
after loosening lock nut (1).

• High-Side Relief Pressure Setting Adjustment Pro-

cedure
1. Loosen lock nut (1). Lightly tighten plug (3) until
the end of plug (3) comes into contact with
piston (2). Retighten lock nut (1).
: 27 mm
: Plug (3): 19.5 N•m (2 kgf•m, 14.5 lbf•ft)
: Lock Nut (1):
68 to 78 N•m
(7 to 8 kgf•m, 51 to 58 lbf•ft)
SM0168

2. Loosen lock nut (4). Turn plug (5) to adjust the

relief pressure setting referring to the table
3
below.
: 27 mm, 32 mm
: Lock Nut (4): 1
78 to 88 N•m
(8 to 9 kgf•m, 58 to 65 lbf•ft) 5

• Low-Side Relief Pressure Setting Adjustment Pro-

cedure 4
3. Loosen lock nut (1). Turn plug (3) counter
clockwisely until the specified value is obtained 2
referring to the table below. Retighten lock nut
(1).
: 27 mm
: Lock Nut (1):
59 to 68 N•m
(6 to 7 kgf•m, 43 to 51 lbf•ft)

4. Recheck the set pressures.

Reference: Standard Change in Pressure

Change in Relief Pressure: Plug (5)

(High-Side Relief Pressure)
SM0177
Turns 1/4 1/2 3/4 1
MPa 7.1 14.2 21.3 28.4
kgf/cm2 72.5 145 217.5 290 Plug 5-3
psi 1031 2062 3093 4120

Change in Relief Pressure: Plug (3)

(Low-Side Relief Pressure)
Pressure Pressure
Increase Decrease
Turns 1/4 1/2 3/4 1
MPa 5.3 10.7 16.0 21.3
kgf/cm2 54 109 163 217
psi 770 1550 2320 3090
SM0178
EX255-EX285 T4-5-9

COMPONENT TEST

Swing Relief Pressure Setting Adjustment Pro- Swing Relief

Valve
cedure

Adjustment:
Adjust the pressure setting of the swing relief valve
using adjusting screw (1) after loosening lock nut (2).

1. Loosen lock nut (2).

2. Turn adjusting screw (1) adjust the pressure

setting referring to the table below.

3. Retighten lock nut (2).

4. Recheck the set pressure.

: 24 mm, 32 mm

: 177 N•m (18 kgf•m, 130 lbf•ft)

SM0179

1
2

SM0180

Reference: Standard Change in Pressure

1
Turns 1/4 1/2 3/4 1
MPa 2.9 5.8 8.7 11.7
kgf/cm2 30 59.5 89 119
psi 430 850 1270 1690 Pressure Pressure
Increase Decrease

SM0181
T4-5-10 EX255-EX285

COMPONENT TEST

Travel Relief Pressure Setting Adjustment Pro-

cedure

Adjustment:
Adjust the pressure setting of the travel relief valve
using adjusting screw (1) after loosening lock nut (2).

: 19 mm

: 6 mm

1. Loosen lock nut (2).

2. Turn adjusting screw (1) to adjust the pressure

setting referring to the table below.
Travel Relief
3. Retighten lock nut (2). Pressure Valve
SM0182

: 49 N•m (5 kgf•m, 36 lbf•ft)

1
2

SM0183

Reference: Standard Change in Pressure

Adjusting
Turns 1/4 1/2 3/4 1 screw
MPa 2.9 5.9 8.8 11.8
kgf/cm2 30 60 90 120
Pressure Pressure
psi 430 850 1280 1710 Increase Decrease

SM0174
EX255-EX285 T4-5-11

COMPONENT TEST

OVERLOAD RELIEF VALVE SET PRES-

SURE

Summary:
Measuring the set pressure of the overload relief
valves on the machine is not recommended for the
following reasons:

1. The circuit pressure must be increased by apply-

ing an external force while blocking the return
circuit from the control valve. This measuring
method is hazardous and the results obtained
with this method are unreliable.
2. Pressure setting of the overload relief valve must
be made at a specified oil flow rate normally far
smaller than the main pump delivery flow rate.
Accordingly, even if the main relief valve set
pressure can be reset higher than the overload
relief valve set pressure, the main pump supplies
too much oil to correctly measure the setting
pressure of the overload relief valve.
For this reason, in order to correctly measure the
set pressure of the overload relief valve, the
overload relief valve unit must be removed from
the machine and tested on a test stand.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload
relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
as follows:

Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (75301519), hose
(75301523) and pressure gauge (75301524) on
the port.

: 6 mm

Or connect Dr.EX to the machine for main pump

delivery pressure monitoring.
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

SM0175
T4-5-12 EX255-EX285

COMPONENT TEST

Measurement:
1. Select the following switch positions:

Engine E Mode HP Mode Work

Control Switch Switch Mode
Dial Switch
Fast OFF OFF General
Idle Purpose
Mode

2. Slowly operate bucket, arm, and boom control

levers to the stroke ends to relieve each function
one at a time.
3. Read the pressures on the pressure gauge while
releasing the front functions.
4. Perform the measurement for the bucket, arm,
and boom, in that order.
5. Repeat the measurement three times and calcu-
late the average value for each front function.

Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
within the specified value range.

Refer to the Performance Standard Table in

Group T4-2.
EX255-EX285 T4-5-13

COMPONENT TEST

Overload Relief Valve Set Pressure Adjusting

Procedure

NOTE - In principle, adjust the overload relief valve

set pressure on a test stand. 1

Adjustment:
Adjust the pressure setting of the overload relief valve
using adjusting screw (2) after loosening lock nut (1).

1. Loosen lock nut (1).

2. Turn adjusting screw (2) to adjust the pressure 2

setting referring to the table below.

3. Retighten lock nut (1). SM0185

: 17 mm

: 6 mm

: 29.5 N•m (3.0 kgf•m, 22 lbf•ft)

4. Recheck the set pressures.

Reference: Standard Change in Pressure

Turns 1/4 1/2 3/4 1

MPa 5.2 10.6 15.9 21.1 Adjusting
kgf/cm2 54 108 162 216 Screw
psi 770 1540 2300 3070
Pressure Pressure
Increase Decrease

SM0174
T4-5-14 EX255-EX285

COMPONENT TEST

MAIN PUMPS FLOW TEST

Summary:
To test the performance of the main pumps, measure 7. Disconnect the vacuum pump. Bleed the air from
the flow rate by connecting a portable flowmeter to the pump by loosening plug K on the pump, until oil
the main pump delivery connections. flows out the port of plug K.

8. Connect a pick-up of engine tachometer to the

Preparation: engine injection pipes. Disconnect sensor N ter-
minal. Fully open both loading regulation valves
1. Shut the engine. Press the air release valve on the
(2) and (3).
top of the hydraulic oil tank to discharge residual
pressures.
9. Start the engine check the portable flow meter
connection for any leakage.

NOTE - Prior to starting the disconnection of the

pipings, check the primary piloting pressure, which Measurement:
must fall within the required values.
1. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).
2. Connect a vacuum pump to the oil filler neck on
the hydraulic oil tank. 2. Select the following switch positions:

NOTE - Operate the vacuum pump while the portable Engine E HP Work Auto Treavel
flowmeter is connected to the main pumps. Control Mode Mode Mode Idle Mode
Dial Switch Switch Switch Switch Switch
A/I
3. Disconnect hoses A and B from the main pumps. Fast OFF OFF Gen. OFF Fast
Connect test pipes (6) and (7) to hoses A and B idle mode mode
disconnected.

4. Connect test pipes (4) and (5) with the half flanges
and bolts to the main pumps. Connect portable
flowmeter kit (75298406) (1), (2) and (3) as illus-
trated in the figure. Eliminate as far as possible all
curves in the hoses and secure them appropri-
ately to prevent all movements.
5. Disconnect hose SA (pump 1 control) from main
pump 1 regulator and plug the hose.
Disconnect hose SA (pump 2 control) from main
pump 2 regulator and plug the hose.
3. Gradually close the loading regulation pump rela-
tive to the pump involved by the test to obtain the
pressures specified in diagram P-Q and measure
the flow rate of the pump and the engine speed.
Repeat step 3. for all pressure points specified in
curve P-Q. To test the other pump, proceed in the
same manner with the other loading valve.
4. Repeat the measurement three times and calcu-
late the average values.

6. Disconnect hose PA from the pilot system pump

and install a T-joint between pilot pump and hose
PA.
To the free port of the T-joint, install another
T-joint to which two hoses have to be connected.
The other end of hoses have to be connected to
ports SA and SB on the pump regulators left free
when pipes SA and SB have been disconnected.
(This shall make the pumps operate at maximum
displacement angle).
EX255-EX285 T4-5-15

COMPONENT TEST

Evaluation:
1. Convert the measured pump flow rate into the one 2. Specified Pump Flow Rate
for the rated pump speed using the following Refer to the Pump P-Q Diagram in Group T4-2.
formula.

Converted Pump Flow Rate:

Qc = Ns x Q / Ne

Where:
Qc: Converted Pump Flow Rate
Q : Measured Pump Flow Rate
Ns : Rated Engine Speed
EX255 = 2000 rpm
EX285 = 2050 rpm
Ne : Measured Engine Speed

A
6

B
4
SB SA
7 8

PA SB
Pilot pump

SA

T-joint

T-joint

To ports SA, SB
on pump
regulators PA hose
SM5403
T4-5-16 EX255-EX285

COMPONENT TEST

Regulator Adjustment

4
6
5

9
3
10

7
8

SM0187

1 - Lock Nut (For Minimum Flow Adjustment) 6 - Adjusting Screw

2 - Adjusting Screw (For Minimum Flow Adjustment) (For Pilot Pressure Characteristic Adjustment)
3 - Lock Nut (For Maximum Flow Adjustment) 7 - Lock Nut (For P-Q Line Adjustment)
4 - Adjusting Screw(For Maximum Flow Adjustment) 8 - Adjusting Screw (For P-Q Line Adjustment)
5 - Lock Nut 9 - Lock Nut (For P-Q Line Adjustment)
(For Pilot Pressure Characteristic Adjustment) 10 - Adjusting Screw (For P-Q Line Adjustment)
EX255-EX285
COMPONENT TEST
Adjustment Item Adjustment Procedure
1. Minimum Flow Rate Loosen lock nut (1) and turn ad-
justing screw (2).
Q
Rotating adjusting screw (2) 1/4
a turn clockwise increases the
minimum pump flow rate by 6.47
cm3/rev. (0.39 in3/rev).
Pi
2. Maximum Flow Rate Loosen lock nut (3) and turn ad-
justing screw (4).
Rotating adjusting screw (4) 1/4
Q a turn clockwise decreases the
maximum pump flow rate by 5.39
cm3/rev. (0.33 in3/rev).
Pd
3. Pilot Pressure Characteris- Loosen lock nut (5) and turn ad-
tics (Pi-Q Line) justing screw (6).
Rotating adjusting screw (6) 1/4
a turn clockwise decreases the
Q flow rate by 10.77 cm3/rev.
(0.66 in3/rev).
Pi
4. P-Q Line A: Loosen lock nut (7) and turn
(Torque Adjustment) adjusting screw (8). Rotating
adjusting screw (8) 1/4 a turn
Q
clockwise increases the
maximum pump flow rate by
10.77 cm3/rev. (0.66 in3/rev.).
B: Loosen lock nut (9) and turn
A
adjusting screw (10). Rotat-
ing adjusting screw (10) 1/4 a
turn clockwise increases the
B
maximum pump flow rate by
Pd 2.60 cm3/rev. (0.16 in3/rev).
T4-5-17
Remarks
1) Do not turn the adjusting screw
more than two turns.
2) Securely retighten lock nut (1)
after the adjustment.
1) Do not turn the adjusting screw
more than two turns.
2) Do not increase the maximum
flow rate.
In other words, do not turn the
adjusting screw counterclock-
wise. Increasing the maximum
flow rate (turning the adjusting
screw counterclockwise), how-
ever, will be required after ad-
justing the pilot pressure char-
acteristics.
3) Securely retighten lock nut (3)
after the adjustment.
1) Do not turn the adjusting screw
more than one turn.
2) When adjusting screw (6) is
turned clockwise, the maxi-
mum flow rate will also be de-
creased.
To maintain the maximum flow
rate unchanged, turn adjusting
screw (4) counterclockwise
twice as much as adjusting
screw (6) is turned.
This ratio of 2 (adjusting screw
(4) counter clockwise turn) to 1
(adjusting screw (6) clockwise
turn) is to counterbalance.
3) Securely retighten lock nut (5)
after the adjustment.
1) Do not turn the adjusting
screws more than one turn.
2) Rotate the adjusting screws
watching the engine perform-
ance.
3) Securely retighten lock nut (7)
or (9) after the adjustment.
T4-5-18 EX255-EX285

COMPONENT TEST

SWING MOTOR DRAINAGE

Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.

NOTE - The amount of drain oil from the swing motor 1

will change depending on hydraulic oil temperature.
Maintain hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

WARNING
Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of the
swing area before starting the measurement.
Also, take care not to fall off the machine while the
measurement.

Preparation:
1. Maintain hydraulic oil temperature at 50 ± 5 °C
OM0400
(122 ± 9 °F). Rotate the swing motor to warm the
inside of the motor.

2. Properly shut down the engine. Press the air

release valve (1) on top of the hydraulic oil tank to 2
release any remaining pressure.

3. Disconnect the swing motor drain hose (2) at the

hydraulic oil tank end. Install plug (75301529) to
the disconnected end on the hydraulic oil tank.

: 22 mm

: 39 N•m (4 kgf•m, 29 lbf•ft)

Preconditions for Measurement:

1. Select the following switch positions:

Engine E Mode HP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF OFF General OFF
Idle Purpose
Mode
SM0189
EX255-EX285 T4-5-19

COMPONENT TEST

Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the
arm tip pin height is the same as the boom foot
pin height. Be sure that the bucket is empty.
(2) Start the engine. Operate and hold the swing The same height as
boom foot pin height
lever full stroke. Start draining oil measure-
ment after the swing speed reaches a con-
stant maximum speed. The measuring time SM0144
should be more than 45 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise direc-
tions, and calculate the average values.

2. Amount of Oil Drained While Relieving Swing

Motor Circuit
(1) Thrust the bucket teeth into the ground as
illustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
hose end. The measuring time should be
more than 45 seconds.
SM0190
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise direc-
tions, and calculate the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

* Conversion of the amount of drain oil measured into

the per-minute value

First measure the amount of drain oil using a cali-

brated container. Then, convert the measured drain
oil into the per-minute value using the formula below:

∆Q = 60 x q / t

Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
SM0191
T4-5-20 EX255-EX285

COMPONENT TEST

TRAVEL MOTOR DRAINAGE

Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor while
rotating the travel motor with the measuring side
track jacked up.

NOTE - The amount of drain oil from the travel motor

1
will change depending on hydraulic oil temperature.
Maintain hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).

Preparation:
1. Maintain hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F). Rotate the travel motor to warm the
inside of the motor.

2. Properly shut down the engine. Press the air

release valve (1) on top of the hydraulic oil tank to
release any remaining pressure.

3. Disconnect the travel motor drain hose (2) at the

travel motor end. Install plug (75301525) to the
disconnected end. Connect the drain hose (3/4-
OM0400
16UN) to the travel motor.
2
: 22 mm, 27 mm

: 93 N•m (9.5 kgf•m, 69 lbf•ft)

Preconditions for Measurement:

1. Select the following switch positions:

Engine E Mode HP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF OFF General OFF
Idle Purpose
Mode
SM0182
EX255-EX285 T4-5-21

COMPONENT TEST

Measurement:
1. Amount of oil drained while travel motor is rotating
(1) Start the engine. Jack up the measuring side
track using the front attachment, as illus-
90° ÷ 110°
trated.

WARNING
Securely support the raised track using wooden
blocks. SM0139

(2) Rotate the raised track with the travel lever

operated full stroke. Start drain oil measure-
ment after the track rotation speed reaches a
constant maximum speed. The measuring
time should be more than 45 seconds.

(3) Repeat the measurement at least three times

in both forward and reverse directions, and
calculate the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

* Conversion of the amount of drain oil measured into

the per-minute value
SM0193

First measure the amount of drain oil using a cali-

brated container. Then, convert the measured drain
oil into the per-minute value using the formula below:

∆Q = 60 x q / t

Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (sec.)
q : Total amount of drain oil (L)
T4-5-22 EX255-EX285

COMPONENT TEST

NOTES
SECTION 5
TROUBLESHOOTING
INDEX
Group 1 - Diagnosing Procedure
Introduction ........................................... T5-1-1
Diagnosing Procedure ......................... T5-1-2
Dr.EX .................................................... T5-1-4
Dr.EX Start-Up Procedure ................... T5-1-4
Dr.EX Fault Code ................................. T5-1-5
Dr.EX Monitoring Function ................... T5-1-6
Dr.EX Special Function
(Service Mode) ................................. T5-1-7
Adjustable Data List ........................... T5-1-14
Group 2 - Component Layout
Main Components ................................ T5-2-1
Electrical System (Overall System) ..... T5-2-2
Electrical System (Cab) ........................... T5-2-3
Electrical System
(Monitor and Switch Panels) .............. T5-2-5
Pump and Related Parts ........................ T5-2-6
Other Components ................................. T5-2-7
Group 3 - Troubleshooting A
Troubleshooting A Procedure .............. T5-3-1
Fault Codes .......................................... T5-3-2
Fault Code 01 ....................................... T5-3-4
Fault Code 02, 03 ................................. T5-3-5
Fault Code 04, 05 ................................. T5-3-6
Fault Code 06 ....................................... T5-3-7
Fault Code 07 ....................................... T5-3-8
Sensor Operating Range List .............. T5-3-9
EX255-EX285
Group 4 - Troubleshooting B
Troubleshooting B Procedure .................. T5-4-1
Relationship between Machine Trouble
Symptoms and Parts in Trouble ........ T5-4-2
Correlation between Trouble
Symptoms and Part Failures .......... T5-4-12
Engine Troubleshooting ...................... T5-4-18
Actuator Control System
Troubleshooting ............................... T5-4-32
Front Attachment Control System
Troubleshooting ............................... T5-4-38
Swing System Troubleshooting ........... T5-4-50
Travel System Troubleshooting ........... T5-4-53
Troubleshooting for Other Functions .. T5-4-58
Engine Speed Adjustment and
Engine Learning ............................. T5-4-60
Exchange Inspection Method ............... T5-4-61
Boom Lowering Method
when Engine Stalls ........................... T5-4-63
Group 5 - Troubleshooting C
Troubleshooting C Procedure ............... T5-5-1
Malfunction of Coolant
Temperature Gauge .......................... T5-5-2
Malfunction of Fuel Gauge ................... T5-5-4
Malfunction of Fuel Level
Indicator ............................................ T5-5-6
Malfunction of Indicator Light
Check System ................................... T5-5-8
Malfunction of Level Check Switch ....... T5-5-8
Malfunction of Engine Oil Level
Indicator .......................................... T5-5-10
INDEX

Malfunction of Coolant Level Group 7 - Harness Check

Indicator ........................................... T5-5-12 Circuit Check .......................................... T5-7-1

Malfunction of Hydraulic Oil Level

Indicator .......................................... T5-5-14
Malfunction of Alternator Indicator .... T5-5-16
Malfunction of Engine Oil Pressure
Indicator .......................................... T5-5-18
Malfunction of Overheat
Indicator .......................................... T5-5-20
Malfunction of Air Filter Restriction
Indicator .......................................... T5-5-22
Malfunction of Buzzer ........................ T5-5-24
Malfunction of Hour Meter ................. T5-5-26

Group 6 - Electrical System Inspection

Precautions for Inspection and
Maintenance ..................................... T5-6-1
Instructions for Disconnecting
Connectors ....................................... T5-6-3
Fuse Continuity Test ............................. T5-6-4
Inspection and Replacement of Maxi
Fusible Links .................................... T5-6-5
Battery Voltage Check ........................... T5-6-6
How to Troubleshoot Alternator
Malfunctions ...................................... T5-6-7
Continuity Check ................................... T5-6-8
Voltage and Current Check .................. T5-6-10
Wiper Controller .................................... T5-6-14
Replacement of Relay ......................... T5-6-16
Relay Box ............................................. T5-6-18
Replacement of QOS
Controller .......................................... T5-6-20
Replacement of Power Outlet ................ T5-6-21
EX255-EX285 T5-1-1

DIAGNOSING PROCEDURE

INTRODUCTION

Each troubleshooting section group is presented in an

orderly fashion so as to make the inspecting and
troubleshooting procedures easy to follow. Use the
troubleshooting section to guide you in locating the
source of any problems that may arise.

The troubleshooting section consists of 6 groups: the

component layout, the troubleshooting A (using fault
codes), troubleshooting B (starting with symptoms),
troubleshooting C (gauges and indicators), the electri-
cal system inspection procedures, and harness check
groups.

• Component Layout Diagrams

• Troubleshooting A (using fault codes)

Use these charts when the self-diagnosing function
of Dr.EX shows any fault codes.
(The controller automatically diagnoses and memo-
rizes malfunctions that have occurred in the signal
sending system.)

Example: Fault Code 01 EC Sensor Failure

• Troubleshooting B (starting with symptoms)

Use these charts when the machine is exhibiting
trouble and when Dr.EX does not indicate any fault
codes.

Example: Even if engine control dial is operated,

engine speed does not change.

• Troubleshooting C (Gauges and indicators)

Use these charts when any gauges or indicators
malfunction.

Example: The fuel gauge does not operate.

• Electrical System Inspection Procedure

Refer to this group for precautions and inspection
procedures of the electrical system when or before
performing inspections on the electrical system.

Example: Fuse Inspection

• Harness Check
Refer to this group for information about the test
harnesses.

Example: 75301706D
T5-1-2 EX255-EX285

DIAGNOSING PROCEDURE

DIAGNOSING PROCEDURE

These six basic steps are essential for efficient

troubleshooting:

1. Study the System

Study the machine’s technical manuals. Know the
system and how it works, and what the construc-
tion, functions and specifications of the system
components are.

2. Ask the operator

Before inspecting, get the full story of malfunctions SM0600

from your star witness ···· the operator.

(a) How is the machine being used? (Find out if the

machine is being operated correctly)

(b) When was the trouble noticed, and what types

of work the machine doing at that time?

(c) What are the details of the trouble? Is the

trouble getting worse, or did it appear suddenly
for the first time?

(d) Did the machine have any other troubles previ-

ously? If so, which parts were repaired before?

SM0601
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator’s manual.

Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the control-
lers, causing total operational failure of the ma-
chine.
Fuse failure is often caused by a fine crack in the
fuse, and such fine cracks are very hard to detect
by visual inspection.

SM0602
EX255-EX285 T5-1-3

DIAGNOSING PROCEDURE

4. Operate the machine yourself.

If the trouble cannot be confirmed, stop the engine
and obtain further details of the malfunction from the
operator.
Also, check for any incomplete connections of the
wire harnesses.

5. Perform troubleshooting

CAUTION SM0603
Never attempt to disconnect harnesses or hydrau-
lic lines while the engine is running. The machine
may malfunction or pressurized oil may spout,
possibly resulting in personal injury. Be sure to
stop the engine before disconnecting harnesses
or hydraulic lines.

Connect the diagnostic analyzer, Dr.EX, to the MC

(Main Controller) to obtain malfunction records.

If any fault codes are displayed on the monitor,

check sensing signal circuits, referring to Trouble- SM0604
shooting A.

If no fault code is indicated on the monitor, go to the

troubleshooting B group.
Note that Dr.EX will be necessary in the trouble-
shooting B procedures for monitoring real time
component performance.

*Note that the fault codes displayed do not neces-

sarily indicate machine trouble. The controller
stores even temporary electrical malfunctions,
such as a drop in battery output voltage or
disconnections of the switches, sensors, etc., for
inspections.
For this reason, the “RETRIAL” is required to erase
the accumulated fault codes from the controller
SM0605
memory and to confirm if any fault codes are
indicated after the “RETRIAL”.

6. Trace possible causes

Before reaching a conclusion, check the most likely
causes again. Try to identify the actual cause of the
trouble.

Based on your conclusion, make a plan for appro-

priate repairs to avoid consequent malfunctions.

SM0606
T5-1-4 EX255-EX285

DIAGNOSING PROCEDURE

Dr.EX

Dr.EX (75301336) is a handy micro computer used for

diagnosing malfunctions of the machine control sys-
tem, including the MC (Main Controller).

When the Dr.EX is connected to the MC, malfunctions

recorded in the MC memory are indicated as fault
codes on the Dr.EX display.
(Self-Diagnosing Function)

Input signals from the sensors or switches that are

connected to the MC, or output signals from the MC to
solenoid valves can be monitored on a real-time basis
while the machine is being operated.
(Real-Time Monitoring Function)

Dr.EX START-UP PROCEDURE

1. Connect the harness of the Dr.EX to the diagnosing

connector of the MC, located near fuse box behind
the operator’s seat.

Start
NOTE - Only this connecting harness can be used to
connect the Dr.EX to the controller. Do not use any
other harness to connect Dr.EX to the controller.
Initial Screen

2. Turn the key switch to the ON position or start the

engine.
Model Code
Can not
Confirmation
3. Turn the Dr.EX ON. After a few seconds, following communicate
patterns will appear on the Dr.EX display: with MC
Check MC
power source Not OK
3-1. Initial Pattern and/or OK?
communication
3-2. Model Code Pattern harness
Dr. EX Other
Example : Software
OK
Model : EX200-5
Ver : XXXX
Self- Monitor Special
3-3. Function Selection Pattern Diagnosing Function Data Functions
F-1 : “Self-diagnosing Results” Selection
F-2 : “Monitor Data”
F-3 : “Special Functions”
Self-Diagnosing Record Data Selecting
Results Pattern
4. Select key F1 (Proceed according to the in- (Fault Code)
structions that appear on the display.)

Monitor
Retrial B Data Display
NOTE - For the operation procedure of the Dr.EX, refer
to the Dr.EX OPERATOR’S MANUAL.
Self-Diagnosing
Results
(Fault Code)
EX255-EX285 T5-1-5

DIAGNOSING PROCEDURE

Dr.EX FAULT CODE

Fault Code Trouble Corrective Action

01 EC sensor failure 1) Perform “Retrial B.”

2) Check harness.
3) Replace EC sensor.

02 Pump 1 delivery pressure sensor failure 1) Perform “Retrial B.”

03 Pump 2 delivery pressure sensor failure 2) Check harness.
3) Replace the pump delivery pressure sensor.

04 Pump 1 control pressure sensor failure 1) Perform “Retrial B.”

05 Pump 2 control pressure sensor failure 2) Check harness.
3) Replace the pump control pressure sensor.

06 Arm roll-in pilot pressure sensor failure 1) Perform “Retrial B.”

2) Check harness.
3) Replace the arm roll-in pilot pressure sensor.

07 Engine control dial failure 1) Perform “Retrial B.”

2) Check harness.
3) Replace the engine control dial.
T5-1-6 EX255-EX285

DIAGNOSING PROCEDURE

Dr.EX MONITORING FUNCTION

Dr.EX has a function to monitor the command signals

from the MC and the input signals to the MC from
various switches and sensors.

Monitor Item Description Display Unit and Form

Pump 1 Control Pressure Input from the PC pressure sensor (4-spool side) kgf/cm2
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

EC Angle Input Signal from EC Sensor V

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Pump 1 Delivery Pressure Input from the pump 1 delivery pressure sensor kgf/cm2
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Pump 2 Delivery Pressure Input from the pump 2 delivery pressure sensor kgf/cm2
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Arm Roll-In Pilot Pressure Input from the arm roll-in pilot pressure sensor kgf/cm2
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Pump 2 Control Pressure Input from the PC pressure sensor (5-spool side) kgf/cm2
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Accelerator Angle
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Dial Angle Input from the engine control dial V

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Arm Regenerative Proportional The value of the command signal to the solenoid kgf/cm2
Solenoid Valve Output valve unit SC
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Travel Motor Displacement The value of the command signal to the solenoid kgf/cm2
Angle Change Pressure valve unit SI
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Pump Proportional Solenoid The value of the command signal to the solenoid kgf/cm2
Valve Output valve unit SD
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Power Boost Pressure The value of the command signal to the solenoid kgf/cm2
valve unit SG
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Target Engine Speed Target engine speed under loaded condition. rpm
(Approx. 150 min-1 difference from engine speed
under no load.)
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Actual Engine Speed Input from the N sensor rpm

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

EC Motor Position step

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Pressure Switch On/off state of the pressure switches BmH, Fr, Tr

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Selected Work Mode Switch Selected work mode S, G, P, A

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

E Mode Switch On/off state of the E mode switch EP

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Auto-Idle Switch On/off state of the auto-idle switch AI

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

HP Mode Switch On/off state of the HP mode switch HP

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Power Boost Switch ON/off state of the power boost switch Pd

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Selected Travel Mode Switch Selected travel mode Lo. Hi

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Key Switch On/off state of the key switch Ky

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Engine Learning Control Done, Undone, Aborted

EX255-EX285 T5-1-7

DIAGNOSING PROCEDURE

Dr.EX SPECIAL FUNCTION (SERVICE

MODE)

1. Purpose
Some data in the MC (Main Controller), such as the
flow rate in the attachment mode, engine speed in
the E mode, can be changed as required.

2. Parts pertaining to the special function.

Dr.EX
Learning Switch MC
Key Switch

3. Operation
• How to Turn Dr.EX in the Service Mode
1) Turn the key switch OFF. Wait 10 seconds or
more.
2) Connect the Dr.EX.
3) Turn the learning switch to the Engine Learning
position.
4) Turn the key switch to the ON position. (Do not
start the engine.)
5) Turn on the switch on the Dr.EX.

• On the following pages, the service mode panels on

the Dr.EX and the service mode operating proce-
dure are shown.
T5-1-8 EX255-EX285

DIAGNOSING PROCEDURE

Service mode related to Dr.EX screen panels, begin-

ning with the start screen, are shown along with the
Dr.EX VER **** corresponding Dr.EX key operations.
However, Dr.EX screen panels which are not related
to the Dr.EX key operation are excluded.

F1 : Start F10 : Model Menu

F1 Press

Model: XXXX-X

Ver : XXXX

Is model correct ?
F1 : Correct F5 : ESC

F1 Press

Service mode selected

In service mode, self diagnosis

operation and / or monitor display
will not be conducted.
F1 : Rechecked F5 : ESC

F1 Press

▼
1
EX255-EX285 T5-1-9

DIAGNOSING PROCEDURE

Select Functions

F3 : Special Functions

F5 : ESC

F3 Press
A
▼

Select Functions Select learning data to be dis-

F6 : F7 Press played.
F7 : Learning Data Display F6 : EC Motor Stop Position
▼

F8 : Parameter Change F7 : EC Motor Maximum Speed

▼

Position
F8 Press
F5 : ESC F5 : ESC

F8 Press F6 Press F5 Press

▼
Select Item
F6 : Li Speed
F7 : E Speed EC Motor Stop Position Learning
F8 : P Speed data is
F3 : Next -XXXX digit displayed.

F5 : ESC F5 : ESC

F3 Press

▼
2
T5-1-10 EX255-EX285

DIAGNOSING PROCEDURE

Select Item
F6 : AI Speed Control
F8 : Crusher (L) Engine Speed
Control An example of “F7: Breaker Engine
F5 Press Speed Control” operation is shown on
the next page.
F4 : Prev. ↑ F5 : ESC
▼
3
F5 Press

(Press F4 to return to the previous screen.)

▼
End
(Returns to panel (A) on the previous page.)
EX255-EX285 T5-1-11

DIAGNOSING PROCEDURE

Breaker Engine Speed Control Breaker Engine Speed Control

adjustable range in HELP F7 Press HELP
Adjustable Range : -500 to+100 rpm

▼
Input the adjusting deviation you Initial : 0 rpm

▼
want. Minimum Adjusting Deviation :
10 rpm
F3 : Next F5 : ESC F7 : HELP F5 Press
F5 : ESC
▼ Values
Adjusted
F3 Press
In Tens
▼
Breaker Engine Speed Control
123
F7 Press
Current : 0 rpm
12
12
Adjustment : 12 rpm
▼

F1 : Execute F2 : Corr F5 Press

F4 : Prev. F5 : ESC F7 : HELP
“-100” is entered as an example here.
SFT
SFT
Press (“123” on the upper right corner of the screen will change to “ABC”.)

-
Press (“-” will be displayed in the Adjustment field.)
3

SFT
Press (“ABC” on the upper right corner of the screen will change to “123”.)
SFT

* Press (“-1” will be displayed in the Adjustment field.)

1

. Press (“-10” will be displayed in the Adjustment field.)

0

. Press (“-100” will be displayed in the Adjustment field.)

0

▼
Breaker Engine Speed Control NOTE - Confirm that “123” is displayed on the upper right
123 corner of the screen before pressing key
Current : 0 rpm
Adjustment : -100 rpm

F1 : Execute F2 : Corr
F4 : Prev. F5 : ESC F7 : HELP

F1 Press
▼
4
T5-1-12 EX255-EX285

DIAGNOSING PROCEDURE

∗Adjusting Deviation∗
∗Data Confirmation∗
Adjusting Deviation Data Name :
Breaker Engine Speed Control

F3 : Next F5 : ESC

F3 Press The value input on the previous page will be displayed again in the
Adjustment field.
▼

Current : 0 rpm
Adjustment : -100 rpm

F1 : Execute F4 : Prev. F5 : ESC

F1 Press
▼
Adjustment was made as follows :
Adjusting Deviation Data Name :
Breaker Engine Speed Control

F3 : Next

F3 Press The last screen for the Breaker Engine Speed Control will be
displayed.
▼

Current : 0 rpm
Adjustment : -100 rpm

F4 : Prev F5 : ESC

Turn off Dr.EX.

▼
End
EX255-EX285 T5-1-13

DIAGNOSING PROCEDURE

• Check the engine performance (Check if the engine

speed has been changed), as follows:

IMPORTANT - Be sure to turn the learning switch to

the OFF (Neutral) position before checking the engine
performance. Because the MC does not perform the
engine, pump, and valve controls if the learning switch
is in the Engine Learning position, engine speed
change cannot be confirmed properly.

1) Turn the key switch OFF.

2) Wait 10 or more seconds.
3) Turn the learning switch to the OFF (Neutral) posi-
tion.
4) Disconnect Dr.EX. (This step can be omitted if you
wish to monitor the engine speed on Dr.EX.)
5) Turn the key switch to the ON position.
6) Start the engine.
7) Operate the machine to check the engine perform-
ance.
T5-1-14 EX255-EX285

DIAGNOSING PROCEDURE

ADJUSTABLE DATA LIST

Adjustable Data Values Adjusted In Adjustable Range Set Adjustment Value Before
Factory Shipment
Li Mode Speed 10’s min-1 (rpm) 0 to 120 min-1 (rpm) 0 min-1 (rpm)
E Mode Speed 10’s min-1 (rpm) -120 to 120 min-1 (rpm) 0 min-1 (rpm)
-1 -1
P Mode Speed 10’s min (rpm) -120 to 120 min (rpm) 0 min-1 (rpm)
AI Mode Speed 10’s min-1 (rpm) -120 to 100 min-1 (rpm) 0 min-1 (rpm)
-1 -1
Breaker Engine Speed 10’s min (rpm) -500 to 100 min (rpm) 0 min-1 (rpm)
Crusher Engine Speed 10’s min-1 (rpm) -500 to 100 min-1 (rpm) 100 min-1 (rpm)
EX255-EX285 T5-2-1

COMPONENT LAYOUT

MAIN COMPONENTS

SM5601

1 - Bucket Cylinder 12 - Engine

2 - Arm Cylinder 13 - Radiator
3 - Boom Cylinder 14 - Oil Cooler
4 - Center Joint 15 - Intercooler
5 - Swing Bearing 16 - Battery
6 - Swing Device 17 - Travel Device
7 - Fuel Tank 18 - Shockless Valve
8 - Hydraulic Oil Tank 19 - Pilot Shut-Off Valve
9 - Control Valve 20 - Travel Pilot Valve
10 - Pilot Filter, Pilot Relief Valve 21 - Front/Swing Pilot Valve
11 - Pump Device
T5-2-2 EX255-EX285

COMPONENT LAYOUT

ELECTRICAL SYSTEM (overall system)

SM5402

1 - Wiper Motor 19 - Engine Oil Pressure Switch

2 - Monitor Panel 20 - Coolant Temperature Switch (Engine Preheat Circuit)
3 - Relays, Relays box 21 - Engine Oil Level Switch (on oil pan)
4 - Windshield 22 - Overheat Switch
5 - Horn 23 - Coolant Temperature Sensor
6 - Work Light 24 - Battery Relay
7,8 - Fuel Sensor with Low Fuel Level Switch 25 - Coolant Level Switch
9 - Solenoid Valve Unit 26 - Battery
10 - Pressure Switch (Travel) 27 - Starter Relay
11 - Hydraulic Oil Level Switch 28 - Air Cleaner Restriction Switch
12 - PC Pressure Sensor (Upper: 4-Spool Side) 29 - Pressure Switch (Boom Raise), Pressure Sensor
13 - PC Pressure Sensor(Lower: 5-Spool Side) (Arm Roll-In)
14 - EC Motor 30 - Pressure Switch (Front)
15 - EC Sensor 31 - Fuse Box
16 - Pump Delivery Pressure Sensor 1 32 - MC (Main Controller)
17 - Pump Delivery Pressure Sensor 2 33 - QOS Controller
18 - N (Engine Speed) Sensor
EX255-EX285 T5-2-3

COMPONENT LAYOUT

ELECTRICAL SYSTEM (cab)

SM5603

1 - Relay box 13 - Breaker relay (R2) variant provision

2 - Air conditioner relays (if installed) 14 - R.H. Rotation bucket relay (R3) variant provision
3 - Connection for cab light (ceiling) 15 - L.H. Rotation bucket relay (R4) variant provision
4 - WWES connection for wiper cut-off microswitch 16 - Cab light relay (R5)
5 - Heater connection 17 - Rear cab light relay (R6)
6 - Air conditoner connection 18 - A, B, K junction connector
7 - Loudspeakers connection 19 - C, D juncton connector
8 - Cab ground 20 - E, F junction connector
9 - Main controller (MC) 21 - G, H junction connector
10 - Q.O.S. controller 22 - Dr. EX. connector
11 - Load momentum alarm buzzer provision 23 - Engine learning switch
12 - Load momentum alarm relay provision (R1) 24 - Fuse box
T5-2-4 EX255-EX285

COMPONENT LAYOUT

ELECTRICAL SYSTEM (cab)

1 2

8 7 5

SM5604

1 - Connectors for monitor and switch panels 7 - Connector not used

2 - Cigarette lighter 8 - Connector
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
EX255-EX285 T5-2-5

COMPONENT LAYOUT

ELECTRICAL SYSTEM (monitor and switch panels)

10

24
11
1 12
23 13
22 14

21 15
16
2 20
17
19
3
18
T157-07-02-001
SM0610

5
25
6
32
4
7

8 26
31

9 27

28
30

T157-01-01-009
29 T157-01-01-018
SM0611 SM0612

1 - Monitor Panel 17 - Fuel Level Indicator

2 - Switch Panel 18 - Overheat Indicator
3 - Power Boost Switch 19 - Alternator Indicator
4 - Key Switch 20 - Engine Oil Pressure Indicator
5 - Cigar Lighter 21 - Engine Oil Level Indicator
6 - HP Mode Switch 22 - Coolant Level Indicator
7 - E Mode Switch 23 - HP Mode Indicator
8 - Engine Control Dial 24 - Coolant Temperature Gauge
9 - Air Conditioner Panel 25 - Work Light Switch
10 - Warm Up Complete Indicator 26 - Wiper Switch
11 - Fuel Gauge 27 - Travel Mode Switch
12 - E Mode Indicator 28 - Work Mode Switch
13 - Auto-Idle Indicator 29 - Buzzer Stop Switch
14 - Hydraulic Oil Level Indicator 30 - Auto-Idle Switch
15 - Preheat Indicator 31 - Washer Switch
16 - Air Filter Restriction Indicator 32 - Level Check Switch
T5-2-6 EX255-EX285

COMPONENT LAYOUT

PUMP AND RELATED PARTS

5 6 7

3-4
8

1 12 11 10 9
SM3004

1 - Pilot Filter 7 - N Sensor

2 - Pilot Relief Valve 8 - Regulator (Pump 1)
3 - EC Motor 9 - Pump Delivery Pressure Sensor (Pump 1)
4 - EC Sensor 10 - Pump 1
5 - Pilot Pump 11 - Pump Delivery Pressure Sensor (Pump 2)
6 - Regulator (Pump 2) 12 - Pump 2
EX255-EX285 T5-2-7

COMPONENT LAYOUT

OTHER COMPONENTS

Swing Device Shockless Valve

4
1
5

8
6

SM0626
T157-01-01-011 SM0627
T157-07-03-018

Travel Device Solenoid Valve Unit

FRONT

10

11
12
2
13
3

SM0628 SM0629
T157-01-01-012 W157-02-11-020

1 - Swing Relief Valve 8 - Check Valve

2 - Counterbalance Valve 9 - Pilot Pressure Sensor (Arm Roll-In)
3 - Travel Relief Valve 10 - Solenoid Valve Unit (SC)
4 - Shockless Valve 11 - Solenoid Valve Unit (SD)
5 - Pilot Pressure Switch (Boom Raise) 12 - Solenoid Valve Unit (SI)
6 - Check Valve 13 - Solenoid Valve Unit (SG)
7 - Shockless Valve
T5-2-8 EX255-EX285

COMPONENT LAYOUT

Control valve

Left travel motor Right travel motor

3 4 5 6 7 8 9 10
2
1
11
41
12
13
14
40
15
16
39
Bucket cylinder
38
37
36
35 Boom cylinder
34

17
Arm cylinder
18
33
32 19
31 20
30 21
29 22
23
26
27
24
28 25

Swing motor
SM0037

1 - Hydraulic Timer 15 - Overload Relief Valve (Bucket) 29 - Load Check Valve (Arm Tandem
2 - Travel Flow Control Valve 16 - Overload Relief Valve (Bucket) Circuit)
3 - Load Check Valve (Travel Paral- 17 - Overload Relief Valve (Boom) 30 - Check Valve
lel Circuit) 18 - Overload Relief Valve (Boom) 31 - Arm Regenerative Valve
4 - Check Valve 19 - Boom Anti-Drift Valve (Check 32 - Check Valve
5 - Main Relief Valve Valve) 33 - Overload Relief Valve (Arm)
6 - Check Valve 20 - Boom Anti-Drift Valve (Switch 34 - Overload Relief Valve (Arm)
7 - Check Valve Valve) 35 - Arm Anti-Drift Valve (Check Valve)
8 - Flow Combiner Valve 21 - Boom Regenerative Valve 36 - Arm Anti-Drift Valve (Switch Valve)
9 - Load Check Valve (Bucket) 22 - Check Valve 37 - Load Check Valve (Boom 2 Parallel
10 - Bucket Flow Control Valve 23 - Pump Control Valve (4-Spool Circuit)
(Switch Valve A) Side) 38 - Travel/Boom Lower Selector Valve
11 - Bucket Flow Control Valve 24 - Check Valve 39 - Check Valve
(Switch Valve B) 25 - Restriction (4-Spool Side Paral- 40 - Load Check Valve (Travel Tandem
12 - Bucket Flow Control Valve lel Circuit) Circuit)
(Poppet Valve) 26 - Load Check Valve (Arm Parallel 41 - Pump Control Valve (5-Spool Side)
13 - Load Check Valve (Boom 1 Par- Circuit)
allel Circuit) 27 - Restriction (Arm 1 Parallel Cir-
14 - Load Check Valve (Boom 1 Tan- cuit)
dem Circuit) 28 - Load Check Valve (Swing)
EX255-EX285 T5-2-9

COMPONENT LAYOUT
H A Section A
B 5
G C
D
E
F

41 8

SM0036 SM0038

Section C Auxiliary Bucket

15

12
39 11

Section D
9
Boom 2

16
Boom 1
Section B SM0040

L. Travel R. Travel 38 20

17 21
19
37
3
2 13

14
10
40
18

SM0039 SM0041
T5-2-10 EX255-EX285

COMPONENT LAYOUT

Left travel motor Right travel motor

3 4 5 6 7 8 9 10
2
1
11
41
12
13
14
40
15
16
39
38 Bucket cylinder
37
36
Boom cylinder
35
34

17
Arm cylinder
18
33
32 19
31 20
30 21
29 22
23
26
27
24
28 25

Swing motor
SM0037

1 - Hydraulic Timer 15 - Overload Relief Valve (Bucket) 29 - Load Check Valve (Arm Tandem
2 - Travel Flow Control Valve 16 - Overload Relief Valve (Bucket) Circuit)
3 - Load Check Valve (Travel Paral- 17 - Overload Relief Valve (Boom) 30 - Check Valve
lel Circuit) 18 - Overload Relief Valve (Boom) 31 - Arm Regenerative Valve
4 - Check Valve 19 - Boom Anti-Drift Valve (Check 32 - Check Valve
5 - Main Relief Valve Valve) 33 - Overload Relief Valve (Arm)
6 - Check Valve 20 - Boom Anti-Drift Valve (Switch 34 - Overload Relief Valve (Arm)
7 - Check Valve Valve) 35 - Arm Anti-Drift Valve (Check Valve)
8 - Flow Combiner Valve 21 - Boom Regenerative Valve 36 - Arm Anti-Drift Valve (Switch Valve)
9 - Load Check Valve (Bucket) 22 - Check Valve 37 - Load Check Valve (Boom 2 Parallel
10 - Bucket Flow Control Valve 23 - Pump Control Valve (4-Spool Circuit)
(Switch Valve A) Side) 38 - Travel/Boom Lower Selector Valve
11 - Bucket Flow Control Valve 24 - Check Valve 39 - Check Valve
(Switch Valve B) 25 - Restriction (4-Spool Side Paral- 40 - Load Check Valve (Travel Tandem
12 - Bucket Flow Control Valve lel Circuit) Circuit)
(Poppet Valve) 26 - Load Check Valve (Arm Parallel 41 - Pump Control Valve (5-Spool Side)
13 - Load Check Valve (Boom 1 Par- Circuit)
allel Circuit) 27 - Restriction (Arm 1 Parallel Cir-
14 - Load Check Valve (Boom 1 Tan- cuit)
dem Circuit) 28 - Load Check Valve (Swing)
EX255-EX285 T5-2-11

COMPONENT LAYOUT

Section E (2) Arm 1

Arm 2

31

32

Section E (1)
Section F
Arm 1 Arm 2
Swing
SM0042
36

34
35 28
24

26 25

27 23
29 22

33 SM0043 SM0045
30
Section H

Section G

6 7

SM0044 SM0046
T5-2-12 EX255-EX285

COMPONENT LAYOUT

NOTE:
EX255-EX285 T5-3-1
TROUBLESHOOTING A

TROUBLESHOOTING A PROCEDURE

Use troubleshooting A procedure when fault codes are shown on Dr.EX.

Ž How to Read the Troubleshoting Flow Charts

YES(OK)
(2)
After checking or measuring item (1), select either Yes (OK) or No (NOT
(1) OK) and proceed to item (2) or (3), as appropriate.

(3)
NO(NG)

Special instructions or reference item are indicated in the spaces under the box. Incorrect
measuring or checking methods will render troubleshooting impossible, and may damage
Key switch: ON components as well.

Explanation of how to use lamp harness kit required. Refer to “Harness Check” Group (Group
T5-7) in this section.

Use the Dr. EX troubleshooting/monitor function for the description in a double line box.

Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes
can be seen without going through the flow chart.

NOTE - For all connector drawings illustrated in this

group, harness end connector terminals seen from the
open end side are shown.

SM0630
T5-3-2 EX255-EX285
TROUBLESHOOTING A

FAULT CODES

FAULT CODE TROUBLE CORRECTIVE ACTION

01 EC sensor failure 1) Perform “Retrial B”.

2) Check harness.
3) Replace EC sensor.

02 Pump 1 delivery pressure sensor failure 1) Perform “Retrial B”.

03 Pump 2 delivery pressure sensor failure 2) Check harness.
3) Replace the pump delivery pressure sensor.

04 Pump 1 control pressure sensor failure 1) Perform “Retrial B”.

05 Pump 2 control pressure sensor failure 2) Check harness.
3) Replace the pump control pressure sensor.

06 Arm roll-in pilot pressure sensor failure 1) Perform “Retrial B”.

2) Check harness.
3) Replace the arm roll-in pilot pressure sensor.

07 Engine control dial failure 1) Perform “Retrial B”.

2) Check harness.
3) Replace the engine control dial.
EX255-EX285 T5-3-3
TROUBLESHOOTING A
T5-3-4 EX255-EX285
TROUBLESHOOTING A

FAULT CODE 01 (EC SENSOR FAILURE)

NO
Faulty MC
Check if breakage or
short circuit exists • After replacement,
YES between MC 22P refer to page T5-4-60.
connector terminal
No.D15 and EC
sensor terminal No. 2. Harness failure
Disconnect EC between MC and EC
sensor connector. YES sensor.
YES Check if voltage
between harness end
connector terminals
Disconnect EC sensor No.1 and No.3 is YES Harness breakage
connector. Check if 5 ± 0.5 V. between MC and EC
resistance between EC sensor terminal No.3.
• Key switch: ON Check if voltage
sensor side connector
terminals No.1 and No.3 between harness end
connector terminals
is 1.7 ± 0.4 kΩ. NO No.1 and vehicle
Connect test harness
frame is 5 ± 0.5 V. Harness breakage
between EC sensor
between MC and EC
connector halves. Turn • Key switch: ON
engine control dial and NO sensor terminal
• 5 ± 0.5 V for the voltage No.1.
check if voltage change standard
changes as specified. values.
Faulty EC sensor
• Test harness: 75301706D NO
• Refer to page T5-3-9 for • After replacement,
the voltage change stand- refer to page T5-4-60.
ard values.

Connector (harness end connector terminals seen from the open end side)

Main Controller (22P): “D” is added for each terminal number in the text.

1 2 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22

EC Sensor

1 2 3
EX255-EX285 T5-3-5
TROUBLESHOOTING A

FAULT CODE 02
(PUMP 1 DELIVERY PRESSURE SENSOR
FAILURE)
FAULT CODE 03
(PUMP 2 DELIVERY PRESSURE SENSOR
FAILURE)

Checking Instruction:
• It is unlikely for both pump delivery pressure sen-
sors (for pumps 1 and 2) to fail simultaneously. For
this reason, if faults codes 2 and 3 are indicated, the
probable cause is harness failure.

NO
Switch pump delivery
pressure sensors
(for pumps 1 and 2)
with each other.
Perform “RETRIAL.”
Check if indicated
fault code changes
to the one for the
other pump delivery
pressure sensor.
YES
YES
Disconnect the pump
delivery pressure
sensor connector.
Check if voltage
between harness end
connector terminals
No.1 and No.3 is
5 ± 0.5 V.
• Key switch: ON
NO No.1 and vehicle
Check if breakage or YES
short circuit exists
between MC 22P
connector terminal
No. D16 (pump 1)/
No. D17 (pump 2)
and pump delivery
pressure sensor ter- NO
minal No.2.
YES
Check if voltage
between harness end
connector terminals
frame is 5 ± 0.5 V.
• Key switch: ON NO delivery pressure
• 5 ± 0.5 V for the voltage
change standard
values.
Harness failure
between MC and
pump delivery
pressure sensor.
Faulty EC sensor
• After replacement,
refer to page T5-4-60.
Harness failure be-
tween MC and pump
delivery pressure
sensor terminal No.3.
Harness failure be-
tween MC and pump
sensor terminal No.1.
Faulty pump delivery
pressure sensor.

Connector (harness end connector terminals seen from the open end side)

Main Controller (22P): “D” is added for each terminal number in the text.

1 2 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22

Pump Delivery Pressure Sensor

1 2 3
T5-3-6 EX255-EX285
TROUBLESHOOTING A

FAULT CODE 04
(PUMP 1 CONTROL PRESSURE SENSOR
FAILURE)
FAULT CODE 05
(PUMP 2 CONTROL PRESSURE SENSOR
FAILURE)

Checking Instruction:
• It is unlikely for both pump control pressure sensors
(ones in 4-spool side and in 5-spool side control
valves) to fail simultaneously. For this reason, if
faults codes 04 and 05 are indicated, the probable
cause is harness failure.
Harness failure be-
Check if breakage or YES tween MC and pump
short circuit exists control pressure sen-
between MC 22P sor.
connector terminal
YES No. D14 (4-spool
side)/No. D19
(5-spool side) and
Disconnect pump pump control pres- Faulty MC
control pressure NO
sure sensor terminal
sensor connector. No.2. • After replacement,
NO Check if voltage refer to page T5-4-60.
between harness end
connector terminals Harness breakage
No.1 and No.3 is YES between MC and
Switch pump control 5 ± 0.5 V. pump control pres-
pressure sensors (ones sure sensor terminal
in 4-spool side and in 5- • Key switch: ON Check if voltage No.3.
spool side control between harness end
valves) with each other. connector terminals
Perform “RETRIAL.” NO No.1 and vehicle
Check if the indicated frame is 5 ± 0.5 V. Harness breakage
fault code changes to between MC and
the one for the other • Key switch: ON NO pump delivery pres-
pump control pressure • 5 ± 0.5 V for the volt- sure sensor terminal.
sensor. age change standard
values.
Faulty pump control
YES pressure sensor.

Connector (harness end connector terminals seen from the open end side)

Main Controller (22P): “D” is added for each terminal number in the text.

1 2 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22

Pump Control Pressure Sensor

1 3
2
EX255-EX285 T5-3-7
TROUBLESHOOTING A

FAULT CODE 06
(ARM ROLL-IN PILOT PRESSURE
SENSOR FAILURE)

Harness failure be-

NO
Replace pilot pressure
sensor with pump con-
trol pressure sensor.
Perform “RETRIAL.”
Check if fault code dis-
appears.
YES
YES
tween MC and pilot
Check if breakage or pressure sensor.
short circuit exists
YES between MC 22P
connector terminal
No.D18 and pilot
pressure sensor ter- Faulty MC
Disconnect pilot minal No.2. NO
pressure sensor • After replacement,
connector. Check if refer to page T5-4-60.
voltage between har-
ness end connector
terminals No.1 and Harness breakage
No.3 is 5 ± 0.5 V. YES between MC and pilot
pressure sensor ter-
Check if voltage minal No.3.
• Key switch: ON
between harness end
connector terminals
NO No.1 and vehicle
frame is 5 ± 0.5 V. Harness breakage
between MC and pilot
• Key switch: ON NO pressure sensor ter-
• 5 ± 0.5 V for the volt- minal No.1.
age change standard
values.
Faulty pilot pressure
sensor (arm roll-in).

Connector (harness end connector terminals seen from the open end side)

Main Controller (22P): “D” is added for each terminal number in the text.

1 2 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22

Pilot Pressure Sensor

1 3
2
T5-3-8 EX255-EX285
TROUBLESHOOTING A

FAULT CODE 07
(ENGINE CONTROL DIAL FAILURE)

Harness failure be-

NO
Disconnect engine con-
trol dial connector.
Check if resistance be-
tween engine control dial
side terminals No.5 and
No.7 is 5 ± 0.5 kΩ.
With the engine control
dial connected, insert
test probe from back of
engine control dial. Turn
engine control dial and
check if voltage changes
as specified.
• Refer to page T5-3-9 for
the voltage change stand-
ard values.
YES
Disconnect engine
control dial connec-
tor. Check if voltage
between harness end
connector terminals
No.5 and No.7 i
5 ± 0.5 V.
• Key switch: ON
NO No.5 and vehicle
YES
YES
tween MC and engine
Check if breakage or control dial.
short circuit exists
between MC 22P
connector terminal
No.D21 and engine
control dial terminal Faulty MC
No.6. NO
• After replacement,
refer to page T5-4-60.
Harness breakage
YES between MC and en-
gine control dial ter-
minal No.7.
Check if voltage
between harness end
connector terminals
frame is 5 ± 0.5 V. Harness breakage
between MC and en-
• Key switch: ON NO gine control dial ter-
• 5 ± 0.5 V for the voltage
minal No.5.
change standard
values.
Faulty engine control
dial.

Connector (harness end connector terminals seen from the open end side)

Main Controller (22P): “D” is added for each terminal number in the text.

1 2 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22

Engine Control Dial

4 3 2 1
5 6 7 8 9
EX255-EX285 T5-3-9
TROUBLESHOOTING A

SENSOR OPERATING RANGE LIST

1. Preconditions for measurement

• Hydraulic Oil Temperature: 50 ± 5 °C (122 ± 9 °F)

• Unless otherwise instructed, set the switches as
follows:

Engine E Mode Work Auto-Idle

Control Dial Switch/HP Mode Switch
Mode Switch Switch
Max. OFF General OFF
Position Purpose
Mode

• Monitor using the Dr.EX.

SM0631
2. Sensor Operating Range

Item Required Control/Switch Operation

At minimum speed position 0.3 to 1.0 V
Engine Control Dial
At maximum speed position 4.0 to 4.7 V
Engine control dial at Min. position 2.5 to 2.7 V
Engine control dial at Max. position with HP mode
switch turned OFF 3.3 to 3.7 V
EC Sensor
Engine control dial at Max. position with HP mode 0.2 V or more larger than the voltage
switch turned ON obtained above (with the engine
control dial at Max. position with HP
mode switch turned OFF)

Control Levers: Neutral 25+15

-7 kgf/cm
2

Pump Delivery Pressure

Sensor Boom Raised to stroke end and main relief 350+20 2
-5 kgf/cm
valve relieved

Control Levers: Neutral

Pilot Control Shut-Off Lever: 0 to 1.0 kgf/cm2
Locked Position
Pilot Pressure Sensor
Control Lever: Full Stroke
Pilot Control Shut-Off Lever: 34 to 40 kgf/cm2
Unlocked Position
Control Levers: Neutral
10 to 16 kgf/cm2
Pump Control Pressure
Sensor One Track Jacked-Up Travel Lever (Raised track
side): Full Stroke 30 to 40 kgf/cm2

NOTE - 1 kgf/cm2 = 0,09807 MPa

T5-3-10 EX255-EX285
TROUBLESHOOTING A
EX255-EX285 T5-4-1

TROUBLESHOOTING B

TROUBLESHOOTING B PROCEDURE

Apply troubleshooting B procedure when no fault code Start the troubleshooting with more probable causes
is displayed on the Dr.EX although the machine’s selected by referring to these tables.
operation is abnormal.
On the front section pages of this group T5-4, are
tables indicating the relationship between machine
trouble symptoms and related parts which may cause
such trouble if failed.

• How to Read the Troubleshooting Flow Charts

YES (OK)
(2)
• After checking or measuring item (1), select either Yes (OK) or No
(1) (NOT OK) and proceed to item (2) or (3), as appropriate.

(3)
NO(NG)

• Special instructions or reference item are indicated in the spaces under the box. Incorrect
measuring or checking methods will render troubleshooting impossible, and may damage
Key switch: ON components as well.

• Explanation of how to use lamp harness kit required. Refer to “Harness Check” Group
(Group 7) in this section.

• Use the Dr. EX troubleshooting/monitor function for the description in a double line box.

• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-2 EX255-EX285

TROUBLESHOOTING B

RELATIONSHIP BETWEEN MACHINE This table indicates the probable machine trouble
TROUBLE SYMPTOMS AND PARTS IN symptoms by part item when each part is failed and
TROUBLE procedures to determine if the part has failed.

Part Name
EC Motor EC Sensor Engine Control Dial

Part function • To operate governor lever. • To detect the slow-idle speed • To instruct the engine
governor lever position (2.5 V). target speed governor lever
position.

Control System • Governor lever does not • Whenever key switch is ON,
Trouble move. governor lever position is learned
as in the slow idle speed position
differing from the correct position.
Accordingly, engine speed is
controlled afterward with the
discrepancy which occurred at this
time.
• Even if engine control dial
is operated, engine speed
is unchanged.
• If harness to engine control
dial is broken, target speed
1600 min-1 is used as the
backup value

Machine Symptoms • Even if engine control dial is • If the discrepancy occurred to the • Engine speed is constantly
operated, engine speed does slower side, engine speed is held at 1600 min-1.
not increase from slow changed by engine control dial. (Auto-idle function
speed range. However, engine speed control operates, and engine can
• Starter rotates but engine range stays slower than normal. be stopped by turning key
(Note: If the discrepancy occurred switch.)
fails to start occasionally.
to the faster side, when engine
• While engine is running at a control dial is turned to the fastest
faster than specific speed, if position, EC motor continues
harness to EC motor is bro- moving. However, EC motor is a
ken, engine stalls. worm gear type so that governor
• While engine is running at a lever is kept holding at the full
slower than specific speed, if stroke position. If engine control dial
harness to EC motor is bro- is turned to the slowest position,
ken, engine becomes uncon- governor lever returns to the slow
trollable. idle position.)
• When engine is started, engine
speed fluctuates.
• Engine start may become difficult

Trouble By Dr.EX Self- - Fault code 01 is displayed. Fault code 07 is displayed.

shooting Diagnosing
Proce- Function
dures -
By Dr.EX Monitor Monitor Item: EC Angle Monitor item:
Function Target Engine Speed

By Lamp Harness • Install test harness - -

Check (75301706B). Then, check
output signal from EC and
check if harness is normal

By Other Check/ - - -
Measurements
Note • Engine is stopped by • If EC sensor is failed, engine -
EC motor. learning operation becomes
No engine stop impossible.
is provided. However, a
fuel shut-off cable is in-
stalled

Descriptions in T2-1 T2-1 T2-1

(Operational Principle)
Technical Manual
EX255-EX285
Pump Control
Pressure Sensor
• To detect pump control valve
pressure in control valve to
control the travel motor
swash angle.
• Sensor output is reduced
to zero and travel motor
swash angle is held to the
maximum angle.
• Even if travel mode switch is
turned to the fast mode
position, travel speed does
not change to the fast
range.
Fault codes 04 and 05 are
displayed.
Monitor items:
Pump 1 Control Pressure
Pump 2 Control Pressure
- -
- -
• Evaluation by Dr.EX
0.25 V or Less: Discontinuity
4.75 V or More: Short Circuit
T2-1
TROUBLESHOOTING B
Pump Delivery
Pressure Sensor
Ž To detect both right and left
pump delivery pressures to
control speed sensing system,
HP mode circuit, arm regen-
erative circuit, and travel motor
swash angle.
• When pump delivery pressure
sensor output is 0 V or 5 V, the
following symptoms appear.
• Travel speed is changed to the
slow speed range. However,
automatic up shifting to the
fast speed range from slow
speed range is impossible.
• HP mode does not work.
• When combined operation is
made, arm speed is slow
(when delivery pressure
sensor for pump 2 has
failed).
Fault codes 02 and 03 are
displayed.
- Monitor item:
- -
T2-1
N Sensor
• To detect engine speed to
control speed sensing system.
• Speed sensing system does
not function.
• Engine stalls when the
machine is operated at a high
altitude or under heavy operating
conditions.
- -
Actual Engine Speed
- • Install lamp harness
- -
T2-1
T5-4-3
Solenoid Valve Unit
(SG)
• To increase relief setting
pressure temporarily.
• If solenoid valve unit (SG)
is not energized, pilot pres-
sure at port SG is 0 MPa
(0 kgf/cm2).
• Main relief pressure set is
unchanged from the
standard setting pressure
of 34 MPa (350 kgf/cm2).
Even if the power boost
switch is depressed, main
relief pressure does not
increase. Digging force
does not increase.
Monitor item:
Power boost pressure
(75301514). Then, check
output signal from MC and
check if harness is normal.
• Proportional solenoid
valve is used for the ON-
OFF valve so that whether
the power boost switch is
depressed or not, as long
as an output signal from
MC is measure by means
of test harness, the control
of solenoid valve unit is
normal. If any output signal
is detected, a broken wire
harness may be a cause.
See NOTE at the end of
TABLE.
T2-1
T5-4-4 EX255-EX285

TROUBLESHOOTING B

Part Name Solenoid Valve Unit (SD) Solenoid Valve Unit (SC) Solenoid Valve Unit (SI)

Part function • To reduce pump swash
angle by guiding pilot
pressure to regulator to ope-
rate the speed sensing
control system.
Control System • Pilot pressure is not fed to
regulator.
Trouble
• When arm is rolled in, arm
speed is increased by guiding
return oil from arm cylinder rod
side to bottom side.
• If solenoid valve unit (SC) is not
energized, pilot pressure at port
SC is 0 MPa (0 kgf/cm2).
Thereby, arm regenerative
function does not work.
• To increase travel speed
by decreasing travel motor
swash angle when fast
travel mode is selected
and pump delivery
pressure is low.
• Travel speed is held in
slow speed range.

Machine Symptoms • Engine may stall under
heavy conditions such as
operation at a high altitude.
• When leveling, arm speed
becomes very slow.
• Travel speed does not
increase even if travel
mode switch is turned to
the fast travel speed
position.

By Dr.EX Self- - - -
Diagnosing
Function

Trouble By Dr.EX Monitor Monitor item: Monitor item: Monitor item:

shooting Function Pump proportional Arm regenerative proportional Travel motor displacement
Proce- Solenoid valve output solenoid valve output angle change pressure
dures

By Lamp Harness • Install test harness • Install test harness • Install test harness
Check (75301514). Then, check (75301514). Then, check output (75301514). Then, check
output signal from MC and signal from MC and check if output signal from MC and
check if harness is normal. harness is normal. check if harness is normal.

By Other Check/ - - -
Measurements

Note Output signal MC must be
measured with the
solenoid valve connected.
See NOTE at the end of
table.
Output signal MC must be
measured with the
solenoid valve connected.
See NOTE at the end of
table.
Output signal MC must be
measured with the
solenoid valve connected.
See NOTE at the end of
table.

Descriptions in T2-1 T2-1 T2-1

(Operational
Principle)Technical
Manual
EX255-EX285
Pressure Switch (Travel)
• To detect that travel spool
is operated (for auto-idle
operation and travel motor
swash angle control).
• No signal is sent to MC.
• Even if machine is traveled
with auto-idle switch ON,
engine speed does not
increase.
• When traveling on a flat
area in the fast travel
mode, travel speed is
slow.
- -
Monitor item: Pressure
Switch
While traveling, monitor to
check if pressure switch is
ON or OFF.
- -
- -
• It is possible to check if
pressure switch has failed
or if a port is clogged by
switching the pressure
switch with an adjacent one
(for front).
T2-1
TROUBLESHOOTING B
Pressure Switch (Front)
• To detect that front and/or
swing spool is operated (for
auto-idle operation).
• No signal is sent to MC.
• Even if either front or swing
control lever is operated with
auto-idle switch ON, engine
speed does not increase.
Monitor item: Pressure Switch
While operating front or swing
function, monitor to check if
pressure switch is ON or
OFF.
• It is possible to check if
pressure switch has failed or
if a port is clogged by
switching the pressure
switch with an adjacent one
(for travel).
T2-1
T5-4-5
Pressure Switch Pilot Pressure Sensor
(Boom Raise) (Arm Roll-In)
• To detect boom raise pilot • To detect arm roll-in pilot
pressure (for arm pressure (for HP mode
regenerative control). control and arm regenera-
tive control).
• No signal is sent to MC. • No signal is sent to MC.
• As arm regenerative function • When the combined opera-
does not work, when boom is tion of swing and arm roll-in
raised and arm is rolled in, is made, arm regenerative
arm speed is slower than function does not work so
normal (difficult to discern). that arm speed is slow
• When beginning to level a when starting to roll in (dif-
ground surface, bucket is ficult to discern).
slightly lowered into the • Arm speed is slow when
ground. leveling.
• HP mode does not function
when arm is rolled in.
- Fault code 06 is displayed.
Monitor item: Pressure Switch. Monitor item:
While raising boom, monitor to check Arm Roll-In Pilot Pressure
if pressure switch is ON or OFF
- -
- -
- -
T2-1 T2-1
T5-4-6 EX255-EX285

TROUBLESHOOTING B

Part Name Learning Switch Power Boost Switch HP Mode Switch

Part function • To start learning engine control
ON: 0 V → Learning
OFF: 5 V → Normal Control
• To operate power boost function
ON: 0 V → Boost function works.
OFF: 5 V → Boost function does
not work.
• To control HP mode
operation
ON: 0 V → HP Mode.
OFF: 5 V → Standard Mode.

Control System • Engine learning does not • Breaking of Wire: Boost function -
function. does not work.
Trouble Short Circuit: Boost function
works for 8 seconds after key
switch is turned ON, but becomes
inoperative afterwards.

Machine Symptoms • If trouble is caused by cir-
cuit discontinuity, engine
control system operates
normally. (Only engine
learning function fails.)
• If trouble is caused by a
short circuit, the learning
mode operates when key
switch is turned ON. There-
fore, engine may stall 5 sec-
onds after engine starts.
• Power boost function does not
work if whether a wire is broken
or short circuit occurs.
• Broken Wire: Even if HP
mode switch is
depressed, HP mode does
not operate.
• Short Circuit: Even if HP
mode switch is turned
OFF, HP mode is not
deactivated.

By Dr.EX Self- - - -
Diagnosing
Function

Trouble By Dr.EX Monitor Monitor item: Monitor item: Power Boost Switch Monitor item: HP Mode
shooting Function Engine Learning Control Switch
Proce-
dures
By Lamp Har- - - -
ness Check

By Other Check/ - - -
Measurements

Note - - -

Descriptions in T2-1 T2-1 T2-1

(Operational
Principle)Technical
Manual
EX255-EX285 T5-4-7

TROUBLESHOOTING B

E Mode Switch Travel Mode Switch MC Pump Control

Valve

• To select E mode.
ON: 0 V → E Mode
OFF: 5 V → Standard Mode
• To change travel speed at two
stages.
Fast Travel Mode:
0 V → Traveling at fast
speed
Slow Travel Mode: 5 V
• To control engine, pump, and
valve operations.
• To develop pump control
pressure in response to the
oil flow rate passing through
the center bypass passage
in the control valve.

- • Discontinuity in Switch:
Travel speed is kept in slow
range (5 V).
• Problems may differ depending
on the trouble. (Machine
troubles shown below signify
that the logic circuit in MC has
some faults.)
• If the pump control valve
spool is seized, or the
spring is broken, pump con-
trol pressure does not
change.

• Broken Wire: Even if E • Even if travel mode switch is
mode switch is depressed,
engine runs at full speed.
• Short Circuit: Engine
speed is not increased up
to full speed.
• Even if key switch is turned to
turned to the fast travel the ON position, EC motor
mode position, travel speed does not rotate to the start
is un-changed. position so that engine cannot
start. Or, even if engine is
started, engine speed does not
increase.
• Pump swash angle is held to a
minimum, all function speeds
are slow.
• When the 5-spool side
pump control valve is faulty:
1.Left track travel speed
only
is slow.
2.Swing function is also slow.
3.Arm speed is slow when
leveling.
4.Single operation of bucket,
boom, or arm is almost
normally performed.
• When 4-spool side pump
control valve is faulty:
1.Bucket single operation
speed is very slow.
2.Boom is not raised when
leveling.
3.Right track travel speed
only is slow.
4.Single operation of boom,
arm, or swing is almost
normally performed.

- - Procedures may differ depending -

on the locations of failures.

Monitor item: Monitor item: - Monitor items:

E Mode Switch Selected Travel Mode Switch Pump 1 Control Pressure
Pump 2 Control Pressure

- - - -

- - - -

- - • Before suspecting a failure in MC, -

check the fuse in this control cir-
cuit.

T2-1 T2-1 - T3-3

T5-4-8 EX255-EX285

TROUBLESHOOTING B

Part Name Flow Combiner Valve Restriction in Arm 1 Check Valve and Restriction in
Parallel Passage 4-Spool Side Parallel Circuit

Part function • To supply hydraulic oil to • To ensure lateral thrust force of • To supply hydraulic oil from
both right and left travel the front by swing function. pump 1 to arm 1 spool in
spools from pump 1 when pump 2 side.
the combined operation of
travel and
front/swing is made.

Control System • When the combined opera-
tion of travel and front/swing
Trouble is made, hydraulic oil is not
supplied to the left travel
spool, or oil flow to the left
travel spool is insufficient.
• If the restriction is clogged,
hydraulic oil does not flow
through the arm 1 parallel
circuit.
• If the check valve is seized
and kept closed, or the
restriction is clogged,
hydraulic oil does not flow
from pump 1 to arm 1
spool.
• If the check valve is seized
and kept opened, hydraulic
oil from pump 2 flows to the
pump 1 side.

Machine Symptoms • While traveling straight, the
machine mistrack when the
swing lever is operated.
• Arm speed is slow when • When check valve is kept
leveling. closed, or restriction is
clogged:
Arm speed is slow when
leveling.
• When check valve is kept
opened:
Left travel speed is slow.

By Dr.EX Self- - - -
Diagnosing
Function

Trouble By Dr.EX Moni- - - -

shoot- tor Function
ing
Proce-
dures By Lamp Harness - - -
Check

By Other Check/ - - -
Measurements

Note - - -

Descriptions in T3-3 T3-3 T3-3

(Operational Principle)
Technical Manual
EX255-EX285 T5-4-9

TROUBLESHOOTING B

Arm Regenerative
Control Valve
• To increase arm speed by
allowing the return oil from the
arm cylinder rod side to flow
into the arm cylinder bot-
tom side when the valve is
switched by pilot pressure
oil led from solenoid valve
unit (SC)
Travel Flow Control Valve
• To reduce the shock load
developed when single travel
operation is switched to the
combined operation of travel
and front by gradually
restricting oil flow in the
travel parallel circuit.
Travel and Boom Lower
Selector Valve
• To ensure the boom lower
force when the combined
operation of travel and boom
lower is made.
Arm Anti-Drift Valve
• To prevent the arm drift
caused by inner leakage
of hydraulic oil in control
valve. Only when arm roll-
in operation is made, anti-
drift valve (check valve) in
the arm cylinder return
circuit is forcibly opened
so that the arm is rolled in.

• Arm regenerative function
does not operate.
• Oil flow is not restricted
properly.
• Boom 2 spool does not move • Check valve does not
when the combined operation open if the changeover
of travel and boom lower is valve is seized.
made.
• Boom 2 spool is moved even if
the single operation of boom
lower is made.

• Arm speed is very slow
when leveling.
- -
• When fully closed:
Great shock is felt when
changed from travel single
operation to travel combined
operation.
• When fully opened:
The boom is not raised
when the combined opera-
tion of travel down a slope
and boom raise with the
bucket loaded is made.
(Boom is raised when boom
single operation is
performed.)
• When fully opened:
Boom lower speed is very fast.
With swing lever fully stroked,
swing speed is slow when the
combined operation of swing
and boom lower is made.
• When fully closed:
With the front lowered while
traveling, the track of the base
machine is not raised off the
ground.
- -
• If check valve does not
open fully, arm roll-in
speed is slow.
• If check valve is kept
opened, arm drift
increases due to the
control valve inner leakage.
• According to the degree of
seizure in check valve,
arm roll-in operation
becomes jerky, or slower.

- - - -

- - - -

- - - -

- - - -

T3-3 T3-3 T3-3 T3-3

T5-4-10 EX255-EX285

TROUBLESHOOTING B

Part Name Boom Anti-Drift Valve
Part function • To prevent the boom drift
caused by inner leakage of
hydraulic oil in control valve.
Only when boom lower
operation is made, anti-drift
valve (check valve) in the
boom cylinder return circuit
is forcibly opened so that
boom is lowered.
Boom Regenerative Valve
• To prevent boom hesitation when
lowering boom by allowing the
return oil from the boom cylinder
bottom side to flow into the boom
cylinder rod side.
Bucket Flow Control
Valve
• To restrict the bucket
circuit to assist boom to
raise when the combined
operation of bucket, arm
roll-in, and boom raise is
made.

Control System • Check valve does not open • With check valve kept closed, • Bucket circuit is always
Trouble if the switch valve is seized. boom lower speed becomes slow. restricted if the switch
• With check valve kept opened, valve is seized.
the track of the base machine is
not raised off the ground by
lowering the boom.

Machine Symptoms • If check valve does not
open, boom is not lowered.
• If check valve is kept
opened, boom drift
increases due to the control
valve inner leakage.
• According to the degree of
seizure in check valve,
boom lower operation
becomes jerky, or slower.
• Same as described in the above
column.
• Bucket speed is slow if
poppet valve is seized and
kept closed, or switch val-
ve is seized so that the
poppet valve is closed.
• Boom is not raised when
the combined operation of
bucket, arm roll-in, and
boom raise is made with
poppet valve fully opened,
or if the switch valve is
seized so that the poppet
valve is fully opened.

By Dr.EX Self- - - -
Diagnosing
Function

Trouble By Dr.EX Monitor - - -

shooting Function
Proce-
dures
By Lamp Harness - - -
Check

By Other Check/ - - -
Measurements

Note - - -

Descriptions in T3-3 T3-3 T3-3

(Operational
Principle)Technical
Manual
EX255-EX285 T5-4-11

TROUBLESHOOTING B

NOTE - The measurement of the control voltage of proportional solenoid valves SG,
SI, SD and SC, must be performed with test harness (75301514) meaning
that the main controller (MC) output must be connected to the load of the
solenoid valve. Under this test configuration, the normal control voltage
changes from 5 through 10 Volt.
On the other hand, when measuring the control voltage directly on the
connector disconnected from the solenoid valve (harness side) the voltage
measured is always 24 Volt and this is irrelevant in troubleshooting the
solenoid valve.
T5-4-12 EX255-EX285

TROUBLESHOOTING B

CORRELATION BETWEEN TROUBLE

SYMPTOMS AND PART FAILURES
Engine Control Pump / Valve Control Switch Panel
EC EC Eng. Coolant QOS Sol. Pump Pump N Arm Press. Press. Auto- Learn- HP
Motor Sen- Cont. Temp. Con- Valve Deliv. Deliv. Sen- Roll Sw. Sw. Idle ing Mode
Trouble Symptom sor Dial Sw. troller Unit Press. Press. sor In Travel Front Sw. Sw. Sw.
(Pre- SD Sensor Sensor Sen- Act.
heat Pump Pump sor
Circuit) 2 1
E-1 Starter does not rotate

E-2 Although starter rotates,

engine does not start.
E-3 Engine runs slower than
normal at all operation
speeds.
Slow idle speed is faster or
slower than normal.

E-4 Even if engine control dial is

turned, engine speed is
unchanged.
E-5 Even if HP mode switch is
depressed, HP mode does
not operate.
E-6 Engine does not stop even
if key switch is turned OFF.
E-7 Auto-idle function does not
function.
E-8 Engine speed does not
change, even if E mode is
depressed.
E-9 Engine stalls several sec-
onds after engine starts.
E-10 Engine stalls when ma-
chine is operated at high
altitude or under adverse
conditions.
E-11 Engine is hard to start at
low ambient temperature.

A-1. All actuators speeds are

slow
A-2. When single travel opera-
tion is made, left side track
slow but right side track is
normal. Single swing op-
eration is slow. Bucket op-
eration is normal. Arm
speed is slow when level-
ing. (All above symptoms
occurred at the same time).
A-3. When single travel opera-
tion is made, right side
track is slow but left side
track is normal. Single
swing operation is normal.
Boom hardly raises when
leveling. (All the above
symptoms occurred at the
same time).
A-4. Actuator does not stop,
even after control lever is in
the neutral position.

NOTE - The above table shows the correlation be-
tween machine operation trouble and related parts
which may cause trouble. However, the correlations in
this table are described based on the condition sup-
posing that each occurs independently.
If any other trouble occur at the same time, find out the
faulty parts causing the trouble by checking all sus-
pected parts in each symptom.
EX255-EX285 T5-4-13

TROUBLESHOOTING B

Switch Panel Engine Pump Control Valve Other

E Key MC Eng. Eng. Gover- Main Pilot Spool Pump Pump Main Pilot Pilot Note
Mode Sw. (Main Elec. Unit nor Pump Pump Cont. Cont. Relief Valve Relief
Sw. Contr.) Parts Unit Valve Valve Valve Valve
5- 4-
Spool Spool
Side Side
Check battery

Check fuel system

Check fuel shut-off

handle. Check engine
control cable. Be sure to
operate engine learning
whenever engine is
replaced.
Check engine control
cable.

Check if fuel system

is clogged

: being linked closely. Checking the part is required.

: being linked, but if this parts is faulty another type of
trouble will be prominent. Therefore this part may not be
the main cause of the trouble.
T5-4-14 EX255-EX285

TROUBLESHOOTING B

Pump/Valve Control Sw. Control valve

Sol. Sol. Pump Arm Press. Power Spool Main Over- Load Boom Re- Check
Valve Valve Deliv. Roll in Sw. Boost Relief load Check Re- stric- Valve
Unit SG Unit SC Press. Sensor Boom Sw. Valve Relief Valve gener- tion & Re-
Sensor Raise Valve ative Arm 1 stric.
Pump 2 Valve Parallel 4-Spool
Parallel
F-1 All front attachment
functions are weak.
F-2 Digging force is not
increased even if
power boost switch is
depressed.
F-3 Some cylinders do
not move or speeds
are slow.
F-4 Boom lower single
operation is fast.
F-5 Arm speed is slow in
a combined opera-
tion.
Arm speed is slow in
leveling operation.
F-6 Bucket digging single
operation is slightly
slow.
Bucket digging single
operation is jerky.
F-7 Arm starting speed is
slow during
combined operations.
Arm operation is
jerky.
During arm roll-in
single operation, arm
starting speed is
slightly slow which often
occurs at low temperature.
F-8 Boom starting speed
is slow during
combined operations.
Boom operation is jerky.
Boom starting speed
is slightly slow during
boom lower single
operation.
F-9 When operating the
control lever to raise
boom or to roll-out
arm, boom or arm
starts to move after
slightly moving in the
reverse direction.
F-10 Front attachment
cylinders drift is large.

S-1 Swing speed is slow or

swing function does
not operate.
S-2 Swing speed is slow
during combined
operation with boom
lower.

NOTE - The above table shows the correlation be- posing that each occurs independently.If any other
tween machine operation trouble and related parts trouble occur at the same time, find out the faulty parts
which may cause trouble. However, the correlations in causing the trouble by checking all suspected parts in
this table are described based on the condition sup- each symptom.
EX255-EX285 T5-4-15

TROUBLESHOOTING B

Control valve Others

Arm Travel Arm Boom Bucket Swing Shock- Pilot Cylinder

Re- Boom Anti Anti Flow Device less Valve Note
gener- Lower Drift Drift Cont. Valve
ative Select. Valve Valve Valve
Valve Valve

Check the work mode switch position

Take care not to confuse power boost

operation with HP mode

Check the work mode switch position

: being linked closely. Checking the part is required.

: being linked, but if this parts is faulty another type of
trouble will be prominent. Therefore this part may not be
the main cause of the trouble.
T5-4-16 EX255-EX285

TROUBLESHOOTING B

Pump/Valve Control Sw. Control valve Others

Sol. PC PC Pump Pump. Press Travel Spool Load Flow Travel Travel Center
Valve Press. Press. Deliv. Deliv. Sw. Mode Check Comb. Boom Device Joint
Trouble Symptom
Unit Sensor Sensor Press. Press. Travel Switch Valve Valve Lower
SI 5 Spool 4 Spool Sensor Sensor Select .
Side Side Pump Pump Valve
2 1
T-1 Both right and left
side tracks do not
move or move
slowly.
T-2 When a single
travel operation is
shifted to a
combined operation
with front functions,
a shock load is felt.
T-3 One side track does
not move or moves
slowly. Or the
machine cannot
travel straight
(mistracks).
T-4 During a combined
operation of travel
and front
attachment
function, the
machine mistracks.
T-5 Steering power and
gradeability are in-
sufficient in the fast
travel mode.
T-6 Travel mode does
not change to the
fast speed range.

O-1 The wiper does not

operate, or will not
retract.

NOTE - The above table shows the correlation be-

tween machine operation trouble and related parts
which may cause trouble. However, the correlations in
this table are described based on the condition sup-
posing that each occurs independently.
If any other trouble occur at the same time, find out the
faulty parts causing the trouble by checking all sus-
pected parts in each symptom.
EX255-EX285 T5-4-17

TROUBLESHOOTING B

Others

Pilot
valve Remarks
.

Refer to A1.

Refert to T-6.

Refer to the troubleshooting section.

: being linked closely. Checking the part is required.

: being linked, but if this parts is faulty another type of
trouble will be prominent. Therefore this part may not be
the main cause of the trouble.
T5-4-18 EX255-EX285

TROUBLESHOOTING B

ENGINE TROUBLESHOOTING

E-1 Starter Does Not Rotate. YES Faulty starter or

disconnected starter ground
line.
Related Fault Code: None

Checking Instructions Regardless of key switch

• Measure each voltage by referring to the tables position ON or START,
voltage at terminal B is 0
below. (zero).
• Electronic system such as MC has nothing to do
with the trouble obstructing the rotation of starter. • Key switch:
ON↔START

Check if each terminal

YES voltage on starter is normal With key switch With key switch
with key switch turned to the positioned at positioned as shown
positions in the following START, voltage at in the following table,
table. terminal C does check if each
not increase to 24 terminal voltage is
volts. normal.
Starter Terminal Voltage Unit: Volt
Key ON ON
switch (Engine START (Engine Starter Relay Terminal Voltage Unit: Volt
not running)
Terminal running) Key ON ON
switch (Engine START (Engine
C 0 24 0 NO not running)
Check if battery Terminal running)
voltage and B 24 24 24
electrolyte density B 24 24 24
M 0 24 0
are normal. C 0 24 0
E 0 0 0
• Voltage:
24 volts or more R 0 0 12
• Density: S 0 24 0
1.26 or more
With key switch
positioned at
Faulty starter or
START, voltage at
disconnected
terminal S does
starter ground line.
not increase to 24
volts.
Faulty Battery
NO
(When key switch is turned to START, in
case voltage at terminal B is 18 V or lower,
battery is faulty.)

• Starter Terminal Voltage Check. • Starter Relay Voltage Check.

(Seen from the back of the connector.)

SM5401 SM6117
EX255-EX285 T5-4-19

TROUBLESHOOTING B

YES Faulty harness between

battery relay and starter.
Check if battery relay clicks
when key switch is turned
OFF from the ON position.
Faulty battery relay
• Key switch: ON↔OFF NO

YES Faulty harness between

Terminal No.1 fusible link and key switch.
With key switch in
voltage: 0 V
START, voltage at Check if fusible link
terminal S does not (40 A) has blown.
Measure voltage
increase to 24 V.
at key switch
terminals No. 1 Blown fusible link 1 (40A).
and No. 6. NO

• Key switch: START

Terminal No.1 voltage: 24 V
Terminal No.6 voltage: 0 V
Faulty key switch.

Terminal No.1 voltage: 24 V

Terminal No.6 voltage: 24 V Faulty harness between key
switch terminal No. 6 and
starter relay terminal S.

Voltage at terminal B is 0 V. Broken harness between

both terminals B on starter
and starter relay.
With key switch in START, voltage at
terminal C is 0 V but voltage at starter
relay terminal C is 24 V. Broken harness between
both terminals C on starter
With key switch in START, voltage at all and starter relay.
terminals other than C is normal. Voltage at
terminal C does not increase to 24 V.
Faulty starter relay.

• Key Switch Voltage Check

NOTE - Remove the key switch from the console.

View A

SM0633
T5-4-20 EX255-EX285

TROUBLESHOOTING B

E-2 Although Starter Rotates, Engine Does Not

Start.

Related Fault Code: None

Checking Instructions
• Check the governor lever and the fuel shut-off lever
positions while the engine is cranking. If their
positions are normal, the engine and the fuel sys-
tem may be faulty.

YES
Faulty engine.

• Refer to engine Section.

With key switch ON, check if
governor lever moves to the
starting position.
• Key switch : ON
Check EC motor activating
NO circuit.

• Governor Lever and Fuel Shut-Off Lever

4 2

1
SM5402

1 - Governor Control Cable

(From EC Motor)
2 - Fuel Shut-Off Cable
[Handle (Emergency Engine
Stop)]
3 - Fuel Shut-Off Lever
4 - Governor Lever
EX255-EX285 T5-4-21

TROUBLESHOOTING B

• Governor Lever Position

A- Key Switch OFF (Engine Stop Position)
B- Key Switch ON (Engine Start Position)

A B
FULL

STOP

P
STO

L
FUL

SM5404

• Fuel Shut-Off Lever

A- Fuel Cut Handle Pulled Position
B- Fuel Cut Handle Returned Position

B
A

SM5405
T5-4-22 EX255-EX285

TROUBLESHOOTING B

E-3 Engine Runs Slower than Normal at

All Operation Speeds.
Slow Idle Speed is Faster or Slower
than Normal.

Related Fault Code: 01

Checking Instructions
• Before the engine learning operation is carried out,
or when the engine learning operation is made in a
wrong procedure, the engine may run slower at all
operation speeds.
• If the EC sensor is faulty, the governor lever
position which is located when the key switch is
turned ON, is learned as the idle position. Then, the
engine is controlled based on this engine learning
operation. Accordingly, the engine runs with dis-
crepancy from the standard control speed. Further
more, this trouble may not reemerge as the extent
of discrepancy in the governor lever position differs
each time when the key switch is turned ON.
• Refer to the Control System Group titled “Engine
Learning Control” in the SYSTEM Section in the
Operational Principle book (Technical Manual).
• Even if the EC motor control becomes abnormal,
the governor lever position is constantly kept at the
full stroke end since the EC motor is a worm gear
type. Accordingly, the engine does not stall.

Restore governor
NO lever or EC motor
cable to correct
Check governor operation.
lever or EC motor YES Faulty EC sensor.
cable for proper
operation.
Check if fault • After replacement, YES End.
code 01 is refer to T5-4-60.
YES displayed.
Check if the
trouble is
NO reconditioned
after engine Monitor the
learning operation engine learning
NO operation.
is conducted.

• Refer to T5-4-60. • Monitor item:

Engine Learning
Control
EX255-EX285 T5-4-23

TROUBLESHOOTING B

Check if governor YES Faulty engine or

lever comes in fuel system.
OK contact with the
stopper when
conducting Faulty control
engine learning cable. Faulty
operation. NO engine governor
lever adjustment.
• Refer to T5-4-60.

Failure in MC.
NOT OK Faulty learning
switch, or
harness between
learning switch
and MC.
• After replacement,
refer to T5-4-60.
T5-4-24 EX255-EX285

TROUBLESHOOTING B

E-4 Even If Engine Control Dial is Turned, En-

gine Speed is Unchanged.

Related Fault Code: 07

Checking Instructions
• Refer to the Control System group titled “Engine
Learning Control” in the SYSTEM Section in the
Operational Principle book (Technical Manual).

Faulty engine control dial or

YES
broken harness between
engine control dial and MC.
Check if fault code 07 is YES Faulty EC motor.
displayed. Connect Lamp Harness
(75301706B) to EC motor. • After replacement, refer to
Check if the lamp comes T5-4-60.
NO ON when engine control dial
is turned. Failure in MC or broken
harness between MC and EC
NO
motor.
• After replacement, refer to
T5-4-60.
EX255-EX285 T5-4-25

TROUBLESHOOTING B

E-5 Even If HP Switch is Depressed, HP Mode

Does NOT Operate.
(Standard Mode Operates Normally.)

Related Fault Codes: 02, 03, and 06

Checking Instructions
• The pressure switches check if the HP mode is
requested so that if these pressure switches fail,
the HP mode does not operate.
• Refer to the Control System group titled “HP Mode
Control” in the SYSTEM Section on the Operational
Principle book (Technical Manual).

Faulty HP mode
NO switch, or broken
harness between
Monitor HP mode
HP mode switch
switch. Check if
and MC.
indication of “HP”
is displayed or
NO deleted on Dr. EX
screen by
operating the HP
mode switch on Check if governor
the right console YES Faulty engine or
lever comes into poor quality fuel.
ON or OFF. contact with full-
Check if fault speed side stopper
code is displayed. • Monitor item: when hydraulic oil
YES pressure is re-
HP Mode Switch
lieved by arm roll-
in operation. Failure in MC.
Faulty sensors, or NO
broken harness • After replacement,
YES between MC and refer to T5-4-60.
sensors.

• Fault codes:
Pump 1 delivery pressure sensor: 02
Pump 2 delivery pressure sensor: 03
Pilot pressure sensor (arm roll-in): 06
T5-4-26 EX255-EX285

TROUBLESHOOTING B

E-6 Engine Does Not Stop Even If Key Switch is

Turned OFF.
(When the engine does not stop, be sure to
start checking after stopping the engine by
pulling the engine stop handle located un-
der the seat stand).

Related Fault Codes: 01 and 07

Checking Instruction
• Trouble symptoms such as “Engine runs slower
than normal at all operation speed” or “Even if
engine control dial is turned, engine speed is un-
changed” are sure to exist at the same time.
Perform the troubleshooting of all symptoms.

E-7 Auto-Idle Function Does Not Function.

Related Fault Code: None

Checking Instruction
• When trouble corresponding to E-1 to E-6 exist,
perform the troubleshooting of them beforehand.
• Refer to the Control System group titled “Auto-Idle
Control” in the SYSTEM Section in the Operational
Principle book (Technical Manual).

Faulty pressure switches

(travel, and front attach-
NO ment).
Faulty harness between
MC and pressure switches.
Monitor pressure switches
Filter in the pilot signal cir-
(travel and front
cuit is clogged.
attachment).
YES Check if indication of “Tr”
and “Fr” is displayed or NOTE - Pressure switches
deleted on Dr.EX screen by (travel, and front attachment)
operating each of the travel are installed on the control
Monitor auto-idle switch. and front control levers.
Check if indication of “AI” valve.
is displayed or deleted on
Dr.EX screen by • Monitor item:
Pressure Switch Failure in MC
operating the auto-idle
switch on the right panel YES
ON or OFF. • After replacement,
refer to T5-4-60.
• Monitor item: Faulty auto-idle switch, or
Auto-Idle Switch broken harness between
NO auto-idle switch and MC.
EX255-EX285 T5-4-27

TROUBLESHOOTING B

E-8 Engine Speed Does Not Change Even If

E Mode Switch is Depressed.

Related Fault Code: None

Checking Instructions
• If trouble corresponding to E-1 to E-7 exist, perform
the troubleshooting of them beforehand.
• Refer to the Control System group titled “E Mode
Control” in the SYSTEM Section in the Operational
Principle book (Technical Manual).

Faulty E mode
Monitor E mode switch, or broken
switch. Check if NO
harness between E
indication of “E” or mode switch and
“P” is displayed MC.
alternately on Dr.EX
screen by operating
the E mode switch Failure in MC.
on the right console YES
ON or OFF.
• After replacement
refer to T5-4-60.

E-9 Engine Stalls Several Seconds After Engine

Starts.

Related Fault Code: None

Checking Instructions
• Refer to the Control System group titled “Engine
Learning Control” in the SYSTEM Section on the
Operational Principle book (Technical Manual).
• If engine learning switch is set to the engine learning
side, engine comes to a stop 5 seconds after engine
is started.

YES Return the switch

End.
to neutral.
Check if engine
learning switch is Faulty learning
turned ON. switch, or short
circuit of harness
between learning
NO switch and MC.
Or, check if the
fuel system is
SM0108
clogged.
T5-4-28 EX255-EX285

TROUBLESHOOTING B

E-10 Engine Stalls When Machine is Operated

at High Altitude, or under Adverse Condi-
tions.

Related Fault Code: None

Checking Instruction
• If speed sensing control does not function, engine
Disconnect har-
may stall under adverse operating conditions. ness from sole-
noid valve unit
Monitor output (SD) and
signal from connect test har-
solenoid valve ness (75301514)
NO between solenoid
unit (SD). With
a pressure gauge valve unit (SD)
installed to port and the discon-
SD, compare the nected harness.
pressure gauge Check if the sole-
NO reading with the noid valve control
monitored voltage is
pressure by present.
Dr.EX. Check if
pressure values
indicated on both Disassemble and
the pressure check regulator.
YES
gauge and the
Dr.EX vary
Monitor engine identically.
NO speed. Check if
engine runs at
abnormal speed. • Monitor item:
Check if fault Pump Proportional
code is displayed. • Monitor item: Solenoid Valve Output
Actual Engine Speed • Refer to Operational
Performance Test
section.

Referring to the Faulty N sensor

displayed fault or faulty harness
code, check YES between N
YES suspectable sensor and MC.
parts.
EX255-EX285 T5-4-29

TROUBLESHOOTING B

YES Faulty solenoid

valve unit (SD).

Broken harness
between solenoid
NO valve and MC.

NOTE - The measurement of the control voltage of proportional solenoid valves SG, SI, SD and SC, must be
performed with test harness (75301514) meaning that the main controller (MC) output must be connected
to the load of the solenoid valve. Under this test configuration, the normal control voltage changes from
5 through 10 Volt.
On the other hand, when measuring the control voltage directly on the connector disconnected from the
solenoid valve (harness side) the voltage measured is always 24 Volt and this is irrelevant in
troubleshooting the solenoid valve.
T5-4-30 EX255-EX285

TROUBLESHOOTING B

E-11 Engine is Hard to Start at Low Ambient

Temperature.
(Even if preheated, engine is hard to start or
does not start at a low ambient temperature
or in a cold climate district.)

Related Fault Code: None

Checking Instruction
• Check if electricity is conducted to glow plugs and
glow plugs are normal.

YES Faulty engine coolant tempe-

rature switch.

Disconnect engine coolant

temperature switch. Check if
voltage at glow plug is 20 to YES
24 V. Faulty QOS controller.
With engine coolant tempera-
• Key switch: ON ture switch
disconnected, ground glow
NO relay terminal No.4 to vehicle
frame. Check if voltage at
With engine coolant
glow plug is 20 to 24 V.
temperature switch, and glow
relay disconnected, check if
• Key switch : ON NO voltage at glow relay harness
• Without removing connector, end connector terminal No.1
ground the terminal to vehicle and No.3 is 20 to 24 V.
frame using a jumper wire,
like a clip, from the reverse
side of the connector.

• Measurement of Glow Plug Voltage and Resistance

Remove
Copper
Plates.

Standard: 20 to 24 V Standard: 10 Ω or Less

SM4049 SM4050
EX255-EX285 T5-4-31

TROUBLESHOOTING B

YES
Faulty glow relay.

10 Ω or less
Faulty engine.

• Refer to engine shop section.

• Refer to T5-4-60 after
Measure glow plug replacing the engine.
NO resistance.

• Key switch: OFF

• After removing copper
plates connecting glow
plugs, measure the glow Replace glow plug.
plug resistance. ∞Ω
T5-4-32 EX255-EX285

TROUBLESHOOTING B

OVERALL ACTUATOR SYSTEM TROU-

BLESHOOTING

A-1 All Actuator Speeds are Slow.

Related Fault Code: None

Checking Instructions
• In case the speed is normal without power, main
relief valve may be faulty (F-1). If speed is ex-
tremely slow, the pump control system may have
malfunction (A-2, or A-3) or the pilot system may be
faulty.
• If N sensor fails, only an abnormal value like
0 min-1 (rpm) is displayed.

YES Normal. Select

general purpose
mode

Check if precision
work mode is Check if
selected. NO
secondary pilot
pressure is normal.
Monitor actual • Arm: Fully rolled in.
NO engine speed. • Monitor item:
Check if abnormal Arm roll-in pilot
speed is pressure
monitored.
• Monitor item: Faulty N sensor
Actual Engine Speed or broken
YES harness in N
Check if any sensor circuit.
fault codes are
NO displayed.

Referring to the
displayed fault
YES code, check
faulty parts.
EX255-EX285 T5-4-33

TROUBLESHOOTING B

NO End

After
disassembling,
cleaning, and
NO adjusting
pilot relief valve,
check if an
abnormal
condition still
remains. Faulty pilot pump
or clogged pilot
YES filter.

Trace the causes

of trouble by
YES checking other
symptoms.
T5-4-34 EX255-EX285

TROUBLESHOOTING B

A-2 When Single Travel Operation is Made, Left

Side Track is Slow But Right Side Track is
Normal. Single Swing Operation is Slow.
Single Bucket Operation is Normal.
Arm Speed is Slow When Leveling.
(All above symptoms occurred at the same
time.)

Related Fault Code: None

Checking Instructions
• Due to some reasons, pump 2 delivery rate is
reduced to the minimum (approx. 20 L/min). Ac-
cordingly, left side track and swing function speeds
are too slow as they are actuated by pressure oil
from pump 2.
• Arm and boom cylinders are also actuated by
pressure oil from pump 1 so that arm and boom
speed is slightly reduced when the single operation
of arm or boom is made. However, when the level
crowding operation is made, oil flow to boom cylin-
ders has priority over arm cylinder. Then, almost no
oil flow is supplied to arm cylinder, reducing arm
speed.
• Refer to “Control Valve” and “Pump Device” groups
in COMPONENT OPERATION Section in the Op-
erational Principle book (Technical Manual).

YES Reconnect
correctly.

Check if pump
NO control pipe lines
NO Faulty pump
are correctly
control valve
connected.
(5 spool side).

Check if fault Monitor pump

code is displayed. control pressure
by operating
NO control lever.
Referring to the
displayed fault Check if pump
code, check control pressure
YES
suspected parts. increases.
Check regulator
YES for pump 2.
• Swing or travel left
• Monitor item:
Pump 2 Control Pressure
EX255-EX285 T5-4-35

TROUBLESHOOTING B

A-3 When Single Travel Operation is Made,

Right Side Track is Slow But Left Side Track
is Normal.
Single Bucket Operation is Slow. Single
Swing Operation is Normal.
Boom Hardly Raises When Leveling.
(All the above symptoms occurred at the
same time.)

Related Fault Code: None

Checking Instructions
• Due to some reasons, pump 1 delivery rate is
reduced to the minimum (approx. 20 L/min). Ac-
cordingly, right side track and bucket function
speeds are too slow as they are actuated by
pressure oil from pump 1.
• Arm and boom cylinders are also actuated by
pressure oil from pump 2 so that arm and boom
speed is slightly reduced when the single operation
of arm or boom is made. However, when the level
crowding operation is made, oil flow to arm cylinder
has priority over boom cylinders. Then, almost no
oil flow is supplied to boom cylinders, causing boom
to become immovable.
• Refer to “Control Valve” and “Pump Device” groups
in COMPONENT OPERATION Section in the Op-
erational Principle book (Technical Manual).

YES Reconnect
correctly.

Check if pump
NO control pipe lines
NO Faulty pump
are correctly
control valve (4
connected.
spool side).

Check if fault Monitor pump

code is displayed. control pressure
by operating
NO control lever.
Referring to the
displayed fault Check if pump
code, check control pressure
YES
suspected parts. increases.
Check regulator
YES for pump 1.
• Bucket or travel right.
• Monitor item:
Pump 1 Control Pressure
T5-4-36 EX255-EX285

TROUBLESHOOTING B

A-4 Actuator Does Not Stop Even After

Control Lever is Returned to Neutral.

Related Fault Code: None

Checking Instruction
• Sticking of pilot valve spool or control valve main
spool may be the cause of the trouble.

YES Faulty Pilot Valve.

• When control lever is in

neutral, pilot pressure is
Check if actuator stops when guided to control valve
pilot control shut-off lever is spool.
raised.

Faulty Control Valve.

NO
• Pilot pressure is not
guided to control valve
spool. However, control
valve is kept open as
spool is stuck.
EX255-EX285 T5-4-37

TROUBLESHOOTING B
T5-4-38 EX255-EX285

TROUBLESHOOTING B

FRONT ATTACHMENT CONTROL SYS-

TEM TROUBLESHOOTING

F-1 All Front Cylinder Functions are Weak.

Related Fault Code: None

Checking Instructions
• If motion speed is normal and power is weak, main
relief valve may be faulty (F-1). If motion speed is
too slow, pump control system may have malfunc-
tion (A-2, or A-3) and pilot system also may be
faulty. NOTE - 1 kgf/cm2=98.07 kPa

Main Relief Valve

is normal. Trace
350 to 370 kgf/cm2 the cause of the
trouble by
Monitor pump 1 checking other
and 2 delivery symptoms.
pressures.
Adjust main relief
• Monitor item: • E mode switch: OFF Less than 350 kgf/cm2 valve.
Pump 1 Delivery Pressure • HP mode switch: OFF
Pump 2 Delivery Pressure • Work mode: General
• Relieve boom, arm, or purpose mode.
bucket.

F-2 Digging Force is Not Increased Even If

Power Boost Switch is Depressed.

Related Fault Code: None

Checking Instruction
• Refer to the Control System Group titled “Power
Boost” in the SYSTEM Section in the Operational
Principle book (Technical Manual).
Normal
Pressure increases from less than (HP mode
350 kgf/cm2 to 370 kgf/cm2. operation might
have been
mistaken for
Monitor the Faulty power Power Boost
delivery Monitor power operation.)
boost switch, or
pressures from boost switch. NO broken harness
pumps 1 and 2. Check if the
between power
indication of “Pd” boost switch and
• Monitor items: is displayed or MC.
Pump 1 Delivery Pressure does deleted on Dr.EX
Pressure not increase. by operating
Pump 2 Delivery power boost Measure oil
Pressure switch. YES pressure at the
• With power port of solenoid
boost switch • Monitor items: valve unit (SG).
depressed, Power Boost Switch
• With power boost
check the pump
switch depressed,
delivery pressure.
check pressure
change.
• Refer to Operational
Performance Test
section
EX255-EX285 T5-4-39

TROUBLESHOOTING B

NOTE - The measurement of the control voltage of proportional solenoid valves SG, SI, SD and SC, must be
performed with test harness (75301514) meaning that the main controller (MC) output must be connected
to the load of the solenoid valve. Under this test configuration, the normal control voltage changes from
5 through 10 Volt.
On the other hand, when measuring the control voltage directly on the connector disconnected from the
solenoid valve (harness side) the voltage measured is always 24 Volt and this is irrelevant in
troubleshooting the solenoid valve.

NOTE - 1 kgf/cm2=98.07 kPa

Disconnect harness
from solenoid valve
unit (SG) and
connect test
YES Faulty solenoid
harness (75301514)
between solenoid valve unit (SG).
Pressure does valve unit (SG)
not change. and the
disconnected
harness. Check
when the switch is Faulty harness
actuating if the between solenoid
NO
solenoid valve valve and MC.
control voltage is
present.

• Power boost switch: ON

Faulty main relief

Pressure increases valve.
from less than 5
kgf/cm2 up to 10
kgf/cm2.
T5-4-40 EX255-EX285

TROUBLESHOOTING B

F-3 Some Cylinders Do Not Move or Speeds

are Slow.

Related Fault Code: None

Checking Instructions
• Discriminate whether the cause of the trouble is in
the pilot system or in the main circuit system.
• If other functions (travel, swing) are normal, the pilot
pump is considered to be normal.
• If bucket single operation speed is slow, refer to
F-6 as well.
• If arm roll-in single operation speed is slow, refer to
F-7 as well.
• If boom lower single operation speed is slow, refer
to F-8 as well.
Faulty cylinder
YES
(Seal kits are
faulty.)
Monitor pump Check if overload
control pressure YES relief pressure is
by slowly normal.
YES operating the
Faulty overload
control lever.
Check if the pilot NO relief valve
Check if the
valve delivery control pressure
pressure is changes Control valve
normal by smoothly. spool is sticking.
NO
monitoring or
measuring.
• Monitor item:
Pump 1 Control
• Pilot valve delivery Pressure
pressure: Refer to Pump 2 Control
Operational Pressure
Performance Test NO Faulty pilot valve
section.
• Monitor Item: Check if the pilot
Arm Roll-In Pilot valve delivery
Pressure NO pressure is
• When measuring the correct at the inlet
pilot valve delivery Shockless valve
port of the spool sticking
pressure for boom YES
shockless valve.
raise or lower, bucket
roll-in or roll-out, or • Only when
arm roll-out, install a operating arm
pressure gauge to the roll-out or boom
control valve pilot oil raise.
port.

Shockless Valve

2 1
3
4
5 1 - From swing left pilot valve
6 2 - From swing right pilot valve
3 - From bucket roll-out pilot valve
7 4 - From bucket roll-in pilot valve
5 - From boom raise pilot valve
6 - From boom lower pilot valve
7 - From arm roll-out pilot valve
8 8 - From arm roll-in pilot valve

SM0634
EX255-EX285 T5-4-41

TROUBLESHOOTING B

F-4 Boom Lower Single Operation Speed is

Fast.

Related Fault Code: None

Checking Instructions
• When the speed is too fast, travel/boom lower
selector valve may be sticking.

NO Trace the cause of the trou-

ble by checking other types
of trouble.

Check if travel/boom lower

selector valve is scored or
stuck.

Faulty travel/boom lower

YES selector valve.
T5-4-42 EX255-EX285

TROUBLESHOOTING B

F-5 Arm Speed is Slow in a Combined Opera-

tion.
Arm Speed is Slow in leveling Operation.

Related Fault Codes: 03 or 06

Checking Instructions
• Refer to the Control System Group titled “Arm
Regenerative Control” in the SYSTEM section in
the Operational Principle book (Technical Manual).
• When arm speed is slow in only a combined opera-
tion with boom lowering, travel/boom lower selector
valve may be faulty.
• Refer to the Control Valve group in the COMPO-
NENT OPERATION section in the Operational
Principle book (Technical Manual).

NOTE - When the grading mode is selected, arm Disconnect

regenerative control does not function so that arm harness from
speed becomes slow. solenoid valve
unit (SC).
Connect test
Monitor the output harness
(75301514) YES Faulty solenoid
signal from
solenoid valve unit between solenoid valve unit (SC)
(SC). Install a NO valve unit (SC)
pressure gauge to and the
port SC and com- disconnected
NO harness. Check Broken harness
pare the
when a combined between solenoid
monitored NO
operation is valve and MC.
pressures by Dr.
Check if any fault EX with the gauge performed, the
codes readings. Check if solenoid valve
are displayed. both pressures control voltage is
vary identically. present.
• Fault codes:
Pump delivery • Perform the combined
pressure sensor operation of boom
(Pump 2): 03 • Monitor Item: raise and arm roll-in.
Pilot pressure sensor Arm Regenerative
(Arm roll-in): 06 Proportional Solenoid
• Perform a combined
operation of boom raise YES
NOTE - If other fault and arm roll-in.
codes are displayed, • Measurement: Refer to
check the suspected parts Operational Performance
referring to the displayed Test section.
fault code.
Faulty sensor or
broken harness
YES between MC and
sensors.
EX255-EX285 T5-4-43

TROUBLESHOOTING B

NOTE - The measurement of the control voltage of proportional solenoid valves SG, SI, SD and SC, must be
performed with test harness (75301514) meaning that the main controller (MC) output must be connected
to the load of the solenoid valve. Under this test configuration, the normal control voltage changes from
5 through 10 Volt.
On the other hand, when measuring the control voltage directly on the connector disconnected from the
solenoid valve (harness side) the voltage measured is always 24 Volt and this is irrelevant in
troubleshooting the solenoid valve.

YES Faulty arm

regenerative
valve

Check if arm
regenerative
Faulty check
valve on 5-spool
YES valve or
control valve is
Check if check restriction
seized or stuck.
valve or (in 4-spool control
restriction in the valve).
parallel passage
NO in the 4-spool YES Faulty restriction
control valve is
(in 5-spool control
seized, bound, or
valve)
clogged. Check if the
NO restriction in
arm 1 parallel Trace the cause
passage in 5- of the trouble by
spool control NO
checking other
valve is clogged. types of trouble.
T5-4-44 EX255-EX285

TROUBLESHOOTING B

F-6 Bucket Digging Single Operation is

Slightly Slow.
Bucket Digging Single Operation is
Jerky.

Related Fault Code: None

Checking Instructions
• Refer to A-3.
• Refer to Control Valve group in the COMPONENT
OPERATION section in the Operational Principle
book (Technical Manual).

NO Trace the cause of the

trouble by checking other
types of trouble.
Check if bucket flow control
valve in control valve is
seized or bound.
Cleaning or replacement of
YES bucket flow control valve.

F-7 Arm Starting Speed is Slow during

Combined Operations. Arm Operation
is Jerky.
During Arm Roll-in Single Operation,
Arm Starting Speed is Slightly Slow
which Often Occurs at Low Tempera-
ture.

Related Fault Code: None

Checking Instructions
• Refer to Control Valve group in the COMPONENT
OPERATION section in the Operational Principle
book (Technical Manual).

NO Trace the cause of the

trouble by checking other
types of trouble.
Check if anti-drift valve is
seized or bound.
Cleaning or replacement of
YES anti-drift valve.
EX255-EX285 T5-4-45

TROUBLESHOOTING B

F-8 Boom Starting Speed is Slow during Com-

bined Operations. Boom Operation is Jerky.
Boom Starting Speed is Slightly Slow dur-
ing Boom Lower Single Operation.

Related Fault Code: None

Checking Instructions

• Refer to Control Valve group in the COMPONENT

OPERATION section in the Operational Principle
book (Technical Manual).

NO Trace the cause of the

NO
Check if boom anti-drift
valve is seized or stuck.
trouble by checking other
symptoms.
Check if boom anti-drift
valve is seized or stuck.
Cleaning or replacement of
boom regenerative valve.
YES

Cleaning or replacement of
YES boom anti-drift valve.
T5-4-46 EX255-EX285

TROUBLESHOOTING B

F-9 When Operating the Control Lever to Raise

Boom or to Roll-out Arm, Boom or Arm
Starts to Move after Slightly Moving in the
Reverse Direction.

Related Fault Code: None

YES Faulty anti-drift valve

YES Check if anti-drift valve for

arm or boom is sized or
bound.
Cylinder internal leakage
Check if load check valve in NO
control valve operates
correctly.

• Disassemble and visually

check. Faulty load check valve
NO
EX255-EX285 T5-4-47

TROUBLESHOOTING B

NOTE - 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve is
(B)
malfunctioning, the oil in the bottom side of
the boom cylinder flows back into the
circuit through the load check valve, caus- When the load check valve
ing the boom cylinder to temporarily re- is malfunctioning: (A)
tract.
2. If the clearance between the piston and the
cylinder barrel is poor, oil pressure in the
bottom side (A) leaks to rod side (B). As oil
pressure and flow rate from the pump is
low during the initial stage of operation,
and if the amount of oil leaking through the
gap between the piston and the barrel is SM0635
large, the cylinder is temporarily retracted.
In addition, cylinder force is reduced. In
this case, the cylinder drift is also in-
creased.
T5-4-48 EX255-EX285

TROUBLESHOOTING B

F-10 Front Attachment Cylinder Drift is Large.

Related Fault Code: None

YES Normal

Check if each front Correctly adjust

NO manual boom
attachment Check if manual
cylinder drift is lowering valve
boom lowering and lock it up.
within the specified NO valve in boom
value. section in 4-spool
control valve is Check if the
Check if the correctly symptom is
cylinder drift is adjusted. deleted when the
NO
reduced when pilot overload valve is
shut-off YES temporarily
valve is closed. switched with one
in an other
cylinder circuit.

Faulty pilot valve

YES

• Boom Cylinder Internal Leakage Check

1. With the bucket cylinder fully retracted and the arm

cylinder slightly extended from the fully retracted
position, lower the bucket tooth tips onto the
ground.

2. Disconnect hoses to the boom cylinder rod side. SM0636

Then, drain oil from hoses and cylinders. (Plug the

disconnected hose ports.)

3. Retract the arm cylinder to lift the bucket above the

ground.

At this time, if oil flows out of the pipes from which

the hoses were disconnected and the boom cylinder
is retracted, internal leakage in the boom cylinder
exists.
If no oil flows out of the pipes from which the hoses
were disconnected but the boom cylinder is re-
tracted, internal leakage in the control valve exists.
EX255-EX285 T5-4-49

TROUBLESHOOTING B

Manual Boom Lowering Valve

Control valve
spool is scored,
NO spring is
damaged, or spool
NO end is loose.
Check if internal SM0637
leakage in cylin-
der exists.
Faulty cylinder Adjustment Procedure:
(replace seal kit.)
YES Tighten (1). Then, tighten (2).

Tightening Torque:
Faulty overload (1)- 7 N⋅m (0.7 kgf⋅m)
relief valve.
(2)- 13 N⋅m (1.3 kgf⋅m)
YES
T5-4-50 EX255-EX285

TROUBLESHOOTING B

SWING SYSTEM TROUBLESHOOTING

S-1 Swing Speed is Slow or Swing Function

Does not Operate.

Related Fault Code: None

Checking Instructions

• Check whether the pilot system is malfunctioning or

the main hydraulic system is malfunctioning.
• If other functions (front attachment or travel) ope-
rate normally, the pilot pump is considered to be
normal. If the pilot system is malfunctioning, the Check if swing
cause of the trouble may exist in the pilot system motor oil drain
after the pilot valve. YES amount is
• When the left travel speed is also slow, refer to normal.
A-2. • Measurement:
YES Check if swing Refer to
relief pressure is Operational
normal. Performance Test
Monitor the pump
control pressure. section.
• Monitor item: Pump 2
While slowly Delivery Pressure
YES operating the • Specification: Refer to
control lever, Operational Faulty swing
check if the pump Performance Test NO relief valve
control pressure section.
changes
smoothly.
Check if the pilot
secondary • Monitor item: Seized control
pressure is Pump 2 Control Pressure valve spool
NO
normal.

• Specification: Refer
to Operational
Performance Test Faulty pilot valve
section.
NO
EX255-EX285 T5-4-51

TROUBLESHOOTING B

NO Faulty swing
Check if swing reduction device
YES motor parking
brake release
valve is stuck or Faulty swing
seized. motor parking
YES brake release
valve

Faulty swing
NO motor
T5-4-52 EX255-EX285

TROUBLESHOOTING B

S-2 Swing Speed is Slow during Swing Com-

bined Operation with Boom Lower.

Related Fault Code: None

Checking Instructions
• Refer to Control Valve group in the COMPONENT
OPERATION section in the Operational Principle
book (Technical Manual).

YES Clean or replace

travel/boom lower selector
valve.
Check if travel/boom lower
selector valve is stuck.
Trace the cause of the trouble
by checking other symptoms.
NO
EX255-EX285 T5-4-53

TROUBLESHOOTING B

TRAVEL SYSTEM TROUBLESHOOTING

T-1 Both Right and Left Travel Side Tracks Do

Not Move or Move Slowly.

Related Fault Code: None

Checking Instructions
• Pilot valves, travel motors, control valve spools in
both right and left travel systems are unlikely to be
faulty at the same time.
• If both travel systems do not operate, the pilot
system, which is applied to both side travel motors,
may be faulty. If the pilot pump delivery pressure is
lower than specification, the front attachment does
not operate as well. Refer to A-1.

T-2 When a Single Travel Operation is Shifted to

a Combined Operation with Front Func-
tions, a Shock Load is Felt.

Related Fault Code: None

Checking Instructions

• Travel flow control valve might be seized.

• Refer to Control Valve group in the COMPONENT
OPERATION section in the Operational Principle
book (Technical Manual).
T5-4-54 EX255-EX285

TROUBLESHOOTING B

T-3 One Side Track does not Move or Move

Slowly, or the Machine cannot Travel
Straight (Mistracks).

Related Fault Code: None

Checking Instructions
• If one side system only does not operate, pilot
valve, control valve, travel motor, or center joint
might be faulty.
• If a symptom such as bucket or swing function YES Check if travel
speed is slow, or arm roll-in or boom raise speed is motor oil drain
amount is normal.
slow during a leveling operation is recognized at the Check if travel
same time, refer to A-2 and A-3. NO relief pressure in
slow speed side Switch rear and
system is normal. front or right and
left travel relief
• Relieve travel valves with each
NO other. Check if
system.
Check if the • Monitor Item: symptom is
YES symptom is reversed.
Pump 1 Delivery
reversed when Pressure
right and left Pump 2 Delivery
travel line hoses Pressure
connected to top • Specification: Refer
Check if travel of center joint are to Operational
pilot secondary switched with Performance Test
pressure is each other. section.
normal.
• Measurement: Refer Seized control
Operational valve spool
YES
Performance Test
section

Faulty pilot valve

NO

• Relation between Faulty Seal Position and

Mistrack Direction

Seal No. Traveling Pivot Turn

1 External oil leakage ←
2 Seal Position

1
3

2
4
Left Travel 3
(Reverse)
Right Travel
5 (Reverse)
Left Travel 4
(Forward)
5 Right Travel
(Forward)
6 6
7

SM0638
7 External oil leakage ←
EX255-EX285 T5-4-55

TROUBLESHOOTING B

NO Faulty travel
motor

YES Faulty travel

Disassemble and reduction device
clean travel motor
YES
servo piston.
Disassemble and Check if same Faulty travel
clean travel motor symptom arises. motor servo
counterbalance piston
valve. Then, NO
YES
recheck if same
symptom arises. Faulty
counterbalance
NO

NO
Faulty center joint

Faulty travel relief

YES valve

Piping Location
1
2
Front

5 4 SM0639

1 - Left Travel (Forward)

2 - Right Travel (Forward)
3 - Pilot
4 - Right Travel (Reverse)
5 - Left Travel (Reverse)
6 - Drain
T5-4-56 EX255-EX285

TROUBLESHOOTING B

T-4 During a Combined Operation of Travel and

Front Function, the Machine Mis-tracks.
YES
Faulty load check valve
Related Fault Code: None
NO Check if load check valve is
normal. NO Trace the cause of the trouble
by checking other symptoms.
Check if flow combiner valve
is normal.

Faulty flow combiner valve

YES

T-5 Steering Power and Gradeability are

Insufficient in the Fast Travel Mode. (Normal
in the Slow Travel Mode)

Related Fault Codes: None

Monitor travel motor swash YES Trace the cause of the trouble
angle. After installing a pres- by checking other symptoms.
sure gauge to solenoid valve
unit (SI) port, repeat traveling
and travel pressure relief op-
eration. Check if the pressure
• Monitor item:
value displayed on Dr.EX
Travel Motor Displacement
equals is to the pressure Seized solenoid valve unit (SI)
Angle Change Pressure
gauge reading and vary iden-
• Travel mode: Fast NO
tically.
• Measurement: Refer to
Operational Performance
Test section.

T-6 Travel Mode Does Not Change to the Fast

Speed Range.

Related Fault Codes: 02, 03, 04, and 05

Checking Instructions
• Refer to the Control group titled “Travel Motor
Swash Angle Control” in the SYSTEM section in the Faulty travel
mode switch or
Operational Principle book (Technical Manual). NO broken harness
between travel
Monitor travel Monitor travel mode switch and
NO mode switch. pressure switch. MC.
Check if “Lo” or Check if the
“Hi”, displayed on display “Tr” is
Dr.EX, changes indicated or
alternately each deleted on Dr.Ex
time the travel screen each time
switch is travel lever is
Check if any fault operated. operated or
codes are YES released.
displayed.
• Monitor item:
Selected Travel Mode • Monitor item:
Switch Pressure Switch

Faulty sensor or • Fault code:

broken harness • Pump delivery pressure sensor (Pump 1): 02
Pump delivery pressure sensor (Pump 2): 03
YES between sensors
Pump control pressure sensor (4-Spool Side): 04
and MC.
Pump control pressure sensor (5-Spool Side): 05

NOTE - If any other fault codes are displayed,

check suspected parts referring to the dis-
played fault codes.
EX255-EX285 T5-4-57

TROUBLESHOOTING B

NOTE - The measurement of the control voltage of proportional solenoid valves SG, SI, SD and SC, must be
performed with test harness (75301514) meaning that the main controller (MC) output must be connected
to the load of the solenoid valve. Under this test configuration, the normal control voltage changes from
5 through 10 Volt.
On the other hand, when measuring the control voltage directly on the connector disconnected from the
solenoid valve (harness side) the voltage measured is always 24 Volt and this is irrelevant in
troubleshooting the solenoid valve.

Faulty travel
pressure switch,
broken harness
between travel
pressure switch
NO and MC, or
clogged filter in
travel pilot signal
Disconnect circuit.
harness from
solenoid valve
unit (SI). Connect
test harness
(75301514)
Monitor travel motor between solenoid
swash angle. After valve unit (SI) YES Faulty solenoid
installing a pressure and the valve unit (SI).
gauge to solenoid disconnected
valve unit (SI) port, NO harness. Check
repeat traveling and when travel
stopping. Check if the mode selector is
pressure value actuated, the Broken harness
displayed on Dr. EX solenoid valve between solenoid
control voltage is NO valve and MC.
equals to the pressure
YES present.
gauge reading and that
both vary identically.
• Travel mode: Fast Faulty travel
• Monitor item: Travel motor swash motor or travel
angle control pressure YES reduction gear.
• Travel mode: Fast
• Measurement: Refer to Operational
Performance Test section.
T5-4-58 EX255-EX285

TROUBLESHOOTING B

TROUBLESHOOTING FOR OTHER FUNC-

TIONS

O-1 Wiper Does Not Operate, or Retract.

Related Fault Code: None

Checking Instructions
• The wiper is controlled by a wiper box in which the • The windshield wiper motor and washer pump con-
relay circuit are operated by the monitor panel. trol relays are moulded inside the wiper controller
• When the wiper does not work, check first that the and cannot be replaced. The wiper controller must
motor and the relevant linkage are operative, using be considered as an assembly.
an auxiliary power source and the test herness.
• If the wiper motor works properly when is powered
throught the test harness, check the upper latch of
front window and wiper cut-off switch for proper
operation.

YES Faulty wiper box.

Remove the test

harness and
YES reconnect the
disconnected
harness to the YES End
As illustrated to the original position.
Replace the
right, connect test
monitor assembly.
harness • Key switch: ON Check if wiper
(75301706C) NO
operates. Faulty cab
between power
outlet and wiper NO harness
motor. Check if
wiper operates.

• Key switch: ON
NO, or lamp
does not light
normally.
YES Faulty wiper
motor or link
NOTE - When the wiper motor is
normal, lamp S comes ON while Check correct
the wiper is moving within the operation of wiper
cut-off switch.
operating range. Then, only when
the wiper reaches the intermittent Faulty wiper cut-
stop position, both lamps B and S NO off switch.
light for a moment at the same
time.
EX255-EX285 T5-4-59

TROUBLESHOOTING B

• Electrical Circuit When Test Harness is Connected.

Power outlet

Lamp S

Wiper Motor
Lamp B

Ground

SM0640

• Wiper’s Operating Range

Intermittent Stop Position

Retracted Position

Wiper Range

SM0641

• Test Harness Connection

Lamp B

Lamp S
Wiper Motor
Power outlet

Test Harness

SM5618
T5-4-60 EX255-EX285

TROUBLESHOOTING B

ENGINE SPEED ADJUSTMENT AND

ENGINE LEARNING

When the following repair or inspection is made, or

when engine speeds deviate from the specifications,
perform the engine speed adjustment and engine
learning.

• When the engine, engine control cable, or EC motor

is removed.
• When MC is replaced.

Engine Speed Adjustment:

1. Turn the key switch to START and run the engine.

(Note: Turn the air-conditioner switch OFF.)
2. Turn the engine control dial to the minimum speed
position. (EC sensor voltage is set to
2.5 V.)
3. Loosen the bolt tightening the control lever to the EC
motor output axis. Bolt
Tightening
4. While checking the engine actual speed with Dr.EX
or a tachometer, adjust the control lever to conform Control Lever
the slow idle speed specification. SM0643

Specification: Refer to Operational Performance

Test section.
5. Tighten the bolt to secure the control lever to the EC
motor output axis.

: 13 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft)

NOTE - Take care not to allow oil or grease to stick to

the motor output axis.

6. Perform engine learning.

Engine Learning :
Rear cover
1. Turn the key switch OFF.

NOTE - If the engine does not stop with the key switch
OFF, pull the fuel shut-off handle under the operator's Fuse box
seat to stop the engine

Engine
2. Remove Dr.EX. Wait for 5 seconds. Learning
3. Turn the engine learning switch ON. switch
Engine
4. Turn the key switch ON. Wait for 5 seconds. Learning
5. Turn the key switch OFF. Wait for 5 seconds. side
6. Turn the engine learning switch OFF.
7. Check the engine speed.

Neutral position (OFF)

SM0108
EX255-EX285 T5-4-61

TROUBLESHOOTING B

EXCHANGE INSPECTION METHOD

Exchange inspection method is used to check if a part

and/or a component is normal by replacing or switch-
ing the part/component with one being identical in
performance characteristics.
Pump 2 Pump 1
Some of sensors and solenoid valves used on this (5-Spool (4-spool
machine are identical in performance characteristics. Side) Side)
Accordingly, the exchange inspection method is ef-
fective to find out if a part/component or harness is
normal. PP2 PP1

Example: Abnormal Pump 1 Delivery Pressure Sen-

sor Failure (Fault Code: 02)
Fig. 1
Check :
1. Switch two delivery sensor connectors from the SM0644
position shown in Fig.1 to Fig.2.
2. Retry troubleshooting.

Result :
If pump 2 delivery pressure is shown as abnormal
(Fault Code: 03), the pump 1 delivery pressure
Pump 2 Pump 1
sensor is faulty. (5-Spool (4-spool
Side) Side)
If pump 1 delivery pressure is shown as abnormal
(Fault Code: 02), the harness which was connected
to the pump 1 delivery pressure sensor is faulty. PP1 PP2

Fig. 2

SM0645
T5-4-62 EX255-EX285

TROUBLESHOOTING B

Exchange Inspection Method Application

Fault Code Trouble Application

01 EC Sensor Failure Not Applicable

02 Pump 1 Delivery Pressure Sensor Failure Applicable

03 Pump 2 Delivery Pressure Sensor Failure Applicable

04 Pump 1 Control Pressure Sensor Failure Applicable

05 Pump 2 Control Pressure Sensor Failure Applicable

06 Arm Roll-In Pilot Pressure Sensor Failure Applicable (Pump Control Pressure Sensor)

07 Engine Control Dial Failure Not Applicable

EX255-EX285 T5-4-63

TROUBLESHOOTING B

BOOM LOWERING METHOD WHEN EN-

GINE STALLS

Excavator not equipped with hose rupture protec-

tion valve
In case the engine has stalled and is difficult to restart
while the boom is raised above the ground, lower the
boom in the following method.

WARNING
Ensure that nobody stands under or near the front 1 2
equipment prior to beginning the boom lowering
procedure.

1. Loosen lock nut (1) and loosen screw (2) half turn.
The boom will start lowering. The lowering speed
can be slightly adjusted by loosening a bit more
screw (2).

NOTE: never loosen screw (2) more than 2 turns, since

it could come out.
S0014

2. After lowering the bucket to the ground, tighten

screw (2) then lock nut (1) to the torques here
below:
Lock nut (1)
- Wrench: 13 mm
- Tightening torque: 1.3 daNm
Screw (2)
- Allen wrench: 4 mm
- Tightening torque: 0.7 daNm

NOTE: in the event the screw and the lock nut are not
adequately tightened, excessive leakages could oc-
cur.
Make sure that screw and lock nut are tightened to the
specified torque.
T5-4-64 EX255-EX285

TROUBLESHOOTING B

Excavator equipped with hose rupture protec-

tion valve

In case the engine has stalled and it is difficult to

restart while the boom is raised above the ground,
lower the boom with the following method.

WARNING
Ensure that nobody stands under or near the front
equipment prior to beginning the boom lowering 1
procedure.

1. Remove protection cap (1) from the relief valve of

3
the hose rupture protection valve located on the
boom right cylinder. 2

2. Make a reference mark on the relief valve and the

lock nut, in correspondence with the hole on the
setting screw.

3. Loosen lock nut (2).

4. Loosen, very slowly, setting screw (3) to lower the

front equipment to the ground.

5. Return the setting screw and the relevant lock nut

into their original position, making reference to the OM0416
mark made as per point 2.

NOTE: it is sufficient to perform the procedure ex-

plained above on one hose rupture protection valve
only.
EX255-EX285 T5-5-1

TROUBLESHOOTING C

TROUBLESHOOTING C
(TROUBLESHOOTING FOR MONITOR)
PROCEDURE

Use troubleshooting C when any monitors, such as

gauges or indicators malfunction.

• How to Read Troubleshooting Flow Charts

YES(OK)
(2)

• After checking or measuring item (1), select either Yes (OK) or No (NOT
(1)
OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NG)

• Special instructions or reference item are indicated in the spaces under the box. Incorrect
measuring or checking methods will render troubleshooting impossible, and may damage
• Key switch: ON components as well.

• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes
can be seen without going through the flow chart.

NOTE - For all connector drawings illustrated in this

group, harness end connector terminals seen from the
open end side are shown.

Wire Harness Side

Open End
Side
Harness End Connector

SM0646
T5-5-2 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF COOLANT
TEMPERATURE GAUGE

Providing that:
• Be sure to inspect wiring connections prior to
troubleshooting.

Gauge pointer does not
move at all. (It does not rise
from zero.)
• Key switch : ON
YES
Remove coolant
temperature sensor terminal,
ground harness side terminal
to vehicle. Does pointer
swing to the (H) side? With sensor terminal discon-
nected, remove 20P connec-
NO tor from monitor, and check
continuity between terminal
No.47 and sensor terminal.

YES

When removing coolant tem- NOT OK

Gauge pointer swings over perature sensor, does
scale. pointer swing back to
zero?
• Key switch : ON
(Continuity)
With sensor terminal discon-
nected, remove 20P connec-
tor of monitor, and check
NO continuity between harness
side terminal and ground.
OK
(No continuity)

YES
Remove coolant
temperature sensor terminal,
Gauge pointer swings and ground harness side ter-
unstably. minal to vehicle. Does the
pointer swing to [H] side, and
stably?
NO
• Key switch : ON
EX255-EX285 T5-5-3

TROUBLESHOOTING C

Approximate Temperature on Coolant Temperature

Gauge

105 °C (221 °F)

95 °C (203 °F)

70 °C (158 °F)
Faulty coolant temperature
sensor.
OK
(Continuity)
Failure in monitor.

Faulty harness (breakage)

NOT OK between monitor and sensor.
(No continuity)
SM0647

Coolant Temperature Sensor

Coolant Resistance
Faulty coolant temperature Temperature
sensor.
(50 °C)
(153.9 Ω)
(122 °F)
Faulty harness (short circuit) 80 °C
between monitor and sensor. 51.9±10 Ω
(176 °F)
100 °C
27.4±4 Ω
Failure in monitor. (212 °F)
(120 °C)
(16.1 Ω)
(248 °F)

NOTE - The value indicated in parentheses is only

a reference value.
Faulty coolant temperature
sensor.

Failure in monitor.

Connector (harness end connector terminals seen

from the open end side)

Monitor (20P)

29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
T5-5-4 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION FUEL GAUGE

Providing that:
• Be sure to inspect wiring connections prior to
troubleshooting.

Gauge pointer does not
swing. (It does not rise from
zero.)
• Key switch : ON
YES
Remove connector of fuel
sensor, short-circuit termi-
nals C and A of harness side
connector by using a jumper
wire. Does pointer swing to With sensor connector dis-
(FULL) side? connected, remove 20P con-
NO nector of monitor, and check
continuity between terminal
No.46 of monitor and terminal
C of fuel sensor.

YES

When fuel sensor NOT OK

Gauge pointer swings over connector is removed,
scale. does pointer swing back to
zero?
• Key switch : ON
(Continuity)
With sensor connector dis-
connected, remove the 20P
connector of monitor, and
NO check continuity between ter-
minal C of harness side con-
nector and ground.
OK
(No continuity)

Remove connector of fuel YES

sensor, and short-circuit ter-
Gauge pointer swings minals C and A of harness
unstably. side connector by using
jumper wire. Does pointer
swing to [FULL] side, and
stably? NO
• Key switch : ON
EX255-EX285 T5-5-5

TROUBLESHOOTING C

Fuel Sensor
1 mm=0.03937 in
Float

FULL

257 mm
3/4

22°
138.6 mm R370
33°
Faulty fuel sensor. 70.5 mm
OK
(Continuity) 27°
Failure in monitor. 1/2
228 mm 28°
Resistance
1/4
292 mm
Faulty harness (breakage) Reserve
NOT OK between monitor and fuel 338 mm
(No continuity) sensor. EMPTY

SM0648

Float Resistance (Ω)

Faulty fuel sensor. FULL 10+0
-4

3/4 26
Faulty harness (short- cir- 1/2 38±5
cuit) between monitor and
fuel sensor. 1/4 53
EMPTY 90+10
0
Failure in monitor.

Connector (harness end connector terminals seen

from the open end side)

Faulty fuel sensor. Monitor (20P)

Fuel Sensor

29 30 31 32 33 34 35 36 37 38
Failure in monitor. 39 40 41 42 43 44 45 46 47 48 C B A

C
Level signal
B
Reserve signal
A Ground
T5-5-6 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF FUEL LEVEL INDICA-

TOR (RESERVE)

Providing that:
• Be sure to inspect wiring connections prior to
troubleshooting.
YES

With fuel sensor

connector re-
moved, short cir-
Reconnect fuel
YES cuit terminals B
level sensor con-
and A of harness
Although fuel nector
Check if indicator side connector Remove 12P
gauge pointer by using a jumper
comes ON when connector of
shows E, the in- wire. Does indi-
key witch is monitor, and
dicator does not cator light? NO
turned ON check continuity
come ON.
• Key switch : ON between terminal
• Key switch : ON No.2 of connec-
tor and vehicle
ground.

NO

YES

Check if indicator
Even if fuel is in goes OFF when
tank, the indicator fuel level sensor Disconnect fuel
comes ON. connector is re- NOT OK (Continuity)
level sensor con-
moved. nector and 12P
connector of
• Key switch : ON monitor, and
NO check continuity
between terminal
No.2 of connec-
tor and vehicle OK (No Continuity)
ground.
EX255-EX285 T5-5-7

TROUBLESHOOTING C

Faulty fuel level

sensor.

YES Failure in
monitor.

Faulty harness
(breakage) be-
tween monitor
and low fuel level
NO
switch.

Burned out indi-

cator light.

Faulty fuel level

sensor.

Faulty harness
(short circuit)
between monitor
and fuel level
sensor.

Failure in
monitor.

Connector (harness end connector terminals seen

from the open end side)

Monitor (12P)

1 2 3 4 5 6
7 8 9 10 11 12
T5-5-8 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF INDICATOR LIGHT

CHECK SYSTEM
Check power line.
• Fuse
YES • Disconnect 20P monitor
connector. Then, check
continuity between harness
side terminal No.30 and
Indicator does not come ON
Check if all indicators do not fuse terminal No.6.
when indicator light check
come ON.
switch is turned ON.
Perform troubleshooting for the
individual indicator which does
NO not come ON.

Connector (harness end connector terminals seen

from the open end side)

Monitor (20P)

29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48

MALFUNCTION OF LEVEL CHECK SWITCH

Process to be taken:
• This troubleshooting is applied when only the level
check switch malfunctions.
If power is not supplied at all when key switch is
turned ON, or indicator does not come ON when
indicator light check is conducted, perform trouble-
shooting for these failures first.

Required Condition:
• Park the machine on level surface.

YES Faulty level

switch or harness
(breakage).
YES Check if oil and
coolant levels are
Check if indicator correct.
does not come Check if all indi- Refill engine oil,
ON when level cators do not hydraulic oil, or
NO coolant.
check switch is come ON.
depressed.

Perform trouble-
shooting for indi-
vidual indicator
NO which does not
come ON.
EX255-EX285 T5-5-9

TROUBLESHOOTING C

MALFUNCTION OF PREHEAT INDICATOR

Providing that:
• Be sure to inspect wiring connections prior to
troubleshooting.

Reference:
• The preheat system operates when the coolant
temperature is 10 °C (50 °F) or lower.
• During preheat operation, the preheat indicator
stays ON for 8 seconds.

YES
Faulty QOS controller

Preheat indicator Check if preheat Short-circuited harness be-

comes ON even if indicator goes OFF With QOS controller YES
tween QOS controller and
preheat system is when QOS controller disconnected, remove
monitor.
not in operation. is disconnected. 20P connector from
monitor. Check for
• Key switch : ON continuity between
NO monitor harness end
connector terminal
No.43 and vehicle
frame. Faulty monitor.
NO

YES
With QOS controller
disconnected, ground
Preheat indicator
harness end con-
does not come ON
nector terminal No.6
during preheat op-
to vehicle frame.
eration.
Check if preheat indi-
cator comes ON.
• Key switch : ON NO
• Without disconnecting
Faulty QOS controller
Broken harness be-
With QOS controller YES
tween QOS control-
disconnected, remove
ler and monitor.
20P connector from
monitor. Check for
continuity between
monitor harness end
connector terminal
No.43 and vehicle
frame. Faulty monitor.
NO
the connector, insert a
jumper wire such as a
clip into the back of the
connector and ground
to the vehicle frame.

Connector (harness end connector terminals seen

from the open end side)

Monitor (20P) Q.O.S. Controller

29 30 31 32 33 34 35 36 37 38 3 2 1
39 40 41 42 43 44 45 46 47 48 6 5 4
T5-5-10 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF ENGINE OIL LEVEL IN-

DICATOR

Providing that:
• Indicator light is not burned out.
• Other indicators work correctly.
• The machine is parked on a level surface.
• Be sure to inspect wiring connections prior to
troubleshooting.

YES
With engine oil level
Indicator does not switch disconnected,
come ON even if the check continuity be-
level check switch is tween engine oil level
depressed. switch connector and
vehicle frame.
YES
Reconnect engine oil
level switch. Discon-
nect 12 P connector
from monitor. Check
for continuity be-
tween harness end
terminal No. 7 and ve-
hicle frame.
NO

NO

With engine oil level

switch disconnected,
disconnect 12P con-
YES nector from monitor.
Check for continuity
Disconnect engine
Lower than 3.5 mm between harness
oil level switch.
below LOW level Check if indicator end terminal No.7
comes ON when and vehicle frame.
Indicator comes ON level check switch is
even if oil level is depressed.
lower than the speci- Check oil level with oil
fied level when level level gauge.
check switch is de- NO
pressed.

Higher than 3.5 mm

below LOW level
EX255-EX285 T5-5-11

TROUBLESHOOTING C

Engine Oil Level Switch

1 mm=0.03937 in

Engine Oil
Level Switch
Oil Level Gauge
ON

Indicator ON

Indicator
OFF
Faulty in monitor.
OFF
A : 3,5 mm
SM6130

Broken harness be-

tween engine oil level
switch and monitor.

Faulty engine oil level

switch.

Connector (harness end connector terminals seen

from the open end side)

Monitor (12P)

YES Short-circuited harness

between engine oil level 1 2 3 4 5 6
switch and monitor. 7 8 9 10 11 12

Faulty monitor.
NO

Faulty engine oil level

switch.

Normal.
T5-5-12 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF COOLANT LEVEL INDI-

CATOR

Providing that:
• Indicator light is not burned out.
• Other indicators work correctly.
• The machine is parked on a level surface.
• Be sure to inspect wiring connections prior to
troubleshooting.

Reconnect cool- YES

ant level switch.
YES Disconnect 12 P
connector of
monitor. Check
With coolant level continuity be-
switch discon- tween harness
Indicator does not nected, check NO
come ON even if side terminal No.8
continuity be- and vehicle
level check switch tween terminals
is depressed. ground.
on level switch 2P
connector.

NO

Leave coolant
level switch dis-
connected.
Disconnect 12 P
YES connector of
monitor. Check
Disconnect cool- continuity be-
ant level switch. tween harness
YES Check if indicator side terminal No.8
comes ON and vehicle
when level check ground.
Indicator comes Check coolant switch is de-
ON even if cool- level at coolant pressed.
ant level is lower reservoir. Check
than specified if coolant level is NO
level when level lower than LOW
check switch is mark.
depressed.

NO
EX255-EX285 T5-5-13

TROUBLESHOOTING C

Coolant Level Switch

Coolant Reservoir

ON
FULL

LOW

Failure Radiator
in monitor. OFF

SM0649
Faulty harness.
(breakage)

Connector (harness end connector terminals seen

from the open end side)
Faulty coolant
level switch.

Monitor (12P) Coolant Level Switch

1 2 3 4 5 6
7 8 9 10 11 12 1 2

YES Faulty harness.

(short circuit)

Failure in
NO monitor.

Faulty coolant
level switch.

Normal
T5-5-14 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF HYDRAULIC OIL LEVEL

INDICATOR

Providing that:
• Indicator light is not burned out.
• Other indicators work correctly.
• The machine is parked on a level surface.
• Be sure to inspect wiring connections prior to
troubleshooting.

Disconnect 12P YES

connector of
monitor. Check
YES continuity be-
tween harness
With hydraulic oil side terminal No.9
level switch dis- and vehicle
Indicator does not NO
connected, ground.
come ON even if
level check switch check continuity
is depressed. between level
switch 2P con-
nector.

NO

Leave hydraulic
oil level switch
disconnected.
Disconnect 12P
YES connector of
monitor. Check
Disconnect oil continuity be-
level switch. tween harness
YES Check if indicator side terminal No.9
comes ON when and vehicle
Indicator comes level check switch ground.
ON even if oil Check oil level is depressed.
level is lower than with level gauge.
the specified level Check if oil can NO
when level check be seen at level
switch is de- gauge.
pressed.

NO
EX255-EX285 T5-5-15

TROUBLESHOOTING C

Hydraulic Oil Level Switch

1 mm=0.03937 in

ON

6.2 mm

Failure OFF
in monitor.

Faulty harness.
(breakage) SM0650

Connector (harness end connector terminals seen

Faulty hydraulic from the open end side)
oil level switch.

Monitor (12P) Hydraulic Oil Level Switch

1 2 3 4 5 6
1 2
YES Faulty harness. 7 8 9 10 11 12
(short circuit)

Failure in
NO monitor.

Faulty hydraulic
oil level switch.

Normal
T5-5-16 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF ALTERNATOR INDI-

CATOR

Providing that:
• Be sure to inspect wiring connections prior to
troubleshooting.

NOTE - (*) Regulator terminals L is water-resistance

type connectors so that it is not practical to measure
voltage at these terminals. Measure voltage at starter
relay terminal R.
Before measuring voltage, check continuity between
the starter relay terminal R and regulator terminal L.
13 V or higher

13 V or Measure voltage at
higher monitor 20 P con-
nector terminal
No.42.

• Engine: Running
Alternator indica-
tor does not go off Measure voltage
after engine is at regulator termi- Less than 13 V
nal L.
started.
• Engine: Running

Less than
13 V

Less than 10 V.

YES Check voltage at

regulator terminal L
(*).
• Key switch: ON
Although alterna- Check if indicator • Engine: Stopped
tor output is low, comes on when
alternator indica- key switch is
tor does not turned to ON po-
come on. sition. 10 V or more

• Key switch: ON

NO
EX255-EX285 T5-5-17

TROUBLESHOOTING C

Connector (harness end connector terminals seen

Faulty monitor.
from the open end side)

Starter Relay
Harness breakage
between regulator E
terminal L and
monitor terminal S R
No.42.

Monitor (20P)
Faulty regulator or
faulty alternator.
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48

Faulty monitor.

Faulty regulator.

Blown indicator bulb.

T5-5-18 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF ENGINE OIL PRES-

SURE INDICATOR

Providing that:
• Be sure to inspect wiring connections prior to
troubleshooting.

YES

With engine oil pres-

sure switch discon-
YES nected, check if indi-
cator comes ON
when terminal
of wire number 33 is
grounded to vehicle.
Although engine Check if indicator NO
oil pressure is comes ON when • Key switch: ON
lower than speci- key switch is
fication, indicator turned to ON po-
does not come sition.
ON
• Key switch: ON
• Key switch: ON
• Engine: Stopped
NO

YES

Check if indicator
Indicator stays goes OFF when
ON after engine engine oil pres-
is started. sure switch is dis-
connected.
• Check if oil filter is
clogged or not. • Key switch: ON
• Engine: Stopped
NO
EX255-EX285 T5-5-19

TROUBLESHOOTING C

Engine Oil Pressure Switch

Pressure Indicator
Approx. ON
98 kPa (1.0 kgf/cm2,
14.2 psi) or Less
More than Approx. OFF
98 kPa (1.0 kgf/cm2,
14.2 psi)
Faulty engine oil
pressure switch.

Reconnect engine oil

pressure switch. Broken harness
YES between monitor
Check if indicator
comes ON when and engine oil Connector (harness end connector terminals seen
monitor terminal pressure switch.
from the open end side)
No.10 is grounded to
vehicle.
• Key switch: ON Monitor (12P)
• Without disconnecting, Faulty
ground connector to monitor.
vehicle using a clip from NO 1 2 3 4 5 6
the back of connector. 7 8 9 10 11 12

Burned out indi-

cator light.

Faulty engine oil

pressure switch,
faulty engine oil
lubrication sys-
tem, or clogged
oil filter.

Short-circuited
With engine oil pres- YES harness between
sure switch con- monitor and en-
nected, remove 12P gine oil pressure
connector from moni- switch.
tor. Check for conti-
nuity between har-
ness end connector
Faulty monitor.
terminal No.10 and NO
vehicle frame.
T5-5-20 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF OVERHEAT INDICA-

TOR

Providing that:
• Be sure to inspect wiring connections prior to
troubleshooting.

YES

With overheat
switch connector
disconnected,
YES check if indicator
comes ON when
Check if indicator terminal of wire
Indicator does not comes ON when number 201 is
come ON even if key switch is grounded to vehi-
engine overheats. turned to HEAT cle. NO
position.
• Key switch: ON
• Key switch: ON

NO

YES

Indicator comes
ON even if cool- Check if indicator
ant goes OFF when
temperature is overheat switch Disconnect over- YES
low. connector is dis- heat switch con-
connected. nector and 12P
connector of
• Key switch: ON monitor. Check if
• Engine: stopped NO continuity be-
tween 12P con-
nector terminal
No.1 and vehicle. NO
EX255-EX285 T5-5-21

TROUBLESHOOTING C

Overheat Switch
Coolant Temperature Indicator
Faulty overheat Lower than 105 °C OFF
switch. (221 °F)
105 °C (221 °F)
or more ON
Reconnect overheat
switch connector.
Check if indicator YES Faulty harness.
comes ON when (breakage) Connector (harness end connector terminals seen
monitor 12P connec-
tor terminal No.1 is from the open end side)
grounded to vehicle.
Monitor (12P)
• Key switch: ON
• Without disconnecting, Failure in
ground connector to monitor. 1 2 3 4 5 6
vehicle using a clip from NO
7 8 9 10 11 12
the reverse side of the
connector.
Burned out indi-
cator light.

Faulty overheat
switch.

Faulty harness
(short circuit) be-
tween monitor
and overheat
switch.

Failure in
monitor.
T5-5-22 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF AIR FILTER RESTRIC-

TION INDICATOR

Providing that:
• Be sure to inspect wiring connections prior to
troubleshooting.

YES

When restriction
switch is discon-
nected, and har-
YES ness side termi-
nal of wire Reconnect re-
When key switch number 203 is striction switch.
When air filter is is returned to grounded to vehi- Disconnect 12P
clogged, indicator HEAT position, cle, does indica- connector of
does not light. does indicator tor light? NO monitor, and
light? check continuity
• Key switch: ON between terminal
• Key switch: ON
No.3 of connector
and vehicle
ground.

NO

YES

When air filter re-

Although air filter striction switch is
is not clogged, disconnected, Disconnect air
indicator lights. does the indicator filter restriction YES
go out? switch connector
• Disassembled and and 12P connec-
visual check • Key switch: ON tor of
• Confirm that air filter monitor, and
is not moist. NO check continuity
between terminal
No.3 of connector
and vehicle NO
ground.
EX255-EX285 T5-5-23

TROUBLESHOOTING C

Air Restriction Switch

Pressure Indicator
62 ± 6 mbar (6.2 ± 0.6 kPa) OFF
(635 ± 58 mmH2O)
or Less
More than 62 ± 6 mbar ON
Faulty air restric- (6.2 ± 0.6 kPa)
tion switch. (635 ± 58 mmH2O)

Connector (harness end connector terminals seen

YES Failure in from the open end side)
monitor.

Monitor (12P)

Faulty harness 1 2 3 4 5 6
(breakage) be- 7 8 9 10 11 12
tween monitor
NO and air restriction
switch.

Burned out indi-

cator light.

Faulty air restric-

tion switch.

Faulty harness
(short circuit) be-
tween monitor
and air restriction
switch.

Failure in
monitor.
T5-5-24 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF BUZZER

NOTE - (*) Regulator terminals L is water-resistance

type connectors so that it is not practical to measure
voltage at these terminals. Measure voltage at starter
relay terminal R.
Before measuring voltage, check continuity between
the starter relay terminal R and regulator terminal L.

13 V or more
Faulty regulator.
Buzzer keeps
sounding when Check voltage at
key switch is monitor terminal
No.42.
turned ON.
Failure in
• Key switch: ON monitor.
(Engine is stopped.) Less than 13 V

YES Failure in engine

oil pressure sys-
tem.
Buzzer keeps Check if engine
sounding when oil pressure indi- YES Overheat of en-
engine is started. cator is ON. gine.
Check if overheat
NO indicator is ON.
Check if buzzer
stops when
buzzer stop
NO switch is de-
pressed.

YES
Normal
Buzzer does not
sound even if en- Check if engine is
gine oil pressure running at 1000
min-1 (rpm) or NO
indicator or over- Normal
heat indicator faster.
comes ON. Check if alterna-
tor indicator is
NO ON.

Check voltage at
alternator termi-
YES nal L.

• Engine speed:
1000 min-1 (rpm) or
faster.
EX255-EX285 T5-5-25

TROUBLESHOOTING C

Connector (harness end connector terminals seen

from the open end side)

Monitor (20P) Starter Relay

29 30 31 32 33 34 35 36 37 38 E
39 40 41 42 43 44 45 46 47 48 S R

YES
Normal

Failure in monitor.
NO

Less than 13 V Faulty regulator or

alternator.

Less than 13 V Faulty harness

Check voltage at (breakage) between
monitor 20P con- alternator terminal L
nector terminal and monitor terminal
13 V or more No.42. No.42.

• Engine speed:
1000 min-1 (rpm) or
faster. Failure in monitor.
13 V or more
T5-5-26 EX255-EX285

TROUBLESHOOTING C

MALFUNCTION OF HOUR METER

Providing that:
• Be sure to inspect wiring connections prior to
troubleshooting.

NOTE - (*) Regulator terminals L is water-resistance

type connectors so that it is not practical to measure
voltage at these terminals. Measure voltage at starter
relay terminal R.
Before measuring voltage, check continuity between
the starter relay terminal R and regulator terminal L.

Broken harness
between monitor
0V
terminal No.29
and No.6 fuse.
Check voltage at
NO monitor 20P con-
nector terminal
No.29.
Failure in
24 V monitor.

Hour meter
does not count
operating Check if alterna-
hours when tor indicator is
engine is run- ON.
ning. Less than 13 V
Faulty regulator
• Engine : Running or alternator.

Check voltage at
alternator terminal L
YES (*).

• Engine speed: 13 to 14.5 V

1 000 min-1 (rpm) or or more Failure in
faster monitor.
Check voltage at
monitor 20P con-
nector terminal
Broken harness
No.42.
between alterna-
13 V or more tor terminal L and
Less than monitor terminal
13 V No.42.

Connector (harness end connector terminals seen

from the open end side)

Monitor (20P) Starter Relay

29 30 31 32 33 34 35 36 37 38 E
39 40 41 42 43 44 45 46 47 48 S R
EX255-EX285 T5-6-1

ELECTRICAL SYSTEM INSPECTION

PRECAUTIONS FOR INSPECTION AND

MAINTENANCE

1. Disconnect the power source.

Be sure to remove the negative terminals from the
batteries first when taking wire harnesses and
connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
2. Wire harnesses identification.
A
The wire harnesses used on electrical system of the
machine are of three colours: red, white and brown.
0511 0511 0511
– The wire harnesses red coloured are used for
the main power supply distribution and for direct 20 ÷ 30 mm
connection to the positive not controlled by key
switch.
– The wire harnesses white coloured are used for B C
the all other functions.
2,5 R 0679
– The wire harnesses brown coloured are used for

0511
0511
ground connection.
Each wire is identified by a four digit numerical
coding printed on the whole lenght every 20 to 30
mm (A).
This coding is also shown on the wiring diagrams of
electrical system (B).
On the general electrical system diagram attached,
numbers and letters are shown before the four digit Right Wrong
coding.
Numbers mean the wire section shown in mm2.
The following letters indicate the wire colours;
where W stands for white, R for Red and Br for
Brown. See detail (C).
SM0651
3. Precautions for connecting and disconnecting ter-
minal connectors.
1) When disconnecting harnesses, grasp them by
their connectors. Do not pull on the wire itself.
Be sure to release the lock first before attempt-
ing to separate connectors, if a lock is provided.
(Refer to “Instructions for Disconnecting Con-
nector” on page T5-6-3.) Right
2) Water-resistant connectors keep water out so Rust
that if water enters them, water will not easily
Wrong
drain from them. When checking water-resi- (deformation)
stant connectors, take extra care not to allow
Wrong
water to enter the connectors. In case water (Separation)
should enter the connectors, reconnect only
after the connectors are thoroughly dried. SM0652
3) Before connecting terminal connectors, check
that no terminals are bent or coming off. In
addition, as most connectors are made of
brass, check that no terminals are rusting.
4) When connecting terminal connectors provided
with a lock, be sure to insert them together until
the lock “clicks.”
T5-6-2 EX255-EX285

ELECTRICAL SYSTEM INSPECTION

4. Precaution for using a circuit tester.

1) Before using a circuit tester, refer to the instruc- Wind a Piece of Wire Tester Probe
tions in the circuit tester manual.
Then, set the circuit tester to meet the object to
be measured, voltage range and current pola-
rity.
2) Before starting the connector test, always Sharpen the end of the Wire
check the connector terminal numbers, refer-
ring to the circuit diagram. SM0653

When the connector size is very small, and the

standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or
a pin around the probe to make the test easier.
EX255-EX285 T5-6-3

ELECTRICAL SYSTEM INSPECTION

INSTRUCTIONS FOR DISCONNECTING

CONNECTORS

• Push the lock to disconnect.

NOTE - 1) Connectors may not be separated if the

lock is pushed while the connectors are
pulled. Be sure to push the lock first before
pulling the connectors.
2) The lock is provide on the female connec- SM0654
tor (harness side).

Locations of This Type Connector

Fuel Gauge Washer N Sensor Radio

Hydraulic Oil Level Switch Pilot Pressure Switch Engine Oil Level Sensor Speaker
Horn EC Motor Coolant Level Switch Learning Switch
Cab Harness EC Sensor Key Switch Wiper
Pressure Switch Pump Delivery Pressure Sensor Engine Control Dial Monitor

• Pull up the lock to disconnect.

Locations of This Type Connector

Pressure Switch (Front)

Pilot Pressure Sensor
Pump Control Pressure Sensor
Relè avviamento

• Pull to disconnect.

Locations of This Type Connector

Solenoid Valve Unit

Dr.EX

SM0656
T5-6-4 EX255-EX285

ELECTRICAL SYSTEM INSPECTION

FUSE CONTINUITY TEST

Fuse failure is often caused by a fine crack in the fuse, NOTE - All the inside terminals of the fuses in the
and such fine cracks are very hard to detect by visual fuse box are connected to the power source,
inspection. while the outside terminals are connected to
Checking fuse continuity with a tester is far superior to the accessories.
sight inspection. Test all fuses using the same method.
(1) Turn the key switch ON
In doing so, the battery relay is activated by the
current from terminal M of the key switch, and
electric power is supplied to all circuit, except the
glow relay circuit.

(2) Remove the fuse box cover and set the correct
voltage measurement range of the tester.
(Measurement range: 0 to 30 V)

(3) Connect the negative probe to the vehicle ground,

and touch the outside terminal of each fuse with the
positive probe of the tester.
When normal continuity of a fuse is intact, the
tester will indicate 20 to 25 volts.

Accessory (Outside)

SM0657

Power Source (Inside)

Glow relay Accessory (Outside)
EX255-EX285 T5-6-5

ELECTRICAL SYSTEM INSPECTION

INSPECTION AND REPLACEMENT OF

MAXI FUSIBLE LINKS

Inspection

1. Remove the negative cable from the battery.

2. Loose the wing nut fixing the protection panel and

open it by rotating forward to gain the access.

3. Withdraw the front cover of the maxi fusible link box

and visually inspect the maxi fusible link inside.

Replacement

1. Make sure that the negative cable is removed from

the battery.

2. Loose the wing nut fixing the protection panel and OM5633
open it by rotating forward to gain the access.

3. Withdraw the front cover of the maxi fusible link box.

4. Take out the maxi fusible link and replace it. Front cover

5. Reinstall the front cover to maxi fusible link box.

6. Reconnect the negative cable to the battery.

Maxi fusible

Body

Bottom cover

SM3032
T5-6-6 EX255-EX285

ELECTRICAL SYSTEM INSPECTION

BATTERY VOLTAGE CHECK

1. Turn the key switch OFF. Check voltage between

the battery positive terminal and the vehicle frame.

Normal Voltage: 24 V

NOTE - If voltage is abnormal, recharge or replace the

battery.

2. Start the engine. Check voltage between the battery

positive terminal and the vehicle frame.
V
Normal Voltage: 26 to 28 V

NOTE - If voltage is abnormal, check the charging

system. SM3034
EX255-EX285 T5-6-7

ELECTRICAL SYSTEM INSPECTION

HOW TO TROUBLESHOOT ALTERNATOR Terminal R Terminal L

MALFUNCTIONS

In general, the alternator indicator remains off when

the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
Terminal B

How to check the circuit

Terminal E
1. Stop the engine. Turn the key switch to the ON
position. Confirm that the alternator indicator
comes on.

2. Measure the voltage between the B and E terminals

of the alternator. If the measured voltage is around
24 V, the alternator circuit can be consi-dered
normal. If the measured voltage is low, a shortage
in battery capacity or looseness of the wire connec-
tors of the alternator circuit might be the cause of
the malfunction. When the voltage is 0 V, the wiring
SM6122
between the fuse box and alternator might be loose
or disconnected.
Also, the alternator cannot generate electricity if the
ground line is disconnect.

3. Next, start the engine and measure the voltage

generated while as the alternator rotates.
As described above, measure the voltage between
terminals B and E on the side of the alternator. If the
voltage is around 28 V, the alternator is operating
normally.
If the rated voltage is not being generated, there is
some trouble with the alternator or the regulator.
T5-6-8 EX255-EX285

ELECTRICAL SYSTEM INSPECTION

CONTINUITY CHECK
Harness
Single-line continuity check
A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity Ω

NOTE - When the one end connector is far apart from

the other, connect one end of connector (A) to the Connect to the a
A
machine chassis using a clip. Then, check continuity machine
of the harness through the vehicle frame as illustrated. chassis.

If the ohm-meter reading is: 0 Ω = Continuity Connect to the Ω

∞ Ω = Discontinuity machine
chassis.

Single-line short-circuit check

Disconnect both end connectors of the harness and A a
check continuity between one end connector of the
Short-circuit
harness and the vehicle frame: between the
If the ohm-meter reading is: harness and
0 Ω = Short circuit is present. Ω
the vehicle
frame
∞ Ω = No short circuit is present.
SM0660
Multi-line continuity check
Disconnect both end connectors of the harness, and
short-circuit two terminals, (A) and (B), at one end First short-circuit
connector, as illustrated. Then, check continuity be-
tween terminals (a) and (b) at the other connector. If
the ohm-meter reading is ∞ Ω, either line (A) - (a), or A a
B b
(B) - (b) is in discontinuity. To find out which line is C c
discontinued, conduct the single line continuity check
on both lines individually, or, after changing the short- Second short-circuit
circuit terminals from (A) - (B) to (A) - (C), check
continuity once more between terminals (a) and (c).
Ω
NOTE - By conducting the multi-line continuity check
twice, it is possible to find out which line is disconti-
SM0661
nued. With terminals (A) and (C) short-circuited, check
continuity between terminals (a) and (c).
If the ohm-meter reading is: Short-circuit between harnesses.

0 Ω = Line (B) - (b) has discontinuity.

A a
∞ Ω = Line (A) - (a) has discontinuity. B b
C c
Multi-line short-circuit check
Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or (C).
If the ohm-meter reading is:
0 Ω = Short-circuit exists between the lines. Ω
∞ Ω = No short-circuit exists between the lines.

SM0662
EX255-EX285 T5-6-9

ELECTRICAL SYSTEM INSPECTION

T5-6-10 EX255-EX285

ELECTRICAL SYSTEM INSPECTION

VOLTAGE AND CURRENT CHECK

Turn switch ON so that the specified voltage (current) 24 Voltage Circuit

is applied to the point to be measured. Then start
measuring either voltage or current. Judge if the
specified voltage is applied.
Start checking in order up to the point where voltage is
measured from either power source or actuator side.
Thereby, the faulty location in the circuit will be found.
Black Probe (Minus) of Tester : To ground (vehicle
frame).
Red Probe (Plus) of Tester : To location to be
measured.

Engine Key Check Point Standard

Switch
Power Source Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Power Source 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current (*) 6 mA
Preheat Circuit
Stopped ON Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON Between (7) and Ground: Glow plugs 20 to 25 V
Stopped ON Between (20) and Ground: QOS Controller power supply 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator Generating Voltage (B) 26 to 30 V
Fast Speed ON Between (10) and Ground: Alternator Generating Voltage 26 to 30 V
Fast Speed ON Between (15) and Ground: Alternator Generating Voltage 26 to 30 V
Fast Speed ON Between (16) and Ground: Alternator Generating Voltage (L) 13 to 30 V
Fast Speed ON Between (17) and Ground: Monitor 13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idling ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idling ON Between (16) and Ground: Alternator (L) 13 to 30 V
Slow Idling ON Between (18) and Ground: Anti Load Dump Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Air Conditioning 20 to 25 V
Stopped ON Between (21) and Ground: Horn 20 to 25 V
Stopped ON Between (22) and Ground: Lighter 20 to 25 V
Stopped ON Between (23) and Ground: Radio 20 to 25 V

(*) After disconnection the minus cable to the battery, start measuring.
EX255-EX285 T5-6-11

ELECTRICAL SYSTEM INSPECTION

QOS Controller Key Switch

Battery
Battery
Relay
Starter Fuse
box

Starter Relay

Glow
Relay
Fuse
box

Monitor
Alternator Glow Plugs

SM5619

Relay box

SM3036
T5-6-12 EX255-EX285

ELECTRICAL SYSTEM INSPECTION

5 Voltage Circuit
Signal or
ground
• Voltage between terminal No.1 and the vehicle Two polarities Power source

frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
• Key switch position: ON
• Tester black terminal (negative):
• Connected to the vehicle (ground)
• Tester red terminal (positive):
SM0664
• Connected to terminal No.1
Three polarities Power source Ground
Evaluation: 1 2 3
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 is normal.

• Voltage between terminal No.1 and the ground SM0665

terminal Two polarities

With the key switch turned OFF, disconnect the 1 2
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the ground
terminal (terminal No.2 for two polarities, or terminal
No.3 for three polarities) under the following condi- V
tions.

• Key switch position: ON

• Tester black terminal (negative):
Connected to the ground terminal
(terminal No.2 or 3)
SM0666
• Tester red terminal (positive):
Connected to terminal No.1 Three polarities

1 2 3
Evaluation:
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 or the ground terminal is
normal.
V

SM0667
EX255-EX285 T5-6-13

ELECTRICAL SYSTEM INSPECTION

• Check Using False Signal

IMPORTANT - On three-polarity connectors, do not Two polarities

short-circuit terminals No.1 and No.2 to No.3 or the (Pressure switch) 1 2
vehicle frame (ground), causing harnesses, control- (N sensor)
lers and fuses to burn due to current overload.

With the key switch turned OFF, disconnect the

sensor connector.
Short-circuit terminal No.1 (power source) and No.2
Short circuit
(signal) on the machine harness side connector and
supply the power source voltage as a false signal to
the controller. Check the controller under this condi- SM0668

tion, using the Dr.EX monitor function.

Evaluation: Three polarities

Except for the pressure switch circuits, if the maxi- 1 2 3
(EC sensor)
mum value is displayed, the MC (Main Controller) and (Pilot pressure sensor)
the circuits up to the machine harness side connector (Pump control pressure
sensor)
are normal. When the pressure switch circuits are (Pump delivery pressure
normal, the Dr.EX monitor displays “ON”. sensor)

Short circuit

SM0669
T5-6-14 EX255-EX285

ELECTRICAL SYSTEM INSPECTION

WIPER CONTROLLER
2

SMW0465

To wiper
motor

To washer
pump

SMW0466

1 - Connector 5 - Board
2 - Box 6 - Diode 1N4007
3 - Diode 1n5408 (q.ty 3) 7 - Wiper controller connector, harness side
4 - Relay
EX255-EX285 T5-6-15

ELECTRICAL SYSTEM INSPECTION

Replacement of wiper controller

1. Remove screw (1) under the right console to detach

cover (2).

2. Remove bolt (3) and turn the console around pin (4).
Then, take out lock pin (5). Push pin (4) to the seat
side, then remove spacer (6).
: 17 mm

3. Move the console to the seat side.

4. Using a sharp-pointed tool, remove cap (9) from 13

cover (7) and duct cover (8) located under the SM5620
monitor.

5. Remove cover (7) and duct cover (8).

6. Remove ashtray (10) and the ashtray screw.

Remove aux. switch panel (11).

7. Remove wiper controller cover (12).

a
8. Replace the wiper controller (13).

5 2 3 1

SM0670
4 6
View a

7 10 11

SM0671

9 8 12

1 - Screw 6 - Spacer 11 - Aux. Switch Panel

2 - Cover 7 - Cover 12 - Wiper controller cover
3 - Bolt 8 - Duct Cover 13 - Wiper controller
4 - Pin 9 - Cap
5 - Lock Pin 10 - Ashtray
T5-6-16 EX255-EX285

ELECTRICAL SYSTEM INSPECTION

REPLACEMENT OF RELAY
(R1, R2, R3, R4, R5, R6)

1. Remove the rear cover (1) by loosen the 3 bolts (3)

and the four bolts (2).
: 13 mm

2. Remove the bolt (4 and 5) fixing the support (6)

: 13 mm

R1-R2-R3-R4-R5-R6

SM5621

3. Lift the support (6).

1 2

SM1126

4. Lift the protection sheet (7).

5 4

SM3039
EX255-EX285 T5-6-17

ELECTRICAL SYSTEM INSPECTION

5. Identify the relay on the terminal board.

SM5622

6. Replace the relay.

T5-6-18 EX255-EX285

ELECTRICAL SYSTEM INSPECTION

RELAY BOX

SM5623

1 - Relay box 2 - Relay box connector harness side

SM5624

- Diodes
d1, d2, d3, d4 : Diode IN4007
D1, D2, D3, D4, D5, D6 : Diode IN5408

- Relay
R1: Anti Load Dump
R2: Horn
R3: Light 2
R4: Light 1
EX255-EX285 T5-6-19

ELECTRICAL SYSTEM INSPECTION

Replacement of relay box

1. Remove the rear cover (1) by loosening the three

bolts (3) and the four bolts (2).

1 2

2. Identify the relay box (4).

3
3. Remove the hexagonal screw M6 and the two
washer (5). SM1126

A
4. Disconnect the connector (6).

5. Remove the relay box (4).

SM3039

View from A
5
6. Install the new relay box (4).

7. Fix the relay box with hexagonal screw M6 and the

two washer (5).

8. Install the connector (6) on the relay box.

6

SM5625

9. Reinstall the rear cover by tightening the four bolts

(2) and the three bolts (3).
T5-6-20 EX255-EX285

ELECTRICAL SYSTEM INSPECTION

REPLACEMENT OF QOS CONTROLLER

1. Remove the rear cover (1) by loosening the 3 bolts

(3) and the four bolts (2).

2. Remove the bolts (4 and 5) fixing the support (6). 1 2

3. Lift the support (6).

4. Lift the protection sheet (7).

3
5. Remove the main controller (MC) (8) by loosening
the four bolts (9). SM1126
Do not disconnect the MC connectors.

6. Remove the QOS controller (10) by loosening the 6

two bolts (11).
Disconnect the connector.
5 4
7. Install the new QOS controller (10) and secure by
tightening the two bolts (11). Properly route the
QOS controller cable tail and fix by tie-wrap. 7
Connect the connector.

SM3039
8. Reinstall main computer (MC) (8) by tightening the
four bolts (9), the protection sheet (7) and the
support (6).

9. Reinstall the rear cover by tightening the four bolts

(2) and the three bolts (3).

SM6127
8
9

10

11

SM6128A
EX255-EX285 T5-6-21

ELECTRICAL SYSTEM INSPECTION

REPLACEMENT OF POWER OUTLET

1. Gain the access to the rear of panel and disconnect

the connector from power outlet.

2. Open the guard.

Power outlet OM0376

3. Using the special plier (Fiat Auto code No.

1876044000) unlock the sleeve from the lock ring.
Panel

Power outlet

4. Withdraw the sleeve from the rear of the panel.

Guard

SM3041

5. Install the new power outlet inserting the sleeve

from the rear of the panel and pushing the lock ring
on the front of the panel.

SM3042

Special plier Fiat Auto Code No. 1876044000

6. Reconnect the connector to the power outlet.
T5-6-22 EX255-EX285

ELECTRICAL SYSTEM INSPECTION

NOTES
EX255-EX285 T5-7-1

HARNESS CHECK

CIRCUIT INSPECTION

To inspect the circuits of the machine, a test har-
nesses kit 75301706 has been developed, including
dedicated harnesses for the inspection of the various
components of the machine, and the test harness
75301514.
The kit 75301706 includes harnesses for the check of
solenoid valves, harnesses for sensor check and
harness for wiper check.
The test harness 75301514 is used to check the
solenoid valves installed on solenoid valve unit.
To check the circuits, connect the appropriate harness
between the male and female connectors of the
component to be checked.
Then check the normal or abnormal operation of the
circuit, measuring with a tester, the power voltage on
the free connections.

Solenoid valve test harness

Two terminals test harness 75301706A.

Use this harness to check the circuit of solenoid
valve.

SM6732

Test harness 75301706A

Two-terminal test harness 75301514.

Use this harness to check the circuit of solenoid
valves SG, SI, SD, SC (installed on solenoid valve
unit). (Refer to pages T5-4-28, -39, -42 and -57).

SMW0491

Test harness 75301514

T5-7-2 EX255-EX285

HARNESS CHECK

EC motor test harness

Test harness 75301706B

Use this harness to check the circuit of the EC
motor.
(Refer to page T 5-4-24).

SM6733

Test harness 75301706B

Sensor test harness

Test harness 75301706D (Red)

Use this harness to measure the signal voltage of the
EC angle sensor circuit.
(Refer to page T5-3-4)
(Blue)
(Black)

SM6734

Test harness 75301706D

Wiper circuit test harness

Test harness 75301706C

Use this harness to check the wiper circuit.
(Refer to page T5-4-58)

SM6735
COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.
Documentation Centre
Strada di Settimo, 323 - S. MAURO T.SE ( TO ) ITALY

Reproduction of text or illustrations,

in whole or in part, is strictly prohibited

Print No. 604.13.196 - VII - 2002

Printed by Satiz - Turin (Italy)

Coordinamento Editoriale Satiz - Torino
EXCAVATOR -

WORKSHOP MANUAL
(Tier 2)

All information, illustrations and specifications in this manual are based on the latest product information avail-
able at the time of publication.
The right is reserved to make changes at any time without notice.

FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. - ENGINEERING -

FORM No. 604.13.201 - Edition - July 2002
EX255-EX285 IN-1

INTRODUCTION

TO THE READER

• This manual is written for an experienced technician - If you have any questions or comments, or if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact:

- Be sure to thoroughly read this manual for correct FIAT KOBELCO CONSTRUCTION
information concerning the service procedures. MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALY
PRODUCT SUPPORT
Fax. ++39 011 6877357

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition

to this service manual:

- Operation and Maintenance Instruction

Manual
- Parts Catalog

SERVICE MANUAL COMPOSITION

• The complete service manual consists of three
books:
- Technical Manual - Operational Principle
- Technical Manual - Troubleshooting
- Workshop Manual
- 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 Technical Manual-Operational Principle in- • The Service Manual for EX255 andEX285 Excava-
cludes the technical information concerning the tors consists of the following book/print numbers:
operation of main devices and systems.

- The Technical Manual -Troubleshooting includes

the technical information needed for operational
performance tests, and troubleshooting proce-
dures.

BOOK PRINT NUMBER

- Technical Manual - Operational Principle 604.13.191
- Technical Manual - Troubleshooting 604.13.196
- Workshop Manual 604.13.201
IN-2 EX255-EX285

INTRODUCTION

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.

To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW CV-PS 1.360
Volume L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature °C °F °C x 1.8 + 32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0
N.m lbf.ft 0.7375
EX255-EX285 S-1

SAFETY PRECAUTIONS

RECOGNISE SAFETY INFORMATION

• This is your SAFETY ALERT SYMBOL.

- When you see this symbol on your machine or in

this Manual, be alert of the potential for personal
injury.
- Follow recommended precautions and safe
operating practices.

S0021

UNDERSTAND SIGNAL WORDS

• In this Manual you will find the following words:

- DANGER;
- WARNING;
- CAUTION.
referring to different hazard risks. DANGER
These words are always accompanied by the safety
alert symbol.
WARNING
DANGER: indicates an imminent hazardous
situation which, if not avoided, will result in death or
serious injury. CAUTION
WARNING: indicated a potential hazardous
situation which, if not avoided, could result in death or
serious injury. IMPORTANT
CAUTION: indicates a potential hazardous situation
which, if not avoided, may result in minor or moderate
injury.
NOTE
IMPORTANT: indicates a situation which, if not
avoided, may cause damage to the machine.

NOTE: indicates an additional explanation for

information purposes.

ENVIRONMENTAL PROTECTION

• This Manual also contains this symbol

accompanying instructions for correct behaviour
as regards environmental protection.

S0024
S-2 EX255-EX285

SAFETY PRECAUTIONS

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 FIAT
KOBELCO 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 S0022
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.

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or an accident occurs.

- Keep the first-aid kit and fire extinguisher on hand.
- Thoroughly read and understand the label
attached to the fire extinguisher to use it properly.
- Establish emergency priority procedures to cope
with fires and accidents.
- Keep emergency numbers for doctors,
ambulance service, hospitals and fire
department posted near the telephone.

S0023
EX255-EX285 S-3

SAFETY PRECAUTIONS

WEAR PROTECTIVE CLOTHING

• Wear close-fitting clothing and safety equipment

appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask.
Be sure to correctly wear equipment and clothing
for the job.
- Do not take any chances. S0025

- Avoid wearing loose clothing, jewellery, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
- Wear a suitable hearing protection such as
earmuffs or earplugs to protect objectionable or
uncomfortably loud noise.

S0026

INSPECT THE MACHINE

• Inspect the machine carefully every day or work-

shift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.

- In the walk-around inspection, be sure to cover all

points detailed in the Chapter "MAINTENANCE",
paragraph "EXTERNAL VISUAL INSPECTION"
of the OPERATION AND MAINTENANCE S0027
INSTRUCTION MANUAL.
S-4 EX255-EX285

SAFETY PRECAUTIONS

USE HAND HOLDS AND STEPS

• Falling is one of the major causes of personal injury.

- When you get on and off the machine, always

face the machine and maintain a three-point
contact with the steps and handrails.

- Do not use any control as a handhold.

- Never jump off the machine. Never get on and

off a moving machine.
S0028
- Be careful of slippery conditions of platforms,
steps, and handrails when leaving the machine.

ADJUST THE OPERATOR'S SEAT

• A seat poorly adjusted for operator or work

requirements may quickly fatigue the operator
leading to improper operations.

- The seat should be adjusted whenever machine

operator changes.

- The operator should be able to fully press the

pedals and correctly move the control levers with
his back resting against the seat back.

- If not, move the seat fore and aft, and check again.

S0029
EX255-EX285 S-5

SAFETY PRECAUTIONS

FASTEN SEAT BELT

• Should the machine overturn, the operator may

become injured and/or thrown from the cab. Not
only, the operator may be crushed by the
overturning machine resulting in serious injury or
even death.

- Prior to operating the machine, thoroughly

examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
S0030

- Be sure to remain seated with the seat belt

securely fastened at all times when the machine
is in operation to minimise injury hazard in case
of accident.

- After a significant accident, replace the seat belts

even though they do not look damaged.

MOVE AND OPERATE MACHINE

SAFELY

• Bystanders can be run over.

- Pay the utmost attention not to run over

bystanders.

- Be sure and aware of the location of bystanders

before moving, swinging or operating the
machine.

- If fitted, keep the travel alarm and horn sounding

to warn people that the machine is about to move.
S0031

- When operating, swinging, or moving the

machine in a congested area use a signal man.

- Co-ordinate hand signals before starting the

machine.
S-6 EX255-EX285

SAFETY PRECAUTIONS

OPERATE ONLY FROM THE DRIVER'S

SEAT

• Inappropriate engine starting procedures may

cause the machine unexpected movement,
possibly resulting in serious injury and even death.
- Start the engine only from the operator’s seat.

- NEVER start the engine while standing on the

track or on the ground.

- Do not start the engine by shorting across starter

motor terminals.
S0032
- Before starting the engine, ensure that all control
levers are in the neutral position.

KEEP RIDERS OFF THE MACHINE

• Riders on the machine are subject to injuries such

as being struck by foreign objects and being thrown
off the machine.

- Only machine operator is allowed on the

machine. Keep riders off.

- Riders also obstruct the operator’s visibility,

resulting in the machine being operated unsafely.

S0033

CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN

• Incorrect travel controls operation may result in

serious injury and even death.

- Before driving the machine, be aware of the

undercarriage position relative to the operator’s
position. If travel motors are located at the front
of the cab, the machine will move reverse when
travel controls are moved towards cab front.
S0037
EX255-EX285 S-7

SAFETY PRECAUTIONS

AVOID INJURY FROM BACK-OVER AND

SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.

• To avoid back-over and swing accidents:

- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.

- Keep the travel alarm in working condition (if

equipped).

- ALWAYS BE ALERT FOR BYSTANDERS

S0042
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.

- USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.

- Use hand signals, which conform to your local

regulations, when work conditions require a
signal person.

- No machine motions shall be made unless S0043

signals are clearly understood by both signalman
and operator.

- Learn the meanings of all flags, signs, and

markings used on the job and confirm with the
person in charge of signalling.

- Keep windows, mirrors, and lights clean and in

good condition.

- Dust, heavy rain, fog, etc., can reduce visibility.

As visibility decreases, reduce speed and use
proper lighting.

- Read and understand all operating instructions in

the OPERATION AND MAINTENANCE
INSTRUCTION MANUAL.
S-8 EX255-EX285

SAFETY PRECAUTIONS

DRIVE MACHINE SAFELY

• Before starting the machine carefully read the

OPERATION AND MAINTENANCE INSTRUC-
TION MANUAL. (Refer to the OPERATING IN-
STRUCTIONS chapter).

• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.

- Pushing down on the front of the travel pedals or

S0038
pushing the levers forward moves the machine
towards the idlers. (Refer to the OPERATION
AND MAINTENANCE INSTRUCTION
MANUAL).

• Traveling on a grade may cause the machine to slip

or to overturn, possibly resulting in serious injury or
death.

- When traveling up or down a grade, keep the

bucket in the direction of travel, approximately 20
to 30 cm (A) above the ground.

- If machine starts to skid or becomes unstable,

lower the bucket immediately. S0039

- Traveling across the face of a slope may cause

the machine to skid or to overturn. When
travelling (ascending/descending) on a slope, be
sure to point the tracks uphill/downhill.

S0004

- Turning on an incline may cause the machine to

tip over.
If turning on an incline is absolutely unavoidable,
do so at a place where the slope is gentle and the
surface is firm.

- When operating on a grade and the fuel reserve

indicator light lights, immediately refuel.

WRONG
S0005
EX255-EX285 S-9

SAFETY PRECAUTIONS

AVOID OVERTURNING

• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death.

• To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the bucket low to the ground and close to
the machine.
- Reduce machine operating speed to avoid
tipping or slipping.
- Avoid changing direction when travelling on
grades. S0002
- NEVER attempt to travel across a grade steeper
than 15 degrees.
- Reduce swing speed as necessary when
swinging loads.

• Be careful when working on frozen ground.

- Temperature increases will cause the ground to
become soft and make ground travel unstable.

S0047

PARK MACHINE SAFELY

• To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Turn auto-idle (A/I) switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Pull the safety lever (pilot-control shut-off lever) to
the LOCK position.
- Close windows, roof window, and cab door.
- Lock all access doors and compartments. S0049
S-10 EX255-EX285

SAFETY PRECAUTIONS

AVOID INJURY FROM UNEXPECTED

MACHINE MOVEMENT

• Death or serious injury may result if you attempt to

get on or off a moving machine.

• To avoid roll-aways:
- Select level ground when possible to park
machine.
- Do not park the machine on a grade.
- Lower the bucket and/or other work tools to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
- Turn the auto-idle switch off.
- Run the engine at slow idle speed without load for
S0040
5 minutes to cool down the engine.
- Stop the engine and remove the key from the key
switch.
- Pull the pilot shut-off lever to LOCK position.
- Block both tracks.
- Position the machine to prevent overturning.
- Park a reasonable distance from other machines.

S0041

PROVIDE SIGNALS FOR JOBS

INVOLVING A NUMBER OF MACHINES

• For jobs involving several machines, provide

signals commonly known by all personnel involved.
Also, appoint a signal person to co-ordinate the job
site. Make sure that all personnel obey the signal
person’s directions.

S0036
EX255-EX285 S-11

SAFETY PRECAUTIONS

INVESTIGATE JOB SITE BEFORE HAND

• When working at the edge of an excavation or on a

road shoulder, the machine could overturn, possibly
resulting in serious injury or death.
- Investigate the configuration and ground
conditions of the job site beforehand to prevent the
machine from overturning and prevent the ground,
stockpiles, or banks from collapsing.
- Make a work plan. Use machines appropriate to
the work and job site.
- Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
- When working on an incline or road shoulder,
employ a signal person as required.
Confirm that your machine is equipped with a S0034

F.O.P.S. (Falling Object Protective Structure) cab

before working in areas where there is the
possibility of falling stones or landslides.
- When footing is weak, reinforce the ground before
starting the work.
- When working on frozen ground, be extremely
alert. As ambient temperature rises, footing
becomes loose and slipped.

PROTECT AGAINST FALLING STONES

AND LANDSLIDES

• Confirm that your machine is equipped with a

F.O.P.S. (Falling Object Protective Structure) cab
before working in areas where there is the
possibility of falling stones.

S0035
S-12 EX255-EX285

SAFETY PRECAUTIONS

DIG WITH CAUTION

• Accidental severing of underground cables or gas

lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
- Before digging, check the location of cables, gas
lines, and water lines.
- Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic
cable should be accidentally severed, do not look
into the end. Doing so may result in serious eye
injury.
- Contact local authorities and/or the utility
companies directly (electric power, gas,
telephone, water, sewers, telecommunications,
etc.) to obtain information about underground S0009

utility lines.

OPERATE WITH CAUTION

• If the front attachment or any other part of the

machine hits against an overhead obstacle, such
as a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury may
results as well.

- Take care to avoid hitting overhead obstacles

with the boom or arm.

S0008

AVOID ELECTRIC LINES

• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines. L
- When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m plus twice the line insulator length (L).
- Check and comply with any local regulations that
may apply.
- Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
- Keep all bystanders or co-workers away from the
site.

S0205
EX255-EX285 S-13

SAFETY PRECAUTIONS

KEEP PERSONNEL CLEAR FROM

WORKING AREA

• A person may be hit severely by the swinging front

attachment or counterweight and/or may be
crushed against an other object, resulting in serious
injury or death.

- Keep all persons clear from the area of operation

and machine movement.
- Before operating the machine, set up barriers to
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.

S0044

NEVER MOVE THE BUCKET OVER ANY

ONE

• Never lift, move, or swing bucket above anyone or

a truck cab.
Serious injury or machine damage may result due
to bucket load spill or due to collision with the
bucket.

S0045

AVOID UNDERCUTTING

• In order to retreat from the edge of an excavation if

the footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.

- If the footing starts to collapse and if sufficient

retreat is not possible, do not panic. Often, the
machine can be secured by lowering the front
attachment, in such cases.

S0011
S-14 EX255-EX285

SAFETY PRECAUTIONS

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could

occur causing serious injury or death.

S0048

SAFETY LOADS MOVING

• The excavator is no lifting and transportation

means, therefore it should not be used to position
loads accurately. Should it be exceptionally used to
lift and lay building components, special caution
must be taken as follows:

- The machine must be equipped without failure

with the appropriate variant supplied, upon
request, by FIAT KOBELCO. Also, totally comply
with the safety precautions for the operation of the
excavator as a lifting equipment.

- Secure the loads to be raised using cables or

chains fastened with appropriate hooking
mechanisms.

- Never hook cables or chains to the bucket teeth.

- Nobody should be allowed to remain under the

raised load or within the excavator operating
range for any reason whatever.
S0165

- Never exceed specified loading capacity.

Incorrect fastening of slings or chains may cause
boom/arm failure or failure of the lifting means
with consequent bodily injuries and even death.

- Always ensure that slings and chains used for

lifting are adequate to the load and in good
condition.

- All loading capacities are referred to the

machine on a level surface and should be
disregarded when working on a slope.
EX255-EX285 S-15

SAFETY PRECAUTIONS

SAFETY TRANSPORTING

• The danger of tipping is present when loading/

unloading the machine onto/from a truck or trailer
bed.
- Be sure to observe local regulations when
transporting the machine on public roads.
- Provide an appropriate truck or trailer for
transporting the machine.

• Take the following precautions when loading/

unloading the machine:
1. Select firm level ground.
2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when loading/ S0052

unloading the machine.

4. Always turn the auto-idle (A/I) switch OFF when
loading or unloading the machine, to avoid
unexpected speed increase due to unintentional
operation of a control lever.
5. Always select the slow speed mode with the
travel speed selector. In the high speed mode,
travel speed may automatically increase.
6. Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify travelling direction, and begin to
drive again.
7. Do not operate any levers besides the travel
levers when driving up or down the ramp.
8. The top end of the ramp where it meets the
flatbed is a sudden jolt. Take care when traveling
over it.
9. Prevent possible injury from machine tipping
while the upperstructure is rotating.
10. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11. Securely fasten machine frame using chains or
cables. Refer to “TRANSPORT” chapter in the
OPERATION AND MAINTENANCE
INSTRUCTION MANUAL for details.
S-16 EX255-EX285

SAFETY PRECAUTIONS

SAFE MAINTENANCE
• To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Kepp the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it is
in motion.
- Kepp hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Switch off the Auto-Idle (A/I).
4. Let the engine idle with no load for at least five
minutes until it has cooled down.
5. Move the key-start switch to the OFF position
to stop the engine.
6. Remove the ignition key from the start switch.
S0053
7. Apply the "Maintenance in progress" tag .
This tag can be applied o the left-hand control
lever, safety lever or cab door.
8. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
9. Let the engine cool down.
- Do not leave the machine unattended if servicing
requires the engine running .
- If the machine is to be raised, place boom and arm
at an angle 90 to 110°. Lock machine components
which should be raised for maintenance or repair
using suitable supporting means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary.
Refer to the the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL. S0054
- Keep all components in good condition and
properly install. Immediately repair any fault.
- Immediately repair any damage.Replace worn or
failed components. Remove grease, oil, debris
build-ups.
- Disconnect the negative cable (−) from the battery
before carry out any work on the electrical system
or arc-welding on the machine.
EX255-EX285 S-17

SAFETY PRECAUTIONS

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injury.

- Before performing any work on the machine,

attach a maintenance in progress tag. This tag can
be applied o the left-hand control lever, safety
lever or cab door.

S0055

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without

securing the machine first.

- Always lower the attachment or tool to the ground

before working on the machine.
- If you must work on a lifted machine or
attachment, securely support the machine or
attachment.
- Do not support the machine on cinder blocks,
bollow tires, or props that may crumble under
continuous load.
- Do not work under a machine that is supported S0054
solely by a jack.

STAY CLEAR OF MOVING PARTS

• Entanglements in moving parts can cause serious

injury.

• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair do
not become entangled when working near rotating
parts.

S0056
S-18 EX255-EX285

SAFETY PRECAUTIONS

DISPOSE OF WASTE IN THE

APPROPRIATE MANNER

• Waste improperly disposed of represents a danger

for the envinronment. Potentially dangerous waste
used on the FIAT KOBELCO excavators includes
lubricants, fuel, coolant, brake fluid, filters and
batteries.

- Used sealed containers when discharging fluids.

Do not use containers for food or beverages
which may induce drinking.

- Do not spill waste over the ground, into drains, or

water beds.
S0064

- Obtain information about the correct methods to

recycle or dispose of waste from local
Authorities, collection centres or your Dealer.

WORK IN A CLEAN AREA

• Before starting an operation, clean the working

area.
Clear the area from all the objects that can be
dangerous for mechanics or people in the working
area.

S0166

PROPERLY LIGHT THE WORKING AREA

• Properly and safely light the working area.

- Use safe portable lamps in order to work inside

and under the machine.

- Make sure that the lamp is shielded by a cage;

the incandescent filament of a lamp, accidentally
broken, can cause fuel or oil fire. F1480

S0167
EX255-EX285 S-19

SAFETY PRECAUTIONS

REGULARLY WASH THE MACHINE

• Remove all the traces of grease, oil and deposits,

in order to avoid people accidents or damages to
things.

- Do not spray water or steam in the cab.

F1462 S0153

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

breakers and blades can fall and cause serious
injury or death.

- Securely store attachments and implements to

prevent falling.

- Keep bystanders away from storage areas.

F1463 S0058

PREVENT ACID SCALDS

• The sulphuric acid, contained in the battery, is
poisonous.
It is strong enough to scald the skin, corrode
clothes and cause blindness, if it is sprayed into
the eyes.
To avoid dangers:
- Fill the batteries in airy areas.
- Wear eye protections and rubber gloves.
- Avoid breathing the electrolyte vapours when
topping up.
- Avoid spilling or dripping the electrolyte.
- Use proper emergency starting techniques.
If you are touched with acid sprays:
- Rinse your skin well with water. F1474 S0168

- Put on your skin sodium bicarbonate or clay to

help the acid neutralization.
- Rinse your eyes with water for 10-15 minutes.
- Immediately see a doctor.
If you have swallowed the acid:
- Drink a big quantity of water or milk, swallow
milk of magnesia, scrabbled eggs or vegetal oil.
- Immediately see a doctor.
S-20 EX255-EX285

SAFETY PRECAUTIONS

STARTING THE ENGINE WITH

BOOSTER BATTERIES

• Battery gas may explode causing serious damages

and injuries.

- If the engine is to be started using booster

batteries, ensure to comply with all procedures
detailed in the chapter “OPERATING
INSTRUCTIONS” of the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL.

- The operator should be sitting in the driver’s seat

to keep the machine under control when the
engine starts. Starting the engine with booster
S0001
batteries is a two man operation.

- Do not use batteries that have been stored in the

cold for a long time.

- Mistakes in following procedures detailed for

starting the engine with slave batteries may
cause the batteries to explode or machine to
move unexpectedly.

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

- Keep sparks, lighted matches, and flames away

from the top of battery.

- Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.

- Do not charge a frozen battery; it may explode.

Warm battery to 16 °C.

• Battery electrolyte is poisonous. If the battery

should explode, battery electrolyte may be S0001

splashed into eyes, possibly resulting in blindness.

- Be sure to wear eye protection when checking

electrolyte specific gravity.
EX255-EX285 S-21

SAFETY PRECAUTIONS

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.

- To prevent possible injury from hot spraying water.

DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap.
- The hydraulic oil tank is pressurized. Again, be S0019

sure to release all pressure before removing the

cap.

Hot fluids and surfaces:

• Engine oil, reduction gear oil and hydraulic oil also

become hot during operation.
The engine, hoses, lines and other parts become hot
as well.

- Wait for the oil and components to cool down

before starting any maintenance or inspection
work.

S0059

KEEP CLEAN THE MACHINE

Keep clean the engine compartment, radiator,

batteries, hydraulic pipes, fuel tank and operator's
position.
The engine compartment temperature can quickly
rise, after stopping the engine.
IN THESE CASES, BE CAREFUL TO POSSIBLE
FIRES.
Open the access doors in order to quicken the engine
cooling process and clean the compartment.

S0177
S-22 EX255-EX285

SAFETY PRECAUTIONS

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.

- Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
SA0016

- Tighten all connections before applying

pressure.

- Search for leaks with a piece of cardboard; take

care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles for
eye protection.

SA0017
- In an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.

SA0018

PREVENT PARTS FROM FLYING OFF

• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result
in serious injury, blindness, or death.

- NEVER attempt to remove GREASE FITTING

or VALVE ASSEMBLY.
- As pieces may fly off, be sure to keep body and
face away from valve.

• Travel reduction gears are under pressure. F3635

S0178
- As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. REDUCTION GEAR OIL is hot. Wait for
gear oil to cool down, then gradually loosen the air
release plug to release pressure.
EX255-EX285 S-23

SAFETY PRECAUTIONS

PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body,

serious injury may result.

- Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.

S0046

HANDLE FLUIDS SAFELY - AVOID

FIRES

• Handle fuel with care: it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.

- Do not refuel the machine while smoking or when

near open flame or sparks.
- Always stop the engine before refuelling the
machine.
- Fill the tank outdoors.

S0050

• All fuels, most lubrificants, and some antifreeze

fluids are flammable.

- Store flammable fluids well away from fire

hazards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn
spontaneously.

S0051
S-24 EX255-EX285

SAFETY PRECAUTIONS

PREVENT FIRES

• Check for Oil Leaks:

- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other,
damage to the oil-cooler, and loose oil-cooler
flange bolts which may cause oil leaks.
- Tighten, repair or replace any missing, loose or S0051
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.

• Check for Shorts circuits which could cause fires:

- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..

• Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.

• Check Key-start Switch:

- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF position
to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.

• Check Heat Shields:

- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
EX255-EX285 S-25

SAFETY PRECAUTIONS

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the

following way:

- Stop the engine by turning the key-start switch to

the OFF position if there is time.

- Use a fire extinguisher if there is time.

- Exit the machine.

S0060

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.

- If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.

S0061

USE APPROPRIATE TOOLS

• Use tools appropriate for the job to be performed.

- Inappropriate tools, parts and procedures might

generate dangerous conditions.

- Use tools of correct size to tighten or loosening

securing elements, in order to avoid injuries
caused by a wrench getting out of control.

- Do not use U.S. Standard or British Standard

tools on metric fasteners and vice versa.

• Use only FIAT KOBELCO genuine spare parts

(please refer to the PARTS CATALOG). S0120
S-26 EX255-EX285

SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.

Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable ma-
terials.

Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area. Install tem-
porary fire resistant guards to protect hoses or other
materials when welding, soldering, etc.

S0062

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

- Do not weld or flame cut pipes or tubes that contain

flammable fluids.

- Clean them thoroughly with non-flammable solvent

before welding or flame cutting them.

REMOVE PAINT BEFORE WELDING OR

HEATING

• Hazardous fumes can be generated when paints is

heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.

- Avoid breathing potentially toxic fumes and dust.

- Do all such work outside or in a well-ventilated

area.

- Dispose of paint and solvents properly.

- Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the S0063
dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
WORKSHOP MANUAL EX255-EX285

ESCAVATOR

SECTION AND GROUP CONTENTS

Section 1 - GENERAL INFORMATION

Group 1 - Precautions for Disassembly and Assembly
Group 2 - Tightening Torque

Section 2 - UPPERSTRUCTURE
Group 1 - Cab
Group 2 - Counterweight
Group 3 - Main Frame
Group 4 - Pump Device
Group 5 - Control Valve
Group 6 - Swing Device
Group 7 - Pilot Valve
Group 8 - Pilot Shut-Off Valve
Group 9 - Shockless Valve
Group 10 - Solenoid Valve Unit
Group 11 - Pilot Relief Valve Unit

Section 3 - UNDERCARRIAGE
Group 1 - Swing Bearing
Group 2 - Travel Device
Group 3 - Center Joint
Group 4 - Track Adjuster
Group 5 - Front Idler
Group 6 - Upper and Lower Roller
Group 7 - Tracks

Section 4 - FRONT ATTACHMENT

Group 1 - Front Attachment
Group 2 - Cylinders
Section 5 - ENGINE AND ACCESSORY
Group 01 - General Information
Group 02 - Maintenance
Group 03 - Engine Disassembly
Group 04 - Engine Inspection and Repair
Group 05 - Engine Reassembly
Group 06 - Lubricating System
Group 07 - Cooling System
Group 08 - Fuel System
Group 09 - Turbocharger
Group 10 - Starting and Charging
Group 11 - Troubleshooting
Group 12 - Repair Standards
SECTION 1 EX255-EX285

GENERAL INFORMATION

CONTENTS

Group 1 - Precautions for Disassem- Group 2 - Tightening Torque

bly and Assembly
Tightening Torque Specification .............. W1-2-1
Precautions for Disassembly and Torque Chart .......................................... W1-2-2
Assembly ............................................. W1-1-1 Piping Joint ............................................ W1-2-5
EX255-EX285
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
PRECAUTIONS FOR DISASSEMBLY AND
ASSEMBLY
Preparations for Disassembly
• Clean the Machine
Thoroughly wash the machine before bringing it
into the shop. Bringing a dirty machine into the
shop may cause machine components to be con-
taminated during disassembling/assembling, re-
sulting in damage to machine components, as well
as decreased efficiency in service work.
• Inspect the Machine
Be sure to thoroughly understand all disassem-
bling/assembling procedures beforehand, to help
avoid incorrect disassembling of components as
well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
- The machine model, machine serial number, and
hour meter reading.
- Reason for disassembly (symptoms, failed
parts, and causes).
- Clogging of filters and oil, water or air leaks, if
any.
- Capacities and condition of lubricants.
- Loose or damaged parts.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the
area for disassembling work.
W1-1-1
Precautions for Disassembly and Assembly
• Precautions for Disassembly
- To prevent dirt from entering, cap or plug the
removed pipes.
- Before disassembling, clean the exterior of the
components and place it on a work bench.
- Before disassembling, drain gear oil from the
reduction gear.
- Be sure to provide appropriate containers for
draining fluids.
- Use matching marks for easier reassembling.
- Be sure to use the specified special tools, when
instructed.
- If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
- Orderly arrange disassembled parts. Mark and
tag them as necessary.
- Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
- Inspect the contact or sliding surfaces of disas-
sembled parts for abnormal wear, sticking, or
other damage.
- Measure and record the degree of wear and
clearances.
• Precautions for Assembly
- Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace it.
- Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
- Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassem-
bled. Apply a film of grease before installing.
- Be sure that liquid-gasket-applied surfaces are
clean and dry.
- If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to
remove the agent.
- Utilize matching marks when assembling.
- Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
- Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no tools are missing.
W1-1-2 EX255-EX285

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

Bleeding Air from Hydraulic System

When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and instal-
lation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:

• Bleeding Air from Hydraulic Pump

IMPORTANT - If the engine is started with air trapped

in the hydraulic pump housing, damage to the pump
may result. Be sure to bleed air before starting the
engine.

- Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
- After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the
engine and run at slow idle speed.
- Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
- After bleeding all the air, securely tighten the
plug.

• Bleeding Air from Travel Motor / Swing Motor

- With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.

• Bleeding Air from Hydraulic Circuit

- After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each
operation (never fully stroke the cylinders during
initial operation stage). As the pilot oil circuit has
an air bleed device, air trapped in the pilot oil
circuit will be bled while performing the above
operation for approx. 5 minutes.
- Reposition the front attachment to check hydrau-
lic oil level.
- Stop the engine. Recheck hydraulic oil level.
Replenish oil as necessary.

SM1000
EX255-EX285 W1-1-3

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

Floating Seal Precautions A

1. In general, replace the floating seal with a new one.

If the floating is to be reused, follow these proce-
dures:

(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces.

(2) Check the seal ring face (A) for scuffing, scor- B SM1001

ing, corrosion, deformation or uneven wear.

(3) Check O-ring (B) for tears, breaks, deformation

or hardening.

2. If incorrectly assembled, oil leakage or damage will

occur. Be sure to do the following, to prevent
trouble.

(1) Clean the floating seal and seal mounting bores

with cleaning solvent. CORRECTLY
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with com-
pressed air.
INCORRECTLY
(2) Clean the floating seal and seal mounting bores,
as dust on them tends to enter the floating seal
when installing it.

(3) Check that the O-ring is not twisted, and that it SM1002

is installed correctly on the seal ring.

(4) After installing the floating seal, check that seal

ring surface (C) is parallel with mating face (A) CORRECTLY INCORRECTLY
by measuring the distances (a) and (b), as A
illustrated. If these distances differ, correct the a a
O-ring seating.
C

b b
a=b a≠b
SM1003
W1-1-4 EX255-EX285

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

NOTES:
EX255-EX285 W1-2-1

TIGHTENING TORQUE

TIGHTENING TORQUE SPECIFICATIONS

No. Descriptions Bolt Diam. Wrench Torque

Size
mm mm Nm kgf m lbf ft

1 Engine cushion rubber mounting bolt 18 27 392 40 290

2 Engine bracket mounting bolt 10 17 64 6.5 47

12 19 108 11 80

3 Hydraulic oil tank mounting bolt 20 30 390 40 290

4 Fuel tank mounting bolt 16 24 205 21 152

5 ORS fittings for hydraulic hoses and piping * 1-3/16"-12 36 175 18 130
* 1-7/16"-12 41 205 21 152
* 1-11/16"-12 50 324 33 239

6 Pump device mounting bolt 10 17 49 5 36

7 Control valve mounting bolt 16 24 205 21 152

8 Control valve bracket mounting bolt 16 24 205 21 152

9 Swing device mounting bolt 22 32 665 68 490

10 Battery mounting bolt 10 17 9.8 1 7

11 Cab mounting nut 16 24 205 21 152

12 Swing bearing mounting bolt to upperst. 27 41 1230 125 900

Swing bearing mounting bolt to undercar. 27 41 1205 123 890

13 Travel device mounting bolt 20 30 620 63 456

14 Sprocket mounting bolt 20 30 490 50 362

15 Upper roller mounting bolt 16 24 265 27 195

16 Lower roller mounting bolt 20 30 500 51 369

17 Track shoe mounting bolt 22 32 940 96 694

18 Low pressure coupling and clamp 8 13 10.3to12.4 1.05to1.26 8 to 16

5 8 2.90 0.30 2
6 10 4.40 0.45 3

*: UNF thread

NOTE - (1) Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to stabilize friction
coefficient of them.
(2) Make sure bolt and nut threads are clean before installing.
(3) Apply Loctite to threads before installing and tightening swing bearing mounting bolts.
W1-2-2 EX255-EX285

TIGHTENING TORQUE

TORQUE CHART

WARNING
Use tools appropriate for the work to be done.
Makeshift tools and procedures can create safety
hazards. For loosening and tightening nuts and
bolts, use the correct tools. Avoid bodily injury
caused by slipping wrenches.

Bolt Types

Tighten nuts or bolts correctly to torque specifications.

Four kinds of bolts, hexagon bolts T, H, M and socket SM1004
bolt, each made of different material, are used. Make
sure to employ the correct bolts and tighten them to
specification when assembling the machine or compo-
nents.

Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

SM1005

Specified Tightening Torque Chart

Bolt Wrench Hexagon T Bolt, Socket bolt H Bolt M Bolt

Dia. Size Wrench
Size Nm kgf m lbf ft Nm kgf m lbf ft Nm kgf m lbf ft

M8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2

M10 17 8 64 6.5 47 49 5 36 19.5 2 14.5
M12 19 10 108 11 80 88 9 65 34 3.5 25.5
M14 22 12 175 18 130 137 14 101 54 5.5 40
M16 24 14 265 27 195 205 21 152 78 8 58
M18 27 14 390 40 290 295 30 220 118 12 87
M20 30 17 540 55 400 390 40 290 167 17 123
M22 32 17 740 75 540 540 55 400 215 22 159
M24 36 19 930 95 690 690 70 505 275 28 205
M27 41 19 1 370 140 1 010 1 030 105 760 390 40 290
M30 46 22 1 910 195 1 410 1 420 145 1 050 540 55 400
M33 50 24 2 550 260 1 880 1 910 195 1 410 740 75 540
M36 55 27 3 140 320 2 310 2 400 245 1 770 930 95 690
EX255-EX285 W1-2-3

TIGHTENING TORQUE

IMPORTANT
(1) Apply lubricant (i. e. white zinc B dissolved into
spindle oil) to nuts and bolts to stabilize their
friction coefficients.
(2) Torque tolerance is ±10 %.
(3) Be sure to use bolts of correct length. Bolts that are
too long cannot be tightened, as the bolt tip comes
into contact with the bottom of the bolt hole. Bolts
that are too short cannot develop sufficient tighten-
ing force.
(4) The torques given in the chart are for general use
only.
Do not use these torques if a different torque is
given for a specific application.
(5) Make sure that the nut and bolt threads are clean
before installing. Remove dirt or corrosion, if any.

Bolt Tightening Order

When tightening two or more bolts, tighten them

alternately, as shown, to ensure even tightening.

Equally tighten upper

and lower alternately Tighten diagonally Tighten from center and diagonally

1 12 9 4 1 6 7 14
1,4 6 3

2,3 4 5
2 13 8 5 2 3 10 11

SM1006
W1-2-4 EX255-EX285

TIGHTENING TORQUE

Service Recommendations for Split Flange

IMPORTANT
(1) Be sure to clean and inspect sealing surfaces.
Scratches / roughness cause leaks and seal wear. SM1007

Unevenness causes seal extrusion. If defects

cannot be polished out, replace the component.
(2) Be sure to use only specified O-rings. Inspect O- WRONG
rings for any damage. Take care not to file O-ring
surfaces. When installing an O-ring into a groove,
use grease to hold it in place.
(3) Loosely assemble split flange halves. Make sure
that the split is centrally located and perpendicular
to the port. Hand-tighten the bolts to hold the parts
in place. Take care not to pinch the O-ring.
(4) Tighten bolts alternately and diagonally, as shown,
to ensure even tightening. SM1008
(5) Do not use air wrenches. Using an air wrench often
causes tightening of one bolt fully before tighten
the others, resulting in damage to O-rings or un-
even tightening of bolts.

Nut and Bolt Lockings

• Lock Plate

SM1009
IMPORTANT- Do not reuse lock plates. Do not try to
bend the same point twice.
RIGHT WRONG

• Cotter Pin

IMPORTANT- Do not reuse cotter pins. Match the

holes in the bolt and nut while tightening, not while
Bend along edge sharply Do not bend it round
loosening.

RIGHT RIGHT WRONG

• Lock Wire

IMPORTANT - Apply wire to bolts in the bolt-tightening

direction, not in the bolt-loosening direction.

Bend along edge sharply

SM1010

RIGHT RIGHT WRONG

RIGHT WRONG
Loosen
Tighten

SM1011
EX255-EX285 W1-2-5

TIGHTENING TORQUE

PIPING JOINT

Pipe Thread Connection / Union Joint Tightening 1 4 3 5 2

Torque Specifications

Union Joint

Metal sealing faces (4) and (5) of adaptor (1) and hose
(2) fit together to seal pressure oil. Union joints are
used to join small-diameter lines.

Joint Body
IMPORTANT SM1012

(1) Do not over-tighten union nut (3). Excessive force

will be applied to metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be sure to tighten
union nut (3) to specifications.
37°
(2) Scratches or other damage to sealing surfaces (4)
or (5) will cause oil leakage at the joint. Take care 37°
not to damage them when connecting /disconnect-
ing.
Male Union Joint Female Union Joint

SM1013

Wrench Size Tightening Torque

Type
Union Nut Joint Body Nm kgf m lbf ft
37° Union Joint 19 17 29 3 22
22 19 39 4 29
27 22 78.5 8 69
36 30, 32 157 16 116
41 36 205 21 152.5
50 46 255 26 188

NOTE - Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.
W1-2-6 EX255-EX285

TIGHTENING TORQUE

O-ring Seal Joint

O-ring (6) seats against the end face of adaptor (7) to

seal pressure oil.
7 6 9

IMPORTANT
(1) Be sure to replace O-ring (6) with a new one when
reconnecting.

(2) Before tightening union nut (9), confirm that O-

ring (6) is seated correctly in O-ring groove (8).
Tightening union nut (9) with O-ring (6) displaced
will damage O-ring (6), resulting in oil leakage. 8 10 Joint body

SM1014
(3) Take care not to damage O-ring groove (8) or
sealing face (10). Damage to O-ring (6) will cause Wrench Size Tightening Torque
oil leakage.
Union Joint Nm kgf m lbf ft
Nut Body
(4) If union nut (9) is found to be loose, causing oil
leakage, do not tighten it to stop the leak. Instead, 27 22 93 9.5 69
replace O-ring (6) with a new one, then tighten union 36 30, 32 175 18 130
nut (9) after confirming that O-ring (6) is securely 41 36 205 21 152
seated in place.
50 46 320 33 240
EX255-EX285 W1-2-7

TIGHTENING TORQUE

Screwed-In Connection PT PF

30°
IMPORTANT - Many types of screwed-in connec-
tions are used for hose connections.
Be sure to confirm that the thread pitch and thread type
(tapered or straight) are the correct type before using
any screw-in connection.
Male Tapered Thread Male Straight Thread
SM1015

Male Tapered Thread

Wrench Tightening Torque
Joint Body Nm kgf m lbf ft
17, 19 34 3.5 25
19, 22 49 5 36
27, 22 93 9.5 69
36, 32 157 16 116
41 205 21 152.5
50 320 33 240
60 410 42 300

Internal Thread
Seal Tape Application

Seal tape is used to seal clearances between male and

female threads, so as to prevent any leakage between
threads. Clearance External Thread SM1016
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap.
Leave one to two pitch threads uncovered

• Application Procedure

Confirm that the thread surface is clean, free of dirt

or damage.
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads.

SM1017

Low-Pressure-Hose Clamp Tightening Torque T-Bolt Type Worm Gear Type

Low-pressure-hose clamp tightening torque differs

depending on the type of clamp.
See below for correct tightening torque of each type of
low-pressure-hose clamp.

T-Bolt Type Band Clamp:

4.4 N m (0.45 kgf m, 3.25 lbf ft )
Worm Gear Type Band Clamp:
5.9 to 6.9 N m (0.6 to 0.7 kgf m, 4.3 to 5.1 lbf ft )
SM1018 SM1019
W1-2-8 EX255-EX285

TIGHTENING TORQUE

Connecting Hose WRONG RIGHT

WARNING
1) When replacing hoses, be sure to use only
genuine parts. Using hoses other than genuine
hoses may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in a fire
on the machine. SM1020

(2) Do not install hoses kinked. Application of high

oil pressure, vibration, or an impact to a kinked
hose may result in oil leakage, hose rupture or WRONG RIGHT
separation of fitting. Utilize print marks on
hoses when installing hoses to prevent hose Rubbing Against Each Other
from being installed kinked.
(3) If hoses rub against each other, wear to the
hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. SM1021
Take care that hoses do not come into contact
with moving parts or sharp objects.

WRONG RIGHT

Clamp Clamp

Rubbing

SM1022

WRONG RIGHT

Rubbing

Clamp
SM1023
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 - Cab
Remove and Install Cab ....................... W2-1-1
Group 2 - Counterweight
Remove and Install Counterweight ....... W2-2-1
Group 3 - Main Frame
Remove and Install Main frame ............ W2-3-1
Group 4 - Pump Device
Remove and Install Pump Device ........ W2-4-1
Disassemble Pump Device .................. W2-4-2
Assemble Pump Device ..................... W2-4-10
Disassemble Regulator ...................... W2-4-22
Assemble Regulator ........................... W2-4-24
Disassemble and Assemble
Pilot Pump ......................................... W2-4-26
Maintenance Standard ....................... W2-4-28
Group 5 - Control Valve
Remove and Install Control Valve ......... W2-5-1
Disassemble Control Valve 1 ................ W2-5-2
Assemble Control Valve 1-1 ................. W2-5-6
Assemble Control Valve 1-2 ................. W2-5-8
Disassemble Control Valve 2 .............. W2-5-10
Assemble Control Valve 2-1 ............... W2-5-14
Assemble Control Valve 2-2 ............... W2-5-16
Disassemble Control Valve 3 .............. W2-5-18
Assemble Control Valve 3-1 ............... W2-5-22
Assemble Control Valve 3-2 ............... W2-5-26
Disassemble Control Valve 4 .............. W2-5-28
Assemble Control Valve 4-1 ............... W2-5-32
Assemble Control Valve 4-2 ............... W2-5-34
Disassemble Control Valve 5 .............. W2-5-38
Assemble Control Valve 5 .................. W2-5-40
EX255-EX285
Group 6 - Swing Device
Remove and Install Swing Device ........ W2-6-1
Disassemble Swing Device (EX255) .... W2-6-2
Assemble Swing Device (EX255) ......... W2-6-6
Disassemble Swing Device (EX285) .. W2-6-12
Assemble Swing Device (EX285) ....... W2-6-16
Disassemble Swing Motor (EX255) .... W2-6-22
Assemble Swing Motor (EX255) ......... W2-6-26
Disassemble Swing Motor (EX285) .... W2-6-30
Assemble Swing Motor (EX285) ......... W2-6-34
Disassemble and Assemble
Parking Brake Release Valve (EX285) W2-6-38
Maintenance Standard ....................... W2-6-39
Group 7 - Pilot Valve
Remove and Install Right Pilot Valve .... W2-7-1
Remove and Install Left Pilot Valve ...... W2-7-4
Remove and Install Travel
Pilot Valve ............................................ W2-7-7
Disassemble Right and Left
Pilot Valve ............................................ W2-7-8
Assemble Right and Left
Pilot Valve .......................................... W2-7-10
Disassemble Travel Pilot Valve ........... W2-7-14
Assemble Travel Pilot Valve ............... W2-7-16
Positioning Pilot Valve
(Triple Articulation Version) ................. W2-7-20
Special Tools ...................................... W2-7-31
Group 8 - Pilot Shut-off Valve
Remove and Install Pilot
Shut-off Valve ...................................... W2-8-1
Disassemble Pilot Shut-off Valve ......... W2-8-2
Assemble Pilot Shut-off Valve .............. W2-8-4
Group 9 - Shockless Valve
Remove and Install Shockless Valve ... W2-9-1
Disassemble and Assemble
Shockless Valve .................................. W2-9-2
Group 10 - Solenoid Valve Unit
Remove and Install Solenoid
Valve Unit .......................................... W2-10-1
Disassemble Proportional
Solenoid Valve ................................... W2-10-2
Assemble Proportional
Solenoid Valve ................................... W2-10-4

Group 11 - Pilot Relief Valve Unit

Remove and Install Pilot Relief
Valve Unit .......................................... W2-11-1
Disassemble Pilot Relief Valve ........... W2-11-2
Assemble Pilot Relief Valve ............... W2-11-4
EX255-EX285 W2-1-1

CAB

REMOVE AND INSTALL CAB

Remove Cab

1. Remove nuts (2) and seat (1).

: 13 mm

SM1125

8 7 8
2. Loosen bolts (6) (3 used) and bolts (4) (4 used)
behind the cab and remove rear cover (5).
: 13 mm
4 5

3. Loosen bolts (8) to remove rear under cover (7).

: 13 mm

6
SM1126

4. Remove filter (20). Loosen screws (9) to remove

duct (10) from the cab.

20
9

10
SM1127
W2-1-2 EX255-EX285

CAB

5. Disconnect cable connectors (11, relais), (12, an-

tenna, ceiling lamp and windshield wiper), (13, 12
loudspeaker) behind the cab and ground (14) inside
the cab. 13

11

SM5526

6. Remove washer vinyl hose (15) behind the cab.

SM5509

7. Remove cap (21) from duct cover (16). Loosen

screws (17) to remove duct cover (16).
21 17 16

SM1130

8. While pushing the mating surface of duct (18)

toward the rear side of the cab, remove duct (18). Mating surface of duct

18

SM1131
EX255-EX285 W2-1-3

CAB

9. Attaccare la cabina al paranco utilizzando cinghie

di sollevamento.

WARNING
The approximate weight of cab:
250 kg (551 lb)

SM1132

10. Remove bolts (19) and nuts (22).

: 17 mm
: 24 mm 19
: 8 mm
22

SM1133

11. Carefully remove cab.

SM1134
W2-1-4 EX255-EX285

CAB

Installation

WARNING
The approximate weight of cab:
250 kg (551 lb)

1. Attach cab to hoist using straps.

Install cab onto frame.

SM1134

2. Tighten bolts (19) and nuts (22).

: 17 mm 19

: 49 N m (5 kgfm, 36 lbf ft)

22
: 24 mm

: 205 N m (21 kgf m, 152 lbf ft)

: 8 mm
SM1133
: 64 N m (6.5 kgf m, 47 lbf ft)

3. Install duct (10) to the cab with screws (9).

Install filter (20) into duct (10).

: 4.9 N m (0.5 kgf m, 3.6 lbf ft)

20
9

10 SM1127

4. Install harness connectors (11, relais), (12, an-

tenna, ceiling lamp and windshield wiper), (13, 12
loudspeaker) behind the cab and ground (14)
inside the cab. 13

: 19.5 N m (2 kgf m, 14.5 lbf ft)

11

SM5526
EX255-EX285 W2-1-5

CAB

5. Connect washer vinyl hose (15) at the rear of the

cab inside.

SM5509

6. Install rear under cover (7) with bolts (8). 8 7 8

: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)
4 5

7. Install rear cover (5) with bolts (6) (3 used) and

bolts (4) (4 used).
: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)
6
SM1126

8. Push duct (18) toward the front of the cab to insert Mating surface of duct
it into the front duct.
18

SM1131
W2-1-6 EX255-EX285

CAB

9. Install duct cover (16) with screws (17).

Install caps (21) onto duct cover (16).
21 17 16

SM1130

10. Secure seat (1) with nuts (2).

: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)

SM1125
EX255-EX285 W2-2-1

COUNTERWEIGHT

REMOVE AND INSTALL COUNTERWEIGHT

1
Removal

WARNING
Approximate weight of counterweight:
5 700 kg (12 566 lb)

1. Remove caps (1) from counterweight. SM1135

Install eye-bolts to the counterweight.

Eye-bolts: M36, Pitch 4.0

2. Attach wire rope (2) to eye-bolts using shackles. 2

Take out slack of wire rope by applying tension
slowly with a crane or hoist.

SM1136

3. Remove bolts (3).

Lift counterweight using a crane or hoist.
: 46 mm

SM1137

4. Lower the counterweight on proper stand.

SM1138
W2-2-2 EX255-EX285

COUNTERWEIGHT

Installation

WARNING
Approx. weight of counterweight:
5 700 kg (12 566 lb)

1. Attach lifting tools to counterweight.

Lift counterweight (4) and install it onto the frame.
Install bolts (3) and washers to counterweight and 4
tighten temporarily.
: 46 mm 3

SM1137

2. Remove wire rope.

Tighten the bolts with a power wrench (6) and
torque wrench (7).

: 46 mm

: 1 570 N m (160 kgf m, 1 157 lbf ft)

6 7 SM1139

3. Remove the eye-bolts.

Install caps (1) to counterweight.
1

SM1135
EX255-EX285 W2-3-1

MAIN FRAME

REMOVE AND INSTALL MAIN FRAME

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil and components to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
Refer to "Hydraulic Circuit Pressure Release Pro-
cedure" on page W4-2-12.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal

WARNING
Approximate weight of cab: 250 kg (551 lb)

1. Remove cab assembly. (See Cab section)

: 24 mm, 17 mm, 13 mm
: 8 mm
SM1134

WARNING
Approximate weight of counterweight:
5 700 kg (12 566 lb)

2. Remove the counterweight.

(See Counterweight section)

: 46 mm
SM1136
W2-3-2 EX255-EX285

MAIN FRAME

WARNING
Approx. weight of front attachment assembly:
• EX255 monobloc: 4550 kg (10 031 lb)
• EX255 triple articulation: 4890 kg (10 780 lb)
• EX285 monobloc: 5600 kg (12 346 lb)
• EX285 triple articulation: 5900 kg (13 007 lb)

3. Remove front attachment assembly from the

upperstructure. (See Front Attachment section)
: 19 mm, 30 mm, 36 mm, 41 mm SM1140

4. Drain hydraulic oil from the hydraulic oil tank, and

disconnect hydraulic lines from the control valve to
the center joint on top of the center joint.

Disconnect drain hose, and remove the fitting and

stopper from the center joint.

: 19 mm, 22 mm, 27 mm, 36 mm

SM1141
EX255-EX285 W2-3-3

MAIN FRAME

WARNING
Approximate weight of main frame:
EX255: 4000 kg (8818 lb)
EX285: 4500 kg (9921 lb)

5. Attach wire ropes to the front and rear of main

frame. See wire ropes taut using a crane. Use chain Rear
blocks for easy adjustment of wire rope lengths and
SM1142
to level the frame.

IMPORTANT - Make sure rear slings do not touch

engine.

Front
SM1143

SM1144

6. Put matching marks on swing bearing and main

frame.
Remove bolts (14) from the swing bearing.

: 32 mm

14
SM1380
W2-3-4 EX255-EX285

MAIN FRAME

7. Lift main frame slightly from undercarriage.

Level main frame by adjusting the chain blocks.

Remove main frame.

SM1146
EX255-EX285 W2-3-5

MAIN FRAME

Installation

13
WARNING
Approximate weight of main frame:
EX255: 4000 kg (8818 lb)
EX285: 4500 kg (9921 lb)

1. Fasten hoist to front and rear of main frame.

Level main frame by adjusting chain blocks (13)
and lower main frame onto undercarriage.
Align the matching mark on the swing bearing with
that on the main frame.
SM1146

2. Install bolts (14) on the swing bearing and tighten

temporary.
Install main frame and tighten bolts to specifica-
tion.
: 32 mm
Upperstructure side
14
: 640 N m (65 kgf m, 470 lbf ft) SM1380

3. Install fitting (10) and connect hose (8) to the

center joint.
4 5
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft)

Connect lines (4 to 7).

: 22 mm, 27 mm, 36 mm
: 39 N m (4 kgf m, 29 lbf ft) 9
: 93 N m (9.5 kgf m, 69 lbf ft) 8

Install stopper (9).

: 36 mm
10
7 6
: 175 N m (18 kgf m, 130 lbf ft)
SM1141
W2-3-6 EX255-EX285

MAIN FRAME

WARNING
Approx. weight of front attachment assembly:
• EX255 monobloc: 4550 kg (10 031 lb)
• EX255 triple articulation: 4890 kg (10 780 lb)
• EX285 monobloc: 5600 kg (12 346 lb)
• EX285 triple articulation: 5900 kg (13 007 lb)

4. Install front attachment assembly (3).

(See Front Attachment section)
: 19 mm
: 29.5 N m (3 kgf m, 21.5 lbf ft)
: 30 mm
: 540 N m (55 kgf m, 400 lbf ft)
: 36 mm
: 137 N m (14 kgf m, 101 lbf ft)
3 SM1140
: 41 mm
: 205 N m (21 kgf m, 152 lbf ft)

WARNING
Approximate weight of counterweight:
5 700 kg (12 566 lb)
1

5. Install counterweight (1).

(See Counterweight in this section)
: 46 mm
SM1136
: 1 570 N m (160 kgf m, 1 157 lbf ft)

WARNING
Approximate weight of cab: 250 kg (551 lb)

6. Install cab (2).

(See Cab in this section)
2

: 24 mm
: 205 N m (21 kgf m, 159 lbf ft)
: 17 mm
: 49 N m (5 kgf m, 36 lbf ft)
: 13 mm
: 20 N m (2 kgf m, 14 lbf ft) SM1134

: 8 mm
: 64 N m (6.5 kgf m, 47 lbf ft)
EX255-EX285 W2-3-7

MAIN FRAME

7. Fill the hydraulic oil tank with hydraulic oil to the

specified level.
Run the engine at slow idle. Check hose connec-
tions for any oil leakage.

SM1147
W2-3-8 EX255-EX285

MAIN FRAME

NOTES:
EX255-EX285 W2-4-1

PUMP DEVICE

REMOVE AND INSTALL PUMP DEVICE

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be
sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal
1 2 Air bleed plug
1. Disconnect connectors.

WARNING 10
Pump device weight: 170 kg (375 lb)
9 3

2. Disconnect hoses (1 to 4, 6 to 10) and pipe (5) from 4

the pump device. 8
: 19 mm, 22 mm, 27 mm, 36 mm
: 8 mm, 10 mm
7

3. Attach eyebolts (M12, Pitch 1.75, Length 22) to the

pump device, then connect to a hoist. 6
4. Remove pump device mounting bolts to remove
pump device.
SM1044
: 17 mm 5

Wrench Tightening Torque Remark

Installation Size (mm) Nm kgf m lbf ft

1. Install the pump device with pump device mounting : 27 93 9.5 69 Hose
bolts.
2. Connect hoses (1 to 4, 6 to 10) and pipes (5). : 36 69 7 51 Hose
3. Connect connectors.
: 10 108 11 80 Bolt
IMPORTANT - Be sure to check hydraulic oil level and
oil leakage, after assembling. : 17 49 5 36 Bolt
Bleed the air from the pump. (Refer to W1-1-2)
:8 49 5 36 Bolt

: 41 mm : 19 29 3 22 Hose
: 78 N m (8 kgf m, 58 lbf ft)
: 22 49 5 36 Pipe
W2-4-2 EX255-EX285

PUMP DEVICE

DISASSEMBLE PUMP DEVICE

97 69 79 81 97

70
98 98
68
65
66
17
24
87 20
74 8
67 73 87 9
21 38
72 74 66 68 19
22
19
83
11
24
62
84
82 20
12 2 8
9
13
38
67
18 38
12 49
38 55 SM1045
13 61 49
52

36 23
47 48
15

34
45 37

46 32 31 30
16
1 40
39
14 41
28
7
6
5
43 3
54
53

55
SM1046
26 25 5 4
EX255-EX285 W2-4-3

PUMP DEVICE

88
51
96
50
74
74
60
93
85 86 64 38

75 71 38
89
35
44 57 58
75 64
35 92
35 33 75 42
29 33
27 91
77 56 59
33
76 78 96
35
77 29 35 90
88
76 33 75
78
SM1047

1 - Gear Casing 34 - Adapter (2 Used) 65 - Pin (2 Used)

2 - Pump Casing 35 - Retaining Ring (12 Used) 66 - Center Shaft (2 Used)
3 - Pilot Gear 36 - Plug 67 - Plug (2 Used)
4 - Gear Shaft 37 - Level Gauge 68 - Spring (2 Used)
5 - Bearing (2 Used) 38 - O-Ring (6 Used) 69 - Regulator (2 Used)
6 - Retaining Ring 39 - Pipe Gauge 70 - Cylinder Block (2 Used)
7 - Retaining Ring 40 - Socket Bolt (2 Used) 71 - Valve Plate
8 - Bearing (2 Used) 41 - Packing 72 - Spring Pin (4 Used)
9 - Bearing Nut (2 Used) 42 - Servo Piston (2 Used) 73 - O-Ring (2 Used)
11 - Drive Disc 43 - Plug 74 - O-Ring (20 Used)
12 - Oil Seal (2 Used) 44 - Set Screw (2 Used) 75 - Lever (4 Used)
13 - Retaining Ring (2 Used) 45 - N sensor 76 - Pin (2 Used)
14 - Gear (Engine Speed Sensor) 77 - Link (2 Used)
15 - Gear 46 - O-Ring 78 - Pin (2 Used)
16 - Retaining Ring (2 Used) 47 - Washer 79 - Pipe
17 - Drive Disc 48 - Socket Bolt 81 - Adapter (2 Used)
18 - Spring Pin (2 Used) 49 - Plug (2 Used) 82 - Clamp
19 - Plunger (14 Used) 50 - O-Ring (2 Used) 83 - Socket Bolt
20 - Spacer Ring (2 Used) 51 - Stopper (2 Used) 84 - Spring Washer
21 - Bolt (6 Used) 52 - Plug (2 Used) 85 - Backup Ring
22 - Spring Washer (6 Used) 53 - Adapter 86 - O-Ring
23 - Packing 54 - Plug 87 - O-Ring (4 Used)
24 - Bearing (2 Used) 55 - Fitting plug (2 Used) 88 - Socket Bolt (16 Used)
25 - Oil Seal 56 - Servo Pipe 89 - Spring Pin (2 Used)
26 - Retaining Ring 57 - Clamp (2 Used) 90 - Stopper (2 Used)
27 - Valve Plate 58 - Bolt 91 - O-Ring (2 Used)
28 - Pilot Pump 59 - Spring Washer 92 - Pin (2 Used)
29 - Pin (4 Used) 60 - Socket Bolt (12 Used) 93 - Selector Head
30 - Socket Bolt (2 Used) 61 - O-Ring (2 Used) 96 - Spring Washer(16 Used)
31 - Spring Washer (2 Used) 62 - Thrust Ring 97 - Socket Bolt (8 Used)
32 - Washer (2 Used) 64 - Pump Pressure Sensor 98 - Spring Washer(8 Used)
33 - Pin (4 Used) (2 Used)
W2-4-4 EX255-EX285

PUMP DEVICE

69 79 81 97

SM1045

83

84
82
2
88
51
96
50
74
74
60
93
64

44 57 58
64
92
36 42
47 48
91
56 59
34 96
45 90
88 SM1048
46

43

53

55
SM1046
EX255-EX285 W2-4-5

PUMP DEVICE

Disassemble Pump Device 8. Remove socket bolts (88), spring washers (96),
stoppers (90), (51) and O-rings (91), (50), (74) from
1. Remove plug (43) to drain oil. selector head (93).

Drain oil: Approx. 1.0 L (1.06 US qt) : 6 mm

: 8 mm
IMPORTANT - Be sure to heat set screw (44) to
remove it. LOCTITE 829 was applied to set screw (44)
2. Remove plug (36) and adapters (34). when installed.

: 17 mm, 36 mm
9. Remove set screws (44), pins (92) and servo
pistons (42) from selector head (93).
3. Loosen socket bolt (83) and then remove spring
washer (84), clamp (82) and N sensor (45) connec- : 6 mm
tors from pump casing (2).

: 5 mm 10. Remove socket bolt (48), spring washer (47), N

sensor (45) and O-ring (46) from gear casing (1).

: 5 mm
WARNING
Pump device weight: 170 kg (375 lb)
11.Remove pipe (79) and adapters (81) from regula-
tors (69).

4. Place the pump device with the transmission side : 22 mm

positioned to the bottom side and secure it.

5. Remove bolt (58), adapter (53) and fitting plug (55).

Remove spring washer (59), clamp (57) and servo
pipe (56) from selector head (93).

: 13, 17, 19 mm

WARNING
Selector head weight: 30 kg (66 lb)

6. Remove socket bolts (60) from selector head (93).

Remove selector head (93) assembly from pump
casing (2).

: 10 mm

7. Remove pump pressure sensors (64) from selector

head (93).

: 27 mm
W2-4-6 EX255-EX285

PUMP DEVICE

85 86

75 71
35 89
75
35
35 33 75
29 33
27
77
33
76 78 35
77 29 35
SM1047
76 33 75
78

97 69 81 97

70
98 98
68
65
66

74
73
21 87
74 66 68 19
22
19

SM1045
EX255-EX285 W2-4-7

PUMP DEVICE

12. Loosen socket bolts (97) and remove spring wash-

ers (98), regulators (69) and O-rings (73), (74), (87)
from pump casing (2).

: 8 mm

13. Remove backup ring (85), O-ring (86) and spring

pins (89).

IMPORTANT - Valve plates (27) and (71) are exclu-

sively used in the right and left pumps respectively.
Take care not to mistake the up and down positions.

14. Remove retaining rings (35) and pins (29) to

remove valve plates (27), (71).

: 7 mm

15. Remove cylinder blocks (70), center shafts (66),

springs (68) and plungers (19) from pump casing
(2).

16. Remove links assemblies (77) from pump casing

(2).

17. Remove retaining rings (35), pins (78), (33), (76)

and levers (75) from links (77).

WARNING
Pump casing weight: 43 kg (95 lb)

18. Attach the pump casing to crane or hoist using

wire ropes.
Loosen bolts (21) and remove pump casing (2)
from gear casing (1).

: 24 mm
W2-4-8 EX255-EX285

PUMP DEVICE

17
24
20
8
9

SM1045
11
24
62
20
12 2 8
9
13

18
12
13 61
52

23

15

32 31 30
16
1
14
28
7
6
5
3

SM1046
26 25 5 4
EX255-EX285 W2-4-9

PUMP DEVICE

19. Remove spring pins (18) from pump casing (2).

Remove packing (23) from gear casing (1).
15 Aligning Mark 14

IMPORTANT - If aligning marks are not made, it is

very hard to align pump timing when reassembling.

17

20. Put three aligning marks on each mashed parts: 11

between gear (14) and drive disc (11) spline, gear
(15) and drive disc (17) spline, gears (14) and (15), 16 16 SM1049
as illustrated.

21. Remove retaining rings (16) and gears (14) and

(15) from to drive discs (11) and (17).

22. Remove retaining rings (13) and oil seals (12) from
drive discs (11) and (17).
75301492

23. Loosen plugs (52) to remove O-rings (61). Using a

press, pull drive discs (11) and (17) assembly out
of pump casing (2). Then, remove thrust ring (62).

24. Using special tool (75301492), remove bearing

nuts (9) from drive discs (11) and (17).

SM1050

25. Using a press, remove bearings (8), (24) and

spacer rings (20) from drive discs (11) and (17).

26. Loosen bolts (30) to remove pilot pump (28) from

gear casing (1).

: 6 mm
75301488
27. Remove retaining rings (6) and (7) from gear
casing (1). Pull off upper side bearing (5) and gear 4
shaft (4) using special tool (75301488).

28. Remove pilot gear (3) from gear casing (1). Then, 3
pull off the other side bearing (5).

29. Remove retaining ring (26) and oil seal (25) from 5
gear casing (1).

SM1051
W2-4-10 EX255-EX285

PUMP DEVICE

ASSEMBLE PUMP DEVICE

34 36

59
2
58

57 10

56

55

SM3017

53 43 64 60

37 39 40 41 28 30 31 32 1

7
16

14

15

18

23

45-46

47-48
98 97 82 83 84 SM1053
EX255-EX285 W2-4-11

PUMP DEVICE

86 35
74 51 50 88 79 81 85 87 74 69 73 76 78 77 65 66 2 8 9 12

13

16

68 17

75 11
72
44

92
25

26

62
29 35
42
38
93 49 SM1054

71 91 96 90 89 33 70 19 52 24 20 22-21
27 35 61

1 - Gear Casing 33 - Pin (4 Used) 65 - Pin (2 Used)

2 - Pump Casing 34 - Adapter (2 Used) 66 - Center Shaft (2 Used)
3 - Pilot Gear 35 - Retaining Ring (12 Used) 67 - Plug (2 Used)
4 - Gear Shaft 36 - Plug 68 - Spring (2 Used)
5 - Bearing (2 Used) 37 - Level Gauge 69 - Regulator (2 Used)
6 - Retaining Ring 38 - O-Ring (6 Used) 70 - Cylinder Block (2 Used)
7 - Retaining Ring 39 - Pipe Gauge 71 - Valve Plate
8 - Bearing (2 Used) 40 - Socket Bolt (2 Used) 72 - Spring Pin (2 Used)
9 - Bearing Nut (2 Used) 41 - Packing 73 - O-Ring (2 Used)
10 - Main pump 42 - Servo Piston (2 Used) 74 - O-Ring (20 Used)
11 - Drive Disc 43 - Plug 75 - Lever (4 Used)
12 - Oil Seal (2 Used) 44 - Set Screw (2 Used) 76 - Pin (2 Used)
13 - Retaining Ring (2 Used) 45 - N sensor 77 - Link (2 Used)
14 - Gear (Engine Speed Sensor) 78 - Pin (2 Used)
15 - Gear 46 - O-Ring 79 - Pipe
16 - Retaining Ring (2 Used) 47 - Washer 81 - Adapter (2 Used)
17 - Drive Disc 48 - Socket Bolt 82 - Clamp
18 - Spring Pin (2 Used) 49 - Plug (2 Used) 83 - Socket Bolt
19 - Plunger (14 Used) 50 - O-Ring (2 Used) 84 - Spring Washer
20 - Spacer Ring (2 Used) 51 - Stopper (2 Used) 85 - Backup Ring
21 - Bolt (6 Used) 52 - Plug (2 Used) 86 - O-Ring
22 - Spring Washer (6 Used) 53 - Adapter 87 - O-Ring (4 Used)
23 - Packing 54 - Plug 88 - Socket Bolt (16 Used)
24 - Bearing (2 Used) 55 - Fitting plug (2 Used) 89 - Spring Pin (2 Used)
25 - Oil Seal 56 - Servo Pipe 90 - Stopper (2 Used)
26 - Retaining Ring 57 - Clamp (2 Used) 91 - O-Ring (2 Used)
27 - Valve Plate 58 - Bolt 92 - Pin (2 Used)
28 - Pilot Pump 59 - Spring Washer 93 - Selector Head
29 - Pin (4 Used) 60 - Socket Bolt (12 Used) 96 - Spring Washer(16 Used)
30 - Socket Bolt (2 Used) 61 - O-Ring (2 Used) 97 - Socket Bolt (8 Used)
31 - Spring Washer (2 Used) 62 - Thrust Ring 98 - Spring Washer(8 Used)
32 - Washer (2 Used) 64 - Pump Pressure Sensor (2 Used)
W2-4-12 EX255-EX285

PUMP DEVICE

34

6
1

3
SM3017

43 5

SM1053

17

11

SM1055

24 20 9
EX255-EX285 W2-4-13

PUMP DEVICE

Assemble Pump Device 7 6 4

5
1. Drive bearing (5) into gear casing (1). Install pilot
gear (3). Drive in gear shaft (4) so that the spline 1
aligns with that of pilot gear (3).
3

2. Drive the other bearing (5) onto gear shaft (4).

5

3. Install retaining ring (7) to gear casing (1) and SM1056

retaining ring (6) to gear shaft (4).

4. Wind seal tape around adapters (34) (2 used) and 8

8
tighten them to gear casing (1).
: 36 mm 20
20
: 69 N m (7 kgf m, 51 Ibf ft)
24
24
5. Tighten plug (43).
: 8 mm 11
17
: 49 N m (5 kgf m, 36 Ibf ft)

SM1057
6. Heat inner race of bearings (24) and (8) to 50 to
80 °C (122 to 176 °F). Apply a film of hydraulic oil
to inner race of bearings (24), then install bearings
(24) onto drive discs (11) and (17) using a press.
75301492 9

7. Apply a film of hydraulic oil to inner race of

bearings (8), then install spacer rings (20) and
bearings (8) onto drive discs (11) and (17) using a
press.

8. Apply a film of hydraulic oil to bearing nuts (9) (2

used) thread.
SM1050
Tighten bearing nuts (9) until they come in contact
with bearings (8), using special tool (75301492).

9. Rotate bearings (8) 2 to 3 turns for break-in, using

special tool (75301491).

10. Follow the above three steps to adjust starting 75301491

torque to specification.
Starting torque specification: 9
2.16±0.49 N m (0.22±0.05 kgf m, 1.59±0.36 Ibf ft) 8

20
IMPORTANT - If starting torque is increased over the
specification, loosen bearing nut (9) then tap drive 24
discs (11) and (17) shaft end to release load. Retry
steps 8. to 10. to adjust the starting torque. 11-17
SM1058
W2-4-14 EX255-EX285

PUMP DEVICE

2 62 8 11

17

SM1059

24

16

14

15

SM1053

12 13

SM1055

52-61
EX255-EX285 W2-4-15

PUMP DEVICE

11. Install thrust ring (62) into pump casing (2). (Drive
disc (11) side only.)

12. Heat pump casing (2) to 50 to 80 °C (122 to 176 °F).

Apply a film of hydraulic oil to the outer circumfer-
ence of roller bearings (8) and (24). Install drive 75301490
disc (11) and (17) assemblies into pump casing (2).
12
13. Apply a film of grease to O-rings (61) (2 used) then
install them onto plugs (52) (2 used).
Tighten plugs (52) to pump casing (2).
: 19 mm
: 34 N m (3.5 kgf m, 25 Ibf ft)

14. Install special tools (75301489 and 75301490)

over the spline parts of drive discs (11) and (17) to 75301489
SM1060

protect oil seals (12) from being damaged. If the

special tools are not available, wind adhesive
tapes over the spline parts.

IMPORTANT - Apply a film of grease to oil seal (12) (2

used) lip. Shaft side
Long
15. Drive oil seal (12) (2 used) as illustrated. Remove Shaft
Side
the special tools. Short
Shaft
16. Install retaining rings (13) (2 used). 75301493 Side

When replacing drive discs (11), (17) and / or

transmission gears (14), (15)

IMPORTANT - Install special tool with the D mark

facing toward long drive disc (11) side.
M8x1,25
SM1061
17. Install special tool (75301493) to drive discs (11),
(17).

18. Rotate drive discs (11), (17) clockwise, as viewed

from the shaft end side to remove circumferential
play between the special tool and drive discs (11),
(17).

19. Install gear (15) and retaining ring (16) onto drive 15 Aligning Mark 14
disc (17).

20. Install gear (14) so that both splines on drive disc

(11) and gear (15) teeth, can correctly engage with
those of gear (14). Install retaining ring (16) onto
drive disc (11). 17

IMPORTANT - Although drive disc (11) is held 11

unrotable with special tool (75301493), it may be
necessary to jolt drive disc (11) in order to install gear (14). 16 16 SM1049

When not replacing drive discs (11), (17) and/or

transmission gears (14),(15)

21. Align the marks for drive disc (11) and gear (14). Also,
align the marks for drive disc (17) and gear (15).
W2-4-16 EX255-EX285

PUMP DEVICE

28

30 31 32 1
53
39 40 41 28 3

55 SM3017

14

23

18

22-21 SM1053

35
76 78 77 2

17

11

SM1054
75 33-35
EX255-EX285 W2-4-17

PUMP DEVICE

22. Install spring pins (18) (2 used) and packing (23) to 28. With retaining rings (35) (2 used) installed to the
gear casing (1). one side of pins (76) (2 used), drive pins (76) (2
used) into links (77) (2 used). Then, install
retaining rings (35) (2 used) to the other side of pins
WARNING (76) (2 used).
Pump casing weight: 43 kg (95 Ib)

29. Install levers (75) (4 used), pins (33) (4 used), and

retaining rings (35) (4 used) to the U type end of
23. Sling pump casing (2) with a crane and install it to links (77) (2 used).
gear casing (1) so that pilot gear (3) engages gear
(14).
30. Install pins (78) (2 used) to links (77) (2 used).

24. Tighten bolts (21) (6 used) with spring washers

(22) (6 used).
: 24 mm
: 147 N m (15 kgf m, 109 Ibf ft)

25. Apply THREEBOND 1215 to gear casing (1) sur-

face.
Install pilot pump (28) to gear casing (1), then
tighten socket bolts (30) (2 used) with spring
washers (31) (2 used) and washers (32) (2 used).
: 8 mm
: 49 N m (5 kgf m, 36 Ibf ft)

26. Install adapter (53) and fitting plug (55) onto pilot
pump (28).
: 27 mm
: 93 N m (9.5 kgf m, 69 Ibf ft)

: 6 mm
: 34 N m (2 kgf m, 15 Ibf ft)

27. Install packing (41) and pipe gauge (39) to gear

casing (1).
Then tighten with socket bolts (40) (2 used).
: 6 mm
: 19.5 N m (2 kgf m, 15 Ibf ft)
W2-4-18 EX255-EX285

PUMP DEVICE

86
74 85 87 74 69 73 78 77 65 66

68 17

75 11

44

92

35- 29
42
SM1054
93

89 70 19 2

45-46

47-48

SM1053
98 97
EX255-EX285 W2-4-19

PUMP DEVICE

31. Apply a film of hydraulic oil to the spherical
surface of drive discs (11) and (17) and insert
plungers (19) (7 used).
32. After applying grease to the hole of center shaft
(66) (2 used), install pins (65). Install center shafts
(66) into the center spherical surface section of
drive discs (11) and (17). Then, install springs (68)
(2 used).
38. Install O-rings (73) (2 used), (74) (10 used), and
(87) (4 used) onto pump casing (2).
Install regulators (69) (2 used) onto pump casing
(2) using socket bolts (97) (8 used) and spring
washers (98) (8 used).
(Refer to "Assemble Regulator" on page W2-4-24.)
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)

39. Install backup ring (85), spring pins (89) (2 used)

33. Assemble plungers (19) (14 used) and center and O-ring (86) into pump casing (2).
shafts (66) (2 used) into cylinder blocks (70) Install O-rings (74) (4 used) to selector head (93).
(2 used).

40. Apply a film of grease to O-ring (46). Install N

34. Pinch the tip of center shafts (66) with pliers to
rotate the center shaft and install pins (65)
(2 used) into the groove on cylinder blocks (70)
(2 used).
sensor (45) to gear casing (1) then tighten with
socket bolt (48) and washer (47).
: 5 mm
: 9.8 N m (1 kgf m, 7.2 lbf ft)

IMPORTANT - Take care not to damage the O-ring 41. Assemble servo pistons (42) (2 used) and pins
(73) groove when driving in pins (78). (92) (2 used) to selector head (93).

35. After installing links (77) (2 used) assembly into IMPORTANT - Apply LOCTITE LI829 to set screws
pump casing (2), drive pins (78) (2 used) into the (44).
groove on the mounting surface of regulators (69)
so that the pin end is flush with the mounting
surface.
42. Tighten set screws (44) (2 used) to the smaller
diameter side of servo pistons (42) (2 used) to
36. Apply a film of LOCTITE LI829 to the threads of secure pins (92) (2 used).
pins (29) (4 used). Then, tighten the pins (2 used) : 6 mm
into valve plates (27) and (71).
: 34 N m (3.5 kgf m, 25 lbf ft)
: 7 mm
: 9.8 N m (1 kgf m, 7.2 lbf ft)

37. Install pins (29) into the hole of levers (75).

Install retaining rings (35) (4 used).

IMPORTANT - Valve plates (27) and (71) are exclu-

sively used in the right and left pumps respectively.
Replacing the right with the left or up-side-down is not
applicable. Install the valve plates so that the suction
port is positioned to the upper side of the center when
viewed from the front.
W2-4-20 EX255-EX285

PUMP DEVICE

96
88 51 50 74 2

11
93

25

26

SM1054

91 88 90 89
96

34 36 1 2

82
83
84
56

59
58
93
57

55
64

60

SM3017
EX255-EX285 W2-4-21

PUMP DEVICE

43. Apply a film of grease to stoppers (51) (2 used),
(90) (2 used) and O-rings (50) (2 used), (91)
(2 used). Assemble O-rings (50) (2 used), (91)
(2 used) to stoppers (51) (2 used), (90) (2 used).
Install stoppers (51) (2 used), (90) (2 used) to
selector head (93), then tighten with spring
washers (96) (16 used) and socket bolts (88)
(16 used).
: 6 mm
: 19.5 N m (2 kgf m, 15 lbf ft)
WARNING
Selector head weight: 30 kg (66 lb)
44. Sling selector head (93) assembly with a crane.
Install O-ring (74) (6 used) to pump casing (2).
Install the selector head onto pump casing (2) so
that spring pins (89) (2 used) align with the pin
holes on the selector head. Then tighten socket
bolts (60) (12 used).
50. Connect servo pipe (56) then clamp it using bolt
(58) and clamp (57).
: 13 mm
: 2.9 N m (0.3 kgf m, 25 lbf ft)
51. Fix the N sensor connector on pump casing (2)
using clamp (82), spring washer (84), and socket
bolt (83).
: 5 mm
: 10 N m (1 kgf m, 7.2 lbf ft)
52. Install special tool (75301490) to drive disc (11).
Apply a film of grease to oil seal (25) and install the
oil seal to drive disc (11). Remove special tool
(75301490) and drive in oil seal (25). Install retain-
ing ring (26). If special tool (75301490) is not
available, wind tape around the spline of drive disc
(11) to protect the oil seal from being damaged
when installing.

: 10 mm
: 108 N m (11 kgf m, 80 lbf ft)
45. Tighten pump pressure sensors (64) (2 used) to
selector head (93).
: 27 mm
: 98 N m (10 kgf m, 72 lbf ft)
53. Supply oil into gear casing (1) through adapter (34)
about 1.0 liters (1.06 US qt). Tighten plug (36) to
adapter (34).
: 17 mm
: 69 N m (7 kgf m, 51 lbf ft)
54. Install level gauge to pipe gauge (39).

46. Temporarily tighten fitting plug (55) onto pump

casing (2).

75301490
47. Temporarily tighten clamps (57) (2 used) to selec- 25
tor head (93) with washer (59) and bolt (58).

48. Insert servo pipe (56) between clamps (57)

(2 used) and tighten the nut for fitting plug (55).
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft)

49. Tighten servo pipe (56). SM1062

: 17 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
W2-4-22 EX255-EX285

PUMP DEVICE

DISASSEMBLE REGULATOR

49 24 27 28 20 21 14 34

15

29

17 17

12

16
16
14

SM1063
9 8 7 6 5 3 2 1 47 48 14 15 13 12

35 97-98 40 41 37-38 36

SM1064

1 - Regulator Casing 15 - O-Ring (2 Used) 36 - Cover

2 - Sleeve A 16 - Nut (2 Used) 37 - Socket Bolt (8 Used)
3 - Spool A 17 - Nut (2 Used) 38 - Spring Washer (8 Used)
5 - Load Cylinder 20 - Piston 40 - Plug
6 - Load Piston 21 - Cylinder 41 - O-Ring
7 - O-Ring 24 - Inner Stopper 47 - Spring
8 - Backup Ring 27 - Sleeve B 48 - Spring
9 - O-Ring 28 - Spool B 49 - Spring
12 - Stopper (2 Used) 29 - Set Screw 97 - Socket Bolt (4 Used)
13 - Stopper 34 - Nut 98 - Spring Washer(4 Used)
14 - O-Ring (3 Used) 35 - Cover
EX255-EX285 W2-4-23

PUMP DEVICE

Disassemble Regulator

IMPORTANT - When disassembling the regulator, do

not disassemble adjusting parts (12), (16), (17), (29),
(34) unless necessary. If disassembled the perform-
ance curve of the regulator is changed. To adjust the
regulator, refer to the Operational Perform-ance Test.
Section in the Technical Manual (Troubleshooting).

1. Hold regulator casing (1) of regulator with a vice and

remove plug (40).

: 41 mm

2. Loosen socket bolts (37) to remove covers (36),

(35) assembly.

: 6 mm

3. Remove springs (47), (48) from regulator casing

(1).

4. Remove load cylinder (5) from regulator casing (1)

by pushing spool A (3).

5. Remove load piston (6), O-ring (7), (9) and backup

ring (8) from load cylinder (5).

6. Remove sleeve A (2) with spool A (3) from regulator

casing (1).

7. Remove spool A (3) from sleeve A (2).

8. Remove sleeve B (27), spool B (28) and spring (49)

from regulator casing (1).

9. Remove piston (20), O-ring (14) and cylinder (21)

from regulator casing (1).
W2-4-24 EX255-EX285

PUMP DEVICE

ASSEMBLE REGULATOR

49 24 27 28 20 21 14 34

15

29

17 17

12

16
16
14

SM1063
9 8 7 6 5 3 2 1 47 48 14 15 13 12

76

SM1066

79 35 97-98 40 41 37-38 36

SM1065

87 74 73

1 - Regulator Casing 17 - Nut (2 Used) 41 - O-Ring

2 - Sleeve A 20 - Piston 47 - Spring
3 - Spool A 21 - Cylinder 48 - Spring
5 - Load Cylinder 24 - Inner Stopper 49 - Spring
6 - Load Piston 27 - Sleeve B 73 - O-Ring
7 - O-Ring 28 - Spool B 74 - O-Ring (5 Used)
8 - Backup Ring 29 - Set Screw 76 - Pin
9 - O-Ring 34 - Nut 79 - Pipe
12 - Stopper (2 Used) 35 - Cover 81 - Adapter
13 - Stopper 36 - Cover 87 - O-Ring (2 Used)
14 - O-Ring (3 Used) 37 - Socket Bolt (8 Used) 97 - Socket Bolt (4 Used)
15 - O-Ring (2 Used) 38 - Spring Washer (8 Used) 98 - Spring Washer (4 Used)
16 - Nut (2 Used) 40 - Plug
EX255-EX285 W2-4-25

PUMP DEVICE

Assemble Regulator 10. Install regulator casing assembly to pump casing,

IMPORTANT - Take care not to mistake the combina-
tion and direction of spool B (28) and sleeve B (27).
1. Apply a film of hydraulic oil to spool B (28) and
sleeve B (27).
Install spool B (28) into sleeve B (27) and install into
regulator casing (1).
2. Apply a film of hydraulic oil to spool A (3) and
sleeve A (2), install into regulator casing (1).
3. Apply a film of grease to O-ring (7), (9) then install
O-rings (7), (9) and backup ring (8) to load cylinder
(5).
then tighten with socket bolts (97) (4 used) and
spring washers (98) (4 used).
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)
IMPORTANT - Install the pin for the link in the groove
for sleeve B (27) and sleeve A (2) in regulator casing
(1). Using tape, hold the grooves for sleeve B (27) and
sleeve A (2) so that both grooves are aligned. Then,
after installing, be sure to remove the tape. Check
through the hole of plug (40) that pin (76) is surely
installed into sleeve B (27) and sleeve A (2).
Before operating the pump, bleed air trapped in the
pump casing and fill the pump casing with hydraulic oil.

4. Install load piston (6) into load cylinder (5) and 11. Tighten adapter (81) and pipe (79) onto regulator
install into regulator casing (1). casing (1).
: 19 mm
5. Apply a film of grease to O-rings (14) (2 used) then : 34 N m (3.5 kgf m, 25 lbf ft)
install on stoppers (12) (2 used).
: 22 mm
IMPORTANT - Stopper (13) length is different from
that of inner stopper (24). : 49 N m (5 kgf m, 36 lbf ft)
Inner stopper (24) is the shortest.

12. Install O-ring (41) onto plug (40), tighten it onto

6. Install cover (35) with spring (49) onto regulator regulator casing (1).
casing (1). : 41 mm
Install and tighten socket bolts (37) (4 used) and
spring washers (38) (4 used). : 78 N m (8 kgf m, 58 lbf ft)

: 6 mm
: 19.8 N m (2 kgf m, 15 lbf ft) IMPORTANT - Be sure to fill the casing with hydraulic
oil before operating the pump.

7. Install O-ring (14), piston (20) in cylinder (21), and

install into regulator casing (1).

8. Install cover (36) with springs (48), (47) onto regu-

lator casing (1)
Install and tighten socket bolts (37) (4 used) and
spring washers (38) (4 used).
: 6 mm
: 19.8 N m (2 kgf m, 15 lbf ft)

9. Apply a film of grease to O-rings (73), (74)

(5 used), (87) (2 used) and install them onto the
pump casing (2).
W2-4-26 EX255-EX285

PUMP DEVICE

DISASSEMBLE AND ASSEMBLE PILOT PUMP

27

13

26

10

10 12
1

9
6
26
14

27
6
9
2

3
5

16
15 SM1066

7
12
EX255-EX285 W2-4-27

PUMP DEVICE

Item Part Name Q.ty Wrench Size Tightening Torque Remarks

mm Nm kgf m lbf ft

1 Housing 1

2 Flange 1

3 Oil Seal 1 Apply grease to oil seal lip when

installing

5 Retaining Ring 1

6 Seal 2 Apply grease to seal when

installing

7 Cover 1

9 Backup Ring 2 Apply grease to backup ring when

installing

10 Key 2

12 O-ring 2 Apply grease to O-ring when

installing

13 Gear 1

14 Gear 1

15 Washer 4

16 Bolt 4 :17 39 to 44 4 to 4.5 29 to 33

26 Bushing 2 Apply a film of hydraulic oil to

bushing when installing

27 Bushing 2 Apply a film of hydraulic oil to

bushing when installing
W2-4-28 EX255-EX285

PUMP DEVICE

MAINTENANCE STANDARD

Pump device
Unit: mm (in)
Standard Allowable Limit Rimedy

Gear Backlash 0.68 (0.03) 1.5 (0.06) Replace

Main Pump

1. Tooth thickness (Driving disc splines).

Unit: mm (in)
Standard Allowable Limit

5.4 (0.21) 3.8 (0.15)

2. Sleeve diameter (Driving disc).

Unit: mm (in)
Standard Allowable Limit

1 45 (1.77) 44.8 (1.76)

2 55 (2.17) 54.8 (2.16)

SM1068
3 55 (2.17) 54.8 (2.16)

3. Clearance between plunger and driving disc (b).

Unit: mm (in)
Standard Allowable Limit
b

0.058 (0.002) 0.4 (0.016)

SM1069

4. Clearance between plunger (a) and cylinder

block (D).
(D - a) Unit: mm (in)
Standard Allowable Limit D

0.043 (0.002) 0.08 (0.003) a

SM1070
EX255-EX285 W2-4-29

PUMP DEVICE

5. Clearance between plunger and connecting rod.

Unit: mm (in)
Plunger
Standard Allowable Limit

0.15 (0.006) 0.4 (0.016) Connecting rod

SM1071

6. Clearance between small chamber (D) and servo

piston (a).
D Small
D-a Unit: mm (in) Chamber
a Side
Standard Allowable Limit

0.083 (0.003) 0.2 (0.008)

7. Clearance between large chamber (D) and servo

piston (a).
D-a Unit: mm (in)
Standard Allowable Limit
a
0.079 (0.003) 0.2 (0.008) Large
D
Chamber SM1072
Side

8. Clearance between valve plate (D) and servo piston

(a).
D-a Unit: mm (in)
D a
Standard Allowable Limit

0.051 (0.002) 0.3 (0.011)

SM1073
W2-4-30 EX255-EX285

PUMP DEVICE

NOTES
EX255-EX285 W2-5-1

CONTROL VALVE

REMOVE AND INSTALL CONTROL VALVE

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
Refer to “Hydraulic Circuit Pressure Release Pro-
cedure” on page W4-2-12.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal 1. Install control valve to frame and tighten the bolts.

NOTE - Attach caps to hoses and pipes. 2. Connect all hoses, pipes and connectors to the
Attach labels or tags to hoses and pipes, to aid in control valve.
assembly.
IMPORTANT - After completing installation:
1. Disconnect all hoses, pipes and connectors from Check hydraulic oil level. Add oil if necessary. Run the
the control valve.
engine. Check the engine components for any oil
: 17 mm leakage.
: 9.8 N m (1 kgf m, 7 lbf ft)
: 19 mm A B
C
: 34 N m (3.5 kgf m, 25 lbf ft) D
: 22 mm
E
: 49 N m (5 kgf m, 36 lbf ft)
: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)
: 8 mm
: 64 N m (6.5 kgf m, 147 lbf ft)
: 10 mm
: 108 N m (11 kgf m, 80 lbf ft) SM1191
E D C B A
WARNING
Control valve assembly weight: 240 kg (530 lb)

2. Remove control valve mounting bolts.

: 24 mm
: 205 N m (21 kgf m, 150 lbf ft)

Installation
SM1192

NOTE - Refer to “Removal” section above for wrench

A = Swing D = Auxiliary
sizes and tightening torques. B = Arm I E = Travel left
C = Boom II
W2-5-2 EX255-EX285

CONTROL VALVE

DISASSEMBLE CONTROL VALVE 1

E = Travel Flow Control Valve

F = Pump Control Valve 1 E
2
3
4
5
6
7
8
17

17

18
12
19
20
F
21
55
22
39
38 23
40 40 37
24
51 41
25
39 39 26
35 27
38
28
35
29
42
30
43
31
44
34 32
39
36
33

SM1193

1 - Plug (Restriction) 22 - Plug 36 - Housing (5-Spool Side)

2 - O-Ring 23 - O-Ring 37 - O-Ring
3 - Plug 24 - Spring 38 - O-Ring
4 - Spool 25 - Seat 39 - O-Ring
5 - Seat 26 - Spool 40 - Spring
6 - Spring 27 - Sleeve 41 - Check Valve
7 - O-Ring 28 - O-Ring 42 - Spring
8 - Plug 29 - Spool 43 - Poppet
12 - Pilot Plate 30 - Sleeve 44 - Sleeve
17 - Socket Bolt 31 - O-Ring 51 - Check Valve
18 - Lock Nut 32 - Seat 55 - Pilot Plate
19 - Screw 33 - Retaining Ring
20 - Washer 34 - Spring
21 - O-Ring 35 - O-Ring
EX255-EX285 W2-5-3

CONTROL VALVE

Disassemble Control Valve 1

• Be sure to thoroughly read “Precautions for Disas-

sembly and Assembly” on page W1-1-1 before
starting the disassembly work.

• Travel Flow Control Valve

1. Loosen and remove plug (8) from pilot plate

(12).
: 36 mm

2. Remove spring (6), seat (5), and spool (4) from

pilot plate (12).

3. Loosen and remove plug (3) from pilot plate

(12).

4. Loosen and remove plug (1) from pilot plate

(12).
: 5 mm

5. Loosen socket bolts (17) to remove pilot plate

(12) from housing (36).
: 10 mm

6. Loosen socket bolts (17) to remove pilot plate

(55) from housing (36).
: 10 mm
W2-5-4 EX255-EX285

CONTROL VALVE

17

18

19

55
22

40 40
24
51 41
25
26

27
Y

29
42
30
43

44
34 32
36
33

SM1193
Z

X = Pump Control Valve

Y = Load Check Valve
Z = Load Check Valve
EX255-EX285 W2-5-5

CONTROL VALVE

• Load Check Valve

7. Remove springs (40) and (42), check valves

(41) and (51), poppet (43), and sleeve (44) from
housing (36).

• Pump Control Valve

8. Remove plug (22) from housing (36). Take

care not to drop spring (24), seat (25), and
spool (26) at this time.
: 38 mm

NOTE - Do not remove lock nut (18) and screw (19).

9. Attach the nut (M8 Pitch 1.25) to spool (29).

Remove spool (29) together with sleeve (30)
from housing (36).

10. Remove retaining ring (33), seat (32), and

spring (34).

11. Pull out spool (29) and sleeve (27) from sleeve
(30).
W2-5-6 EX255-EX285

CONTROL VALVE

ASSEMBLE CONTROL VALVE 1-1

C
B
A
36 36

51 51
36
17 39 39
17
12 40 40
55
55 55

38 40

SM1194
39

51
SM1195
SM1196

18 21 25 26 28 27 29 32 34 32 33

A= Side View of 5 - Spool Control Valve

B= Swing
C= Arm I
D
D= Pump Control Valve
E= Boom II
SM1197
F= Travel (left)

19 20 22 23 24 31 30

F
E

36

44
36
43
51
39
39
42
40
12
12
40
38
39

41
SM1199
SM1198

12 - Pilot Plate 24 - Spring 32 - Seat 42 - Spring

17 - Socket Bolt 25 - Seat 33 - Retaining Ring 43 - Poppet
18 - Lock Nut 26 - Spool 34 - Spring 44 - Sleeve
19 - Screw 27 - Sleeve 36 - Housing (5-Spool Side) 51 - Check Valve
20 - Washer 28 - O-Ring 38 - O-Ring 55 - Pilot Plate
21 - O-Ring 29 - Spool 39 - O-Ring
22 - Plug 30 - Sleeve 40 - Spring
23 - O-Ring 31 - O-Ring 41 - Check Valve
EX255-EX285 W2-5-7

CONTROL VALVE

Assemble Control Valve 1-1

• Pump Control Valve

1. Insert spool (29) onto sleeve (30).

2. Install seat (32), spring (34), and seat (32) on

spool (29), in that order. Secure with retaining
ring (33).

3. Install O-rings (28) (2 used) on sleeve (27).

Insert sleeve (27) into sleeve (30).

4. Install O-rings (31) (3 used) on sleeve (30).

Install sleeve (30) into housing (36).

5. Install spool (26) onto spool (29).

6. Install spring (24), seat (25), and O-ring (23)

onto plug (22). Install plug (22) onto housing
(36).
: 38 mm
: 84 N m (8.6 kgf m, 62 lbf ft)

• Load Check Valve (5-spool side)

7. Install poppet (43) and spring (42) into sleeve

(44). Install sleeve (44) into housing (36).

8. Install pairs of check valve (41) and spring

(40), and check valves (51) and springs (40)
(5 used each) into housing (36).

9. Install O-rings (39) and (38) onto housing (36).

10. Install pilot plate (55) on housing (36).

: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)
W2-5-8 EX255-EX285

CONTROL VALVE

ASSEMBLE CONTROL VALVE 1-2

B

36
17
X
17
12
55 55

51

36
SM1194

SM1196
C
1 3 2

A = Side view of 5 Spool Control Valve

B = Arm I
C = Cross Section X
D = Auxiliary
E = Travel (left)
F = Travel Flow Control Valve

SM1200
12

D E

36
39 36

F 8 7
40
6
51
5
12
4
37
12
38

SM1199

SM1201

1 - Plug (Restriction) 6 - Spring 36 - Housing 40 - Spring

2 - O-Ring 7 - O-Ring (5-Spool Side) 51 - Check Valve
3 - Plug 8 - Plug 37 - O-Ring 55 - Pilot Plate
4 - Spool 12 - Pilot Plate 38 - O-Ring
5 - Seat 17 - Socket Bolt 39 - O-Ring
EX255-EX285 W2-5-9

CONTROL VALVE

Assemble Control Valve 1-2

• Load Check Valve (5-spool side)

1. Install check valve (51) and spring (40) into

housing (36).

2. Install O-rings (37), (38), and (39) on housing

(36).

3. Install pilot plate (12) on housing (36).

: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)

• Travel Flow Control Valve

4. Install spool (4), seat (5), spring (6) into pilot

plate (12). Install O-ring (7) on plug (8). Install
plug (8) onto pilot plate (12).
: 36 mm
: 98 N m (10 kgf m, 72 lbf ft)

5. Install plug (1) onto pilot plate (12).

6. Install O-ring (2) onto plug (3). Install plug (3)

onto pilot plate (12).
: 5 mm
: 15 N m (1.5 kgf m, 11 lbf ft)
W2-5-10 EX255-EX285

CONTROL VALVE

DISASSEMBLE CONTROL VALVE 2

61
59 2
60
3
58
4
57 F
5
56 6
6
55 7
21
54 22 6 8
23 8
53 H
24 G
52 6
6
51
9
50 20
30 26
49 10
29 31 25 8
47 32
48 33 27 11
34 28
45 46 12
30
13
38 L
37 14
39
36
35 15
16
19 17
18
19
F= Load Check Valve
SM1202
G= Load Check Valve
H= Bucket Flow Control (Restriction)
L = Bucket Flow Control Valve
(Switch Valves A and B)

1 - Housing (4-Spool Side) 15 - O-Ring 29 - Plug 48 - O-Ring

2 - Spool 16 - O-Ring 30 - O-Ring 49 - Plug
3 - Spring 17 - Plug 31 - Retaining Ring 50 - O-Ring
4 - O-Ring 18 - Filter 32 - Seat 51 - Spring
5 - Plug 19 - Socket Bolt 33 - Spring 52 - Seat
6 - O-Ring 20 - Check Valve 34 - Spool 53 - Spool
7 - Check Valve 21 - Check Valve 35 - Pilot Plate 54 - Sleeve
8 - Spring 22 - O-Ring 36 - Spool 55 - O-Ring
9 - Poppet 23 - O-Ring 37 - Seat 56 - Spool
10 - Poppet 24 - O-Ring 38 - Spring 57 - Sleeve
11 - Spring 25 - Plug 39 - Pilot Plate 58 - O-Ring
12 - Plug 26 - Screw 45 - Screw 59 - Seat
13 - Spring 27 - O-Ring 46 - Lock Nut 60 - Spring
14 - Spacer 28 - Backup Ring 47 - Washer 61 - Retaining Ring
EX255-EX285 W2-5-11

CONTROL VALVE

Disassemble Control Valve 2

• Be sure to thoroughly read “Precautions for Disas-

sembly and Assembly” on page W1-1-1 before
starting the disassembly work.

1. Loosen socket bolts (19) to remove pilot plate

(39) from housing (1).
: 10 mm

• Bucket Flow Control Valve (Switch Valve A)

2. Remove plug (29) from pilot plate (35).

: 10 mm

3. Remove spool (34) from pilot plate (35).

4. Remove retaining ring (31), seat (32), and

spring (33) from spool (34).

• Bucket Flow Control Valve

(Switch Valve B, Poppet Valve)

5. Remove plug (29) from pilot plate (35).

6. Remove spring (38), seat (37), and spool (36)

from pilot plate (35).

7. Loosen socket bolts (19) to separate pilot plate

(35) from housing (1).

NOTE - Take care not to drop spacer (14) and spring

(13) at this time.

:10 mm

8. Remove plug (12) from housing (1). Remove

spring (11) and poppet (10) from poppet (9).
: 8 mm

• Load Check Valve

9. Remove springs (8) and check valves (7), (20),

and (21) from housing (1).
W2-5-12 EX255-EX285

CONTROL VALVE

F 1

61
59 2
60 G
3

57
5
56

54
53
52
51

49
46
45

17

SM1202

F = Pump Control Valve

G = Flow Combiner Valve
EX255-EX285 W2-5-13

CONTROL VALVE

• Pump Control Valve

10. Remove plug (49) from housing (1). Take care

not to drop spring (51), seat (52), and spool (53)
at this time.
: 38 mm

NOTE - Do not remove lock nut (46) and screw (45).

11. Attach the nut of bolt (M8 Pitch 1.25) to spool

(56). Remove spool (56) together with sleeve
(57) from housing (1).

12. Remove retaining ring (61), seat (59), and

spring (60).

13. Pull out spool (56) and sleeve (54) from sleeve
(57).

• Flow Combiner Valve

14. Remove plug (5), spring (3) and spool (2) from
housing (1).
: 36 mm

15. Remove plug (17) from housing (1).

: 19 mm
W2-5-14 EX255-EX285

CONTROL VALVE

ASSEMBLE CONTROL VALVE 2-1

B
A
1

21
1
39 6

35
39

8
SM1203
6

21
57 54 55 53 50 49 47 46 45 SM1204

C A = Side View of 4 - Spool Valve

B = Arm II
C = Pump Control Valve
D = Boom I
SM1209
E = Bucket
61 59 60 56 58 52 51 48

D E

1 1

21 6

8
35

39

8 8

6 6

7 20
SM1205 SM1206

1 - Housing (4-Spool Side) 39 - Pilot Plate 51 - Spring 58 - O-Ring

6 - O-Ring 45 - Screw 52 - Seat 59 - Seat
7 - Check Valve 46 - Lock Nut 53 - Spool 60 - Spring
8 - Spring 47 - Washer 54 - Sleeve 61 - Retaining Ring
20 - Check Valve 48 - O-Ring 55 - O-Ring
21 - Check Valve 49 - Plug 56 - Spool
35 - Pilot Plate 50 - O-Ring 57 - Sleeve
EX255-EX285 W2-5-15

CONTROL VALVE

Assemble Control Valve 2-1

• Pump control valve

1. Insert spool (56) onto sleeve (57).

2. Install seat (59), spring (60), and seat (59) on

spool (56), in that order. Secure with retaining
ring (61).

3. Install O-rings (55) (2 used) on sleeve (54).

Insert sleeve (54) into sleeve (57).

4. Install O-rings (58) (3 used) on sleeve (57).

Install sleeve (57) into housing (1).

5. Install spool (53) onto spool (56).

6. Install spring (51), seat (52), and O-ring (50)

onto plug (49). Install plug (49) onto housing
(1).
: 38 mm
: 84 N m (8.6 kgf m, 62 lbf ft)

• Check Valve (4-spool side)

7. Install check valve (7), check valve(20), check

valves (21) (3 used) and spring (8) (5 used) into
housing (1).

8. Install O-rings (6) (5 used) on housing (1).

W2-5-16 EX255-EX285

CONTROL VALVE

ASSEMBLE CONTROL VALVE 2-2 B

A 1

1
39
17
19
19
39
35

SM1203

9 10 11 12 SM1204

A= Side View of 4-Spool Control Valve

B= Arm II
C= Bucket
C D= Travel (Right)
SM1210
E= Bucket Flow Control Valve A
D (Switch Valve)
F = Bucket Flow Control Valve B
(Switch Valve Orifice)
G = Flow Combiner Valve

1 1 15 16 18
6

13-14 E 17

36 35 6
26
37 2
25
38 34 3

30
27-28
29 33 5
32
6 22 29 31
30 4
1 35
SM1206 SM1207
G
F SM1208

1 - Housing (4-Spool Side) 12 - Plug 25 - Plug 34 - Spool

2 - Spool 13 - Spring 26 - Screw 35 - Pilot Plate
3 - Spring 14 - Spacer 27 - O-Ring 36 - Spool
4 - O-Ring 15 - O-Ring 28 - Backup Ring 37 - Seat
5 - Plug 16 - O-Ring 29 - Plug 38 - Spring
6 - O-Ring 17 - Plug 30 - O-Ring 39 - Pilot Plate
9 - Poppet 18 - Filter 31 - Retaining Ring
10 - Poppet 19 - Socket Bolt 32 - Seat
11 - Spring 22 - O-Ring 33 - Spring
EX255-EX285 W2-5-17

CONTROL VALVE

Assemble Control Valve 2-2 • Flow Combiner Valve

• Bucket Flow Control Valve (Switch Valve B,
Poppet Valve)
1. Attach poppet (10) and spring (11) to poppet (9).
Tighten plug (12) onto poppet (9).
: 8 mm
: 39 N m (4 kgf m, 29 lbf ft)
2. Install poppet (9) into housing (1).
3. Install O-rings (6) and (22) onto housing (1).
10. Install spool (2) and spring (3) into housing (1).
11. Tighten plug (5) onto housing (1).
: 36 mm
: 157 N m (16 kgf m, 116 lbf ft)
12. Install O-rings (15) and (16) onto plug (17).
Tighten plug (17) onto housing (1).
: 19 mm
: 76 N m (7.7 kgf m, 56 lbf ft)

4. Install spacer (14) and spring (13) into pilot plate

(35). Install pilot plate (35) onto housing (1).

5. Tighten pilot plate (35) onto housing (1) using

socket bolts (19).
: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)

6. Install spool (36), seat (37), and spring (38) into

pilot plate (35). Tighten plug (29) onto pilot plate
(35).
: 10 mm
: 71 N m (7.2 kgf m, 52 lbf ft)

• Bucket Flow Control Valve (Switch Valve A)

7. Attach seat (32) onto spool (34) and secure it

using retaining ring (31).

8. Install spring (33) onto spool (34) and insert

them into pilot plate (35).

9. Install O-ring (30) onto plug (29). Tighten plug

(29) onto pilot plate (35).
: 10 mm
: 71 N m (7.2 kgf m, 52 lbf ft)
W2-5-18 EX255-EX285

CONTROL VALVE

DISASSEMBLE CONTROL VALVE 3

L = Anti-Drift Valve
M = Travel/Boom Lower
Selector Valve
N = Arm Regenerative Valve

2
5

4 3

44 7
45
46
47

48 13
49
L 50 4
12
43
42 1
41 11
0 9
40 10
9
M 8

26
N 25 14
27 24 15
28 23 16
29 17
39 30 20
38 31 22
37 32 18
36 33 21
35 12 SM1211

34 19

J - Plug 14 - Spool (Swing) 28 - Spring 42 - O-Ring

1 - Socket Bolt 15 - Spool (Arm I) 29 - O-Ring 43 - Body
2 - Pilot Plate 16 - Spool (Boom II) 30 - Backup Ring 44 - Spacer
3 - Overload Relief Valve 17 - Spool (Auxiliary) 31 - O-Ring 45 - O-Ring
4 - O-Ring 18 - Spacer 32 - O-Ring 46 - Spring
5 - Housing (5-Spool Side) 19 - Backup Ring 33 - Spacer 47 - Seat
6 - Main Relief Valve 20 - O-Ring 34 - Spring 48 - Spool
7 - Pilot Housing 21 - Spring 35 - Spacer 49 - O-Ring
8 - Bolt (5 Used) 22 - Check Valve 36 - Backup Ring 50 - Plug
9 - Seat (10 Used) 23 - Sleeve 37 - O-Ring
10 - Spring (5 Used) 24 - Spool 38 - Spool
11 - Spool (Travel Left) 25 - Spring 39 - O-ring
12 - O-Ring 26 - O-Ring 40 - Socket Bolt
13 - O-Ring 27 - Check Valve 41 - Plug
EX255-EX285 W2-5-19

CONTROL VALVE

Disassemble Control Valve 3 • Arm Regenerative Valve

• Be sure to thoroughly read “Precautions for Disas-
sembly and Assembly” on page W1-1-1 before
starting the disassembly work.
• 5-Spool Side Main Spool
1. Loosen socket bolts (1), then remove pilot plate
(2) and pilot housing (7) from housing (5).
: 10 mm
2. Pull out five spools (11) , (14 to 17) from housing
(5).
9. Remove spring (34) and spool (38) from hous-
ing (5).
10. Heat spacer (35) mounting part on spool (38)
using a hair dryer to melt adhesive.
11. Put spool (38) in a vise. Remove spacer (35)
from spool (38).
NOTE - Place protectors, such as wooden plates,
between the vise and the spool so as not to damage
the spool.

3. Put the chamfered end of spool (11) in a vise.

Remove bolt (8). : 14 mm

: 22 mm
• Travel/Boom Lower Selector Valve
4. Remove seat (9), spring (10) and seat (9) from
bolt (8).
12. Remove sleeve (23), spool (24), and spring
(25) from housing (5).
5. Disassemble spools (14), (15), (16) and (17),
referring to the steps 3 and 4 above.

• Arm Anti-Drift Valve

6. Loosen socket bolts (40) to remove body (43)

from housing (5).

NOTE - Spacer (44) and spring (46) may fly off at this
time.

: 10 mm

7. Pull out spacer (18) from housing (5) using a bolt

(M5, Pitch 0.8).

8. Pull out spring (21) and check valve (22) from

housing (5) using a magnet.
W2-5-20 EX255-EX285

CONTROL VALVE

27
28

33
SM1211
EX255-EX285 W2-5-21

CONTROL VALVE

• Check Valve

13. Pull out spacer (33) from housing (5) using a

bolt (M6, Pitch 1.0).

14. Pull out spring (28) and check valve (27) from
housing (5) using a magnet.

• Overload Relief Valve

15. Remove overload relief valve (3) from housing

(5).

: 32 mm

• Main Relief Valve

16. Loosen plug (J) to remove main relief valve (6)

from housing (5).

: 32 mm
W2-5-22 EX255-EX285

CONTROL VALVE

ASSEMBLE CONTROL VALVE 3-1

B
A C 3
5
34
1
39
41-42 2
35
36
M
37
M

38

SM1212

SM1213 SM1214

6 3 43 40 5 Cross section
M-M
H

A= Top View of Control Valve

26
B= Arm Regenerative Valve
C= Bottom View of Control Valve 24
E= Arm I
F= Anti-Drift Valve
G= Boom II
23
H= Travel/Boom Lower Selector Valve
I = Main Relief Valve G 25
SM1215
I
6
E
43 48 50 49 F J
47 3 5
12
46
32 5
45- 44
31
12
33
20-19
30
18
29
21
28
22
27

4 4
5
2
3 2
SM1198
SM1196 SM1216

J - Plug 21 - Spring 32 - O-Ring 43 - Body

1 - Socket Bolt 22 - Check Valve 33 - Spacer 44 - Spacer
2 - Pilot Plate 23 - Sleeve 34 - Spring 45 - O-Ring
3 - Overload Relief Valve 24 - Spool 35 - Spacer 46 - Spring
4 - O-Ring 25 - Spring 36 - Backup Ring 47 - Seat
5 - Housing (5-Spool Side) 26 - O-Ring 37 - O-Ring 48 - Spool
6 - Main Relief Valve 27 - Check Valve 38 - Spool 49 - O-Ring
12 - O-Ring 28 - Spring 39 - O-Ring 50 - Plug
18 - Spacer 29 - O-Ring 40 - Socket Bolt
19 - Backup Ring 30 - Backup Ring 41 - Plug
20 - O-Ring 31 - O-Ring 42 - O-Ring
EX255-EX285 W2-5-23

CONTROL VALVE

Assemble Control Valve 3-1

• Overload Relief Valve

1. Install two overload relief valves (3) to hous-

ing (5).
: 32 mm
: 83 N m (8.5 kgf m, 62 lbf ft)

2. Install five O-rings (4) onto housing (5).

3. Install pilot plate (2) onto housing (5) using

socket bolts (1) (6 used).
: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)

• Check Valve

4. Install check valve (27) and spring (28) into

housing (5).

5. Install O-rings (29), (31), and (32) and backup

ring (30) onto spacer (33). Install spacer (33)
into housing (5).

• Arm Regenerative Valve

6. Install O-ring (37) and backup ring (36) onto

spacer (35).

7. Apply LOCTITE 271 to the threads of spacer

(35). Install spacer (35) onto spool (38).

8. Put spool (38) in a vise. Tighten spacer (35)

onto spool (38).

NOTE - Place protectors, such as wooden plates,

between the vise and the spool so as not to damage
the spool.

: 14 mm
: 18.6 N m (1.9 kgf m, 14 lbf ft)

9. Install spool (38) and spring (34) into housing

(5).

10. Install O-ring (39) onto housing (5).

W2-5-24 EX255-EX285

CONTROL VALVE

B
A C
5

SM1212

SM1213 SM1214

6 43 40 5 Cross section
M-M
H
26
A= Top View of Control Valve
B= Arm Regenerative Valve
C= Bottom View of Control Valve
24
E= Arm I
F = Arm Anti-Drift 23
G= Boom II
H= Travel/Boom Lower Selector Valve
I = Main Relief Valve G 25
SM1215
I
6
E
43 48 50 49 F J
47 5
12
46
45- 44 5
12
20-19
18
21
22

SM1196
SM1198

SM1216
EX255-EX285 W2-5-25

CONTROL VALVE

• Arm Anti-Drift Valve

11. Install check valve (22) and spring (21) into

housing (5).

12. Install O-rings (12) and (20) and backup ring

(19) on spacer (18). Install spacer (18) into
housing (5).

13. Install spool (48), seat (47), and spring (46) into
body (43).

14. Install O-ring (45) onto spacer (44). Install

spacer (44) into body (43).

15. Install O-rings (12) (3 used) onto housing (5).

16. Install body (43) onto housing (5).

: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)

17. Install O-ring (49) onto plug (50). Install plug

(50) onto body (43).
: 6 mm
: 29 N m (3 kgf m, 22 lbf ft)

• Travel/Boom Lower Selector Valve

18. Install spring (25), spool (24), and sleeve (23)

into housing (5).

19. Install O-ring (26) onto housing (5).

• Main Relief Valve

20. Install main relief valve (6) onto housing (5).

21. Tighten plug (J) of main relief valve (6).

: 32 mm
: 83 N m (8.5 kgf m, 62 lbf ft)
W2-5-26 EX255-EX285

CONTROL VALVE

ASSEMBLE CONTROL VALVE 3-2

A= Top View of Control Valve

B= Travel (left)
C= Auxiliary A A
D= Boom II
E= Arm I
F= Swing

SM1212

7 1

B C D E F

7 9
10
13 8
9
5
4
11
14

15

16
17

SM1217

Cross section A-A

1 - Socket Bolt 9 - Seat (10 Used) 15 - Spool (Arm I)

4 - O-Ring 10 - Spring (5 Used) 16 - Spool (Boom II)
5 - Housing (5-Spool Side) 11 - Spool (Travel Left) 17 - Spool (Auxiliary)
7 - Pilot Housing 13 - O-Ring
8 - Bolt (5 Used) 14 - Spool (Swing)
EX255-EX285 W2-5-27

CONTROL VALVE

Assemble Control Valve 3-2

• 5-Spool Side Main Spool

1. Put the chamfered end of spool (11) in a vise.

2. Install seat (9), spring (10), and seat (9) on spool

(11) in that order.
Install bolt (8).

: 22 mm
: 15 N m (1.5 kgf m, 11 lbf ft)

3. Assemble spools (14) to (17) referring to steps

1 and 2 above.

4. Install spools (11), (14), (15), (16), and (17) into

housing (5).

5. Install O-rings (4) (5 used) and O-rings (13)

(3 used) onto housing (5).

6. Install pilot housing (7) onto housing (5).

7. Tighten socket bolts (1) (6 used).

:10 mm
: 78 N m (8 kgf m, 58 lbf ft)
W2-5-28 EX255-EX285

CONTROL VALVE

DISASSEMBLE CONTROL VALVE 4

3 4 5 6
A = Boom Anti-Drift Valve

2 7
16
8
15
14
1 13 9
18
10
5
17 12 5 11

19 2
22

17 21
22 20 19
23
24
25

A 41
40
39
38
37
36 26
42 34 27
43 35
44 34
45 33 29
46 32 28
20 31
52 30
51
50
49
48
47 SM1218

1 - Pilot Plate 14 - Spring 27 - Plug 40 - Backup Ring

2 - Socket Bolt 15 - O-Ring 28 - O-Ring 41 - Plug
3 - Body 16 - Spacer 29 - Spring 42 - Check Valve
4 - Socket Bolt 17 - O-Ring 30 - Washer 43 - Spring
5 - O-Ring 18 - Housing (4-Spool Side) 31 - Sleeve 44 - O-Ring
6 - Plug 19 - O-Ring 32 - Poppet 45 - Backup Ring
7 - Lock Nut 20 - O-Ring 33 - Bolt (4 Used) 46 - Spacer
8 - Poppet 21 - Pilot Housing 34 - Seat (8 Used) 47 - Check Valve
9 - O-Ring 22 - Overload Relief Valve 35 - Spring (4 Used) 48 - Spring
10 - Plug 23 - Spool (Travel Right) 36 - Spool (Arm II) 49 - O-Ring
11 - Plug 24 - Spool (Bucket) 37 - Poppet 50 - Backup Ring
12 - Spool 25 - Spool (Boom I) 38 - Spring 51 - O-Ring
13 - Seat 26 - Backup Ring 39 - O-Ring 52 - Spacer
EX255-EX285 W2-5-29

CONTROL VALVE

Disassemble Control Valve 4 • Boom Anti-Drift Valve

• Be sure to thoroughly read “Precautions for Disas- 10. Loosen socket bolts (4) to remove body (3)
sembly and Assembly” on page W1-1-1 before from housing (18).
starting the disassembly work.
NOTE - Spacer (16) and spring (14) may fly off at this
time.
• 4-Spool Side Main Spool
: 10 mm
1. Loosen socket bolts (2), then remove pilot plate
(1) and pilot housing (21) from housing (18). 11. Pull out spacer (46) from housing (18) using a
: 10 mm bolt (M5 Pitch 0.8).

2. Pull out four spools (36), (23 to 25) from housing 12. Pull out spring (43) and check valve (42) from
(18). housing (18) using a magnet.

3. Put the chamfered end of spool (36) in a vise.

Remove bolt (33).
: 22 mm

4. Remove seat (34), spring (35) and seat (34)

from bolt (33).

5. Disassemble spools (23), (24), (25), referring to

the steps 3 and 4 above.

• Boom Regenerative Valve

6. Heat plug (27), (41) mounting part on spool (25)

using a hair dryer to melt adhesive.
75301502
7. Put spool (25) in a vise. Remove plugs (27),
(41) from spool (25) using special tool
(75301502).

NOTE - Place protectors, such as wooden plates,

between the vise and the spool so as not to damage SM1219
the spool.

8. Remove spring (29), washer (30), sleeve (31),

and poppet (32) from one end of spool (25).

9. Remove spring (38) and poppet (37) from the

other end of spool (25).
W2-5-30 EX255-EX285

CONTROL VALVE

A = Emergency Boom Lower Mechanism

A

7
8

18
10

22

52

48
47
SM1218
EX255-EX285 W2-5-31

CONTROL VALVE

• Check Valve

13. Pull out spacer (52) from housing (18) using a

bolt (M6 Pitch 1.0).

14. Pull out spring (48) and check valve (47) from
housing (18) using a magnet.

• Overload Relief Valve

15. Remove overload relief valves (22) from hous-

ing (18).
: 32 mm

• Emergency Boom Lower Mechanism

16. Loosen lock nut (7) to remove poppet (8) from

body (3).
: 13 mm
: 4 mm

17. Remove plug (10) from body (3).

: 19 mm
W2-5-32 EX255-EX285

CONTROL VALVE

ASSEMBLE CONTROL VALVE 4-1

A= Top View of Control Valve

11 5 9 5 B
B= Emergency Boom Lower Mechanism
C= Bottom View of Control Valve
D= Boom I 3 7
E= Boom Anti-Drift Valve
12 8
13 10
14 6
22 3 22
16
4 15 5
A
SM1220
18

D E

3
20

20

44-45

SM1212 46

43
C 42

18
22

18
SM1205

SM1214

22

3 - Body 11 - Plug 20 - O-Ring

4 - Socket Bolt 12 - Spool 22 - Overload Relief Valve
5 - O-Ring 13 - Seat 42 - Check Valve
6 - Plug 14 - Spring 43 - Spring
7 - Lock Nut 15 - O-Ring 44 - O-Ring
8 - Poppet 16 - Spacer 45 - Backup Ring
9 - O-Ring 18 - Housing 46 - Spacer
10 - Plug (4-Spool Side)
EX255-EX285 W2-5-33

CONTROL VALVE

Assemble Control Valve 4-1 • Emergency Boom Lower Mechanism

• Overload relief valve 9. Install O-ring (9) onto poppet (8). Install poppet
(8) into plug (10).
1. Install four overload relief valves (22) to housing
(18). 10. Install O-ring (5) onto plug (10). Install plug (10)
onto body (3).
: 32 mm
: 83 N m (8.5 kgf m, 62 lbf ft) 11. Tighten poppet (8) until it comes in contact with
body (3) inside. Then, install lock nut (7).

• Boom Anti-Drift Valve

NOTE - Use an alien wrench so that poppet (8) does
2. Install check valve (42) and spring (43) into not turn when tightening lock nut (7).
housing (18).

3. Install O-rings (20) and (44) and backup ring (45) : 13 mm

on spacer (46). Install spacer (46) into housing : 29 N m (3 kgf m, 22 lbf ft)
(18).
: 4 mm
4. Install spool (12), seat (13), and spring (14) into
body (3).

5. Install O-ring (15) onto spacer (16). Install

spacer (16) into body (3).

6. Install O-rings (20) (3 used) onto housing (18)

and tighten socket bolts (4).

7. Install body (3) onto housing (18).

: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)

8. Install O-ring (5) onto plug (11). Install plug (11)

onto body (3).
: 6 mm
: 29 N m (3 kgf m, 22 lb ft)
W2-5-34 EX255-EX285

CONTROL VALVE

ASSEMBLE CONTROL VALVE 4-2

A= Top View of Control Valve B C D E 33

B= Travel (right) 34
C= Bucket
21
D= Boom I 35
E= Arm II 19
G= Bottom View of Control Valve
34
H= Boom Regenerative Valve 18
17
23
36
18 A
25
2 47

21 48
49-50
A A
24 51

1 52
Cross Section A-A 17
SM1221

34
SM1212
35

33
G 34 27

29 26

30 28

32 31
H
25

38 37

39-40
1
41
SM1214
18 2 SM1222

1 - Pilot Plate 28 - O-Ring 39 - O-Ring

2 - Socket Bolt 29 - Spring 40 - Backup Ring
17 - O-Ring 30 - Washer 41 - Plug
18 - Housing (4-Spool Side) 31 - Sleeve 47 - Check Valve
19 - O-Ring 32 - Poppet 48 - Spring
21 - Pilot Housing 33 - Bolt (4 Used) 49 - O-Ring
23 - Spool (Travel Right) 34 - Seat (8 Used) 50 - Backup Ring
24 - Spool (Bucket) 35 - Spring (4 Used) 51 - O-Ring
25 - Spool (Boom I) 36 - Spool (Arm II) 52 - Spacer
26 - Backup Ring 37 - Poppet
27 - Plug 38 - Spring
EX255-EX285 W2-5-35

CONTROL VALVE

Assemble Control Valve 4-2

• Check Valve

1. Install check valve (47) and spring (48) into

housing (18).

2. Install O-rings (49) and (51) and backup ring

(50) on spacer (52). Install spacer (52) into
housing (18).

3. Install O-rings (17) (4 used) onto housing

(18).

4. Install pilot plate (1) onto housing (18) using

socket bolts (2) (7 used).
: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)

• Boom Regenerative Valve

5. Attach poppet (32) and spring (29) to sleeve

(31).

6. Install O-ring (28) and backup ring (26) onto

plug (27). Apply LOCTITE 271 to the threads
of plug (27). 75301502

7. Put spool (25) in a vise. Tighten plug (27)

onto spool (25) using special tool
(75301502).

SM1219
NOTE - Place protectors, such as wooden plates,
between the vise and the spool so as not to damage
the spool.

: 14 mm
: 15 N m (1.5 kgf m, 11 lbf ft)

8. Attach poppet (37) and spring (38) to spool

(25).

9. Install O-ring (39) and backup ring (40) onto

plug (41). Apply LOCTITE 271 to the threads 75301502
of plug (41).

10. Put spool (25) in a vise. Tighten plug (41)

onto spool (25) using a special tool
(75301502).
SM1219
NOTE - Place protectors, such as wooden plates,
between the vise and the spool so as not to damage
the spool.

: 14 mm
: 15 N m (1.5 kgf m, 11 lbf ft)
W2-5-36 EX255-EX285

CONTROL VALVE

A= Top View of Control Valve

B= Travel (right) B C D E 33
C= Bucket
D= Boom I 21 34
E= Arm II 35
G= Bottom View of Control Valve 19
34
18
17
A 23
18 36
2 25

21

A A
24

Cross Section A-A

SM1221

SM1212
34

35

33
G 34

25

SM1214
18 SM1222
EX255-EX285 W2-5-37

CONTROL VALVE

• 4 - Spool Side Main Spool

11. Install seat (34), spring (35), and seat (34) on

spool (36) in that order.

12. Put the chamfered end of spool (36) in a vise.

Install bolt (33).
: 22 mm
: 15 N m (1.5 kgf m, 111 lbf ft)

13. Assemble spools (23) to (25) referring to steps

11 and 12 above.

14. Install spools (36), (23), (24), and (25) into

housing (18).

15. Install O-rings (17) (4 used) and O-rings (19) (3

used) onto housing (18).

16. Install pilot housing (21) onto housing (18).

17. Tighten socket bolts (2) (7 used).

: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)
W2-5-38 EX255-EX285

CONTROL VALVE

DISASSEMBLE CONTROL VALVE 5

A= Hydraulic Timer

3
2

1
8
7
6

8
7

6
5
4

15
14
13
12
11
10 A

2
3

SM1223

1 - Housing (5-Spool Side) 5 - Spring 9 - Housing (4-Spool Side) 13 - Poppet

2 - O-Ring 6 - O-Ring 10 - Spring 14 - O-Ring
3 - Plug 7 - Cover 11 - Filter 15 - Plug
4 - Check Valve 8 - Socket Bolt 12 - Restriction
EX255-EX285 W2-5-39

CONTROL VALVE

Disassemble Control Valve 5

• Be sure to thoroughly read “Precautions for Disas-

sembly and Assembly” on page W1-1-1 before
starting the disassembly work.

• Hydraulic Timer

1. Remove plug (15) from housing (9).

: 22 mm

2. Remove poppet (13) and spring (10) from hous-

ing (9). Note that filter (11) cannot be removed
as it is fixed to poppet (13).

• Check Valve

3. Loosen socket bolts (8) to remove covers (7)

from housings (1) and (9).

: 8 mm

4. Remove springs (5) and check valves (4) from

housings (1) and (9).

5. Remove plugs (3) from housings (1) and (9).

: 19 mm
W2-5-40 EX255-EX285

CONTROL VALVE

ASSEMBLE CONTROL VALVE 5

A = Hydraulic Timer

5 4 9

7 7
8

6 6
7
6 5

5 4
4 SM1217

SM1221

A
15

14 3 2
12
11
13
10 SM1227
SM1224

9 9
1 1
SM1226
SM1225

1 - Housing (5-Spool Side) 5 - Spring 9 - Housing 12 - Restriction

2 - O-Ring 6 - O-Ring (4-Spool Side) 13 - Poppet
3 - Plug 7 - Cover 10 - Spring 14 - O-Ring
4 - Check Valve 8 - Socket Bolt 11 - Filter 15 - Plug
EX255-EX285 W2-5-41

CONTROL VALVE

Assemble Control Valve 5

• Check Valve

1. Install check valves (4) (3 used) and springs (5)

(3 used) into housings (1) and (9).

2. Install O-rings (6) (3 used) onto housings (1) and

(9). Install cover (7) onto housing (1) and tighten
socket bolt (8).
: 8 mm
: 61 N m (6.2 kgf m, 45 lbf ft)

• Hydraulic Timer

3. Attach poppet (13) and spring (10) to plug (15).

4. Install O-ring (14) onto plug (15). Install plug (15)

onto housing (9).
: 22 mm
: 76 N m (7.7 kgf m, 56 lbf ft)

5. Install O-ring (2) on each plug (3) (2 used).

Install plugs (3) on housings (1) and (9).
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
W2-5-42 EX255-EX285

CONTROL VALVE

NOTES
EX255-EX285 W2-6-1

SWING DEVICE

REMOVE AND INSTALL SWING DEVICE

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation
1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal
1. Disconnect hoses (1, 3, 5 to 8).
: 41 mm
: 205 N m (21 kgf m, 152 lbf ft) 1
: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft)
: 19 mm
2
: 29.5 N m (3 kgf m, 22 lbf ft)
: 8 mm 3
: 64 N m (6.5 kgf m, 147 lbf ft)
NOTE - Attach caps to hoses and pipes. 8

2. Remove adapter (2) and install an eyebolt to the 7

swing device assembly to sling it with a wire rope.
Eyebolts: (M27 Pitch 2.0) 6
: 36 mm
: 108 N m (11 kgf m, 80 lbf ft) 5
4
WARNING
Swing device assembly weight: 330 kg (730 lb)

3. Remove swing device mounting bolts (4).

4. Sling the swing device assembly with a crane or
hoist.
: 32 mm SM1024

: 640 N m (65 kgf m, 470 lbf ft)

Installation
1. Install the swing device assembly to frame and
tighten bolts (4).
IMPORTANT - Before installing the swing device
assembly, apply liquid packing to both mounting
surfaces on the swing reduction gears and frame.
2. Install adapter (2). Connect hoses (1, 3, 5 to 8).
IMPORTANT - Be sure to fill the swing motor with
hydraulic oil after installing it. Check hydraulic oil
level. Add oil if necessary. Run the engine. Check the
components for any oil leakage.
W2-6-2 EX255-EX285
EX255

SWING DEVICE

DISASSEMBLE SWING DEVICE (EX255)

31
2

5
30
21 6
29 22
20 7
28 23
4 8
27
19 9

7
18 10
26
17 11
25 24
16 12
15 13

14

13
SM3501

1 - Swing Motor 12 - Spring Pin (3 Used) 23 - Drain Plug

2 - Socket Bolt (8 Used) 13 - Thrust Plate (6 Used) 24 - Bolt (10 Used)
3 - First Stage Sun Gear 14 - Second Stage Planetary Gear (3 Used) 25 - Oil Seal
4 - Thrust Plate (2 Used) 15 - Bearing 26 - Cover
5 - Pin (3 Used) 16 - Retaining Ring 27 - Shaft
6 - Spring Pin (3 Used) 17 - Second Stage Carrier 28 - O-Ring
7 - Thrust Plate (6 Used) 18 - O-Ring 29 - Sleeve
8 - Needle Bearing (3 Used) 19 - Ring Gear 30 - Bearing
9 - First Stage Planetary Gear (3 Used) 20 - Second Stage Sun Gear 31 - Housing
10 - Socket Bolt (12 Used) 21 - First Stage Carrier
11 - Pin (3 Used) 22 - Drain Pipe
EX255-EX285
EX255 W2-6-3

SWING DEVICE

Disassemble Swing Device

WARNING
• Be sure to thoroughly read “Precautions for Disas- Remaining component weight
sembly and Assembly” on page W1-1-1 before (Housing, shaft,etc.): Approx. 160 kg (350 lb)
starting the disassembly work.

1. Remove plug (23) to drain oil and disconnect drain 8. Turn over housing (31). Loosen bolts (24). Re-
pipe (22). move cover (26).
Drain oil: 13.2 L (13.95 US qt) : 19 mm
: 27 mm
9. Remove oil seal (25) from cover (26).

WARNING 10. Push shaft (27) out of housing (31) using a press.
Swing motor weight: 60 kg (132 Ib)

2. Put matching marks on swing motor, ring gear

(19), and housing (31). Remove socket bolts (2).
Remove motor (1) using a crane.
: 10 mm

NOTE - Insert a screwdriver between the motor and

ring gear (19) to pry the motor up for easy separation.

3. Remove first stage sun gear (3). Remove first

stage carrier (21) assembly from ring gear (19).

WARNING
Ring gear weight: 29 kg (64 lb)

4. Remove socket bolts (10). Remove ring gear (19)

using a crane.
: 14 mm

NOTE - Insert a screwdriver to the notches on hous-

ing (31) to pry ring gear (19) up for easy separation.

5. Remove O-ring (18) from housing (31).

WARNING
Second stage carrier assembly weight:
30 kg (66 lb)

6. Remove second stage sun gear (20) and second

stage carrier (17) assembly.

7. Remove retaining ring (16) from shaft (27).

W2-6-4 EX255-EX285
EX255

SWING DEVICE

31
2

5
30
21 6
29 22
20 7
28 23
4 8
27
19 9

7
18 10
26
17 11
25 24
16 12
15 13

14

13
SM3501
EX255-EX285
EX255 W2-6-5

SWING DEVICE

11. Pull bearing (30) out of shaft (27) using a press.

12. Remove sleeve (29) from shaft (27). Remove

O-ring (28) from sleeve (29).

13. Remove bearing (15) from housing (31).

14. Drive spring pins (6) (3 used) out of first stage

carrier (21) using a round bar and a hammer.

15. Remove pins (5) (3 used), first stage planetary

gears (9) (3 used), thrust plates (7) (6 used), and
needle bearings (8) (3 used) from first stage
carrier (21).

16. Remove thrust plate (4) from first stage carrier

(21).

17. Disassemble second stage carrier (17) assembly

referring to steps 14 to 16 above. (Note that no
needle bearings are used on the second stage
planetary gears).
W2-6-6 EX255
EX255-EX285

SWING DEVICE

ASSEMBLE SWING DEVICE (EX255)

3 6 5
1 2
21 8

4 7
12
19
14
20
10
18
13
17
11
16
4
15 22

30

31

24
26

25 23
29

SM3518
28 27

1 - Swing Motor 12 - Spring Pin (3 Used) 23 - Drain Plug

2 - Socket Bolt (8 Used) 13 - Thrust Plate (6 Used) 24 - Bolt (10 Used)
3 - First Stage Sun Gear 14 - Second Stage Planetary Gear (3 Used) 25 - Oil Seal
4 - Thrust Plate (2 Used) 15 - Bearing 26 - Cover
5 - Pin (3 Used) 16 - Retaining Ring 27 - Shaft
6 - Spring Pin (3 Used) 17 - Second Stage Carrier 28 - O-Ring
7 - Thrust Plate (6 Used) 18 - O-Ring 29 - Sleeve
8 - Needle Bearing (3 Used) 19 - Ring Gear 30 - Bearing
9 - First Stage Planetary Gear (3 Used) 20 - Second Stage Sun Gear 31 - Housing
10 - Socket Bolt (12 Used) 21 - First Stage Carrier
11 - Pin (3 Used) 22 - Drain Pipe
EX255-EX285
EX255 W2-6-7

SWING DEVICE

Assemble Swing Device

1. Install needle bearing (8) in each of first stage WARNING

planetary gears (9) (3 used). Housing weight: 92 kg (203 lb)

IMPORTANT - Set thrust plate (4) with the grooved 9. Attach housing (31) to a crane using eye bolts. Lift
side upwards. and mount housing (31) onto shaft (27).

2. Install thrust plate (4) in first stage carrier (21). 10. Install bearing (15) into housing (31) using a
press.

IMPORTANT - Set thrust plates (7) with the grooved

sides facing toward the planetary gear end. Also, set 11. Install retaining ring (16) onto shaft (27).
the thrust plates so that the bent parts fit along the
periphery of the carrier flange.

3. Install first stage planetary gears (9) (3 used) and

thrust plates (7) (6 used) into first stage carrier
(21).

4. Aligning the hole on pin (5) with spring pin hole on

first stage carrier (21), drive pins (5) (3 used) into
first stage carrier (21).

5. Tap spring pins (6) (3 used) into first stage carrier

(21) and pin (5).

NOTE - Be sure that the slit part of spring pin (6) faces
upwards as shown.when driving it into the first stage
carrier and the pin.

6 Slit

6. Assemble second stage carrier (17), referring to

steps 2 to 5 above.

NOTE - Thrust plates (13) do not have any bent parts.

7. Install O-ring (28) on sleeve (29). Install sleeve

(29) onto shaft (27).

8. Install bearing (30) onto shaft (27) using a press.

W2-6-8 EX255
EX255-EX285

SWING DEVICE

21

10
19

20

18

17

31

24
26

25

SM3518
27
EX255-EX285
EX255 W2-6-9

SWING DEVICE

12. Apply THREEBOND 1215 to oil seal (25) mount- 18. Install first stage carrier (21) into ring gear (19).
ing part of cover (26). Install oil seal (25) onto
cover (26).
IMPORTANT - Be sure to position the sun gear with
the stepped end facing downward.
13. Apply THREEBOND 1215 on cover (26) mount-
ing part of housing (31).
19. Install first stage sun gear (3) into first stage
carrier (21).
WARNING
Total weight assembled so far
(housing, shaft, etc.): Approx. 145 kg (320 lb)

IMPORTANT - Be sure that the lip part of oil seal (25)

does not come into contact with the tooth end of shaft
(27) when installing the cover.

14. Turn over housing (31). Install cover (26) using

bolts (24).
: 19 mm
: 88 N m (9 kgf m, 65 lbf ft)

WARNING
Second stage carrier weight: 30 kg (66 lb)

15. Turn over housing (31). Install second stage

carrier (17) assembly into housing (31). Install O-
ring (18) on housing (31).

16. Install second stage sun gear (20) into second

stage carrier (17).

WARNING
Ring gear weight: 29 kg (65 lb)

17. Attach ring gear (19) to a crane using eye bolts

(M12 Pitch 1.75).
Lift and install ring gear (19) into housing (31).
Tighten socket bolts (10).

NOTE - Be sure to align the matching mark on ring

gear (19) with that on housing (31).

: 14 mm
: 205 N m (21 kgf m, 152 lbf ft)
W2-6-10 EX255-EX285
EX255

SWING DEVICE

1 2

19

22

31

23

SM3518
EX255-EX285
EX255 W2-6-11

SWING DEVICE

20. Install drain plug (23) on drain pipe (22). Install

drain pipe (22) onto housing (31).
: 10 mm
: 49 N m (5 kgf m, 36 Ibf ft)
: 27 mm
: 93 N m (9.5 kgf m, 69 Ibf ft)

21. Fill the swing reduction gear with proper oil.

Proper Oil: 13.2 L (13.95 US qt)

22. Apply THREEBOND 1102 to the swing motor

mounting surface of ring gear (19).

WARNING
Swing motor weight: Approx. 60 kg (132 lb)

23. Lift and mount motor (1) onto ring gear (19).
Tighten socket bolts (2).

NOTE - Be sure to align the matching mark on motor

(1) with that on ring gear (19).

: 10 mm
: 88 N m (9 kgf m, 65 Ibf ft)
W2-6-12 EX255-EX285
EX285

SWING DEVICE

DISASSEMBLE SWING DEVICE (EX285)

1
2

16
15
3

4 5 6

21
31
7
20
8
12 11
4 9
22 7
30
33 23
17
26
25 13 32
24 28 14
13
29
10

19
27
18
SM5102

1 - Swing Motor 12 - Spring Pin (3 Used) 23 - Drain Plug

2 - Socket Bolt (12 Used) 13 - Thrust Plate (6 Used) 24 - Bolt (10 Used)
3 - First Stage Sun Gear 14 - Second Stage Planetary Gear (3 Used) 25 - Oil Seal
4 - Thrust Plate (2 Used) 15 - Bearing 26 - Cover
5 - Pin (3 Used) 16 - Retaining Ring 27 - Shaft
6 - Spring Pin (3 Used) 17 - Second Stage Carrier 28 - O-Ring
7 - Thrust Plate (6 Used) 18 - O-Ring 29 - Sleeve
8 - Needle Bearing (3 Used) 19 - Ring Gear 30 - Bearing
9 - First Stage Planetary Gear (3 Used) 20 - Second Stage Sun Gear 31 - Housing
10 - Socket Bolt (12 Used) 21 - First Stage Carrier 32 - O-Ring
11 - Pin (3 Used) 22 - Drain Pipe 33 - O-Ring
EX255-EX285
EX285 W2-6-13

SWING DEVICE

Disassemble Swing Device

WARNING
• Be sure to thoroughly read “Precautions for Disas- Remaining component weight
sembly and Assembly” on page W1-1-1 before (housing, shaft,etc.): approx. 210 kg (463 lb)
starting the disassembly work.

1. Remove plug (23) to drain oil and disconnect drain 8. Turn over housing (31). Loosen bolts (24). Re-
pipe (22). move cover (26).
Drain oil: 17 L (17.96 US qt) : 19 mm
: 27 mm 9. Remove oil seal (25) and O-Ring (33) from cover
(26).
WARNING
Swing motor weight: 70 kg (154 Ib) 10. Push shaft (27) out of housing (31) using a press.

2. Put matching marks on the swing motor, ring gear

(19), and housing (31). Remove socket bolts (2).
Remove motor (1) using a crane.

: 10 mm

NOTE - Insert a screwdriver between the motor and

ring gear (19) to pry the motor up for easy separation.

3. Remove first stage sun gear (3). Remove first

stage carrier (21) assembly from ring gear (19).
Remove O-ring (32) from ring gear (19).

WARNING
Ring gear weight: 35 kg (77 lb)

4. Remove socket bolts (10). Remove ring gear (19)

using a crane.

: 17 mm

NOTE - Insert a screwdriver to the notches on hous-

ing (31) to pry ring gear (19) up for easy separation.

5. Remove O-ring (18) from housing (31).

WARNING
Second stage carrier assembly weight:
35 kg (77 lb)

6. Remove second stage sun gear (20) and second

stage carrier (17) assembly.

7. Remove retaining ring (16) from shaft (27).

W2-6-14 EX255-EX285
EX285

SWING DEVICE

1
2

16
15
3

4 5 6

21
31
7
20
8
12 11
4 9
22 7
30
33 23
17
26
25 13 32
24 28 14
13
29
10

19
27
18
SM5102
EX255-EX285
EX285 W2-6-15

SWING DEVICE

11. Pull bearing (30) out of shaft (27) using a press.

12. Remove sleeve (29) from shaft (27). Remove

O-ring (28) from sleeve (29).

13. Remove bearing (15) from housing (31).

14. Drive spring pins (6) (3 used) out of first stage

carrier (21) using a round bar and a hammer.

15. Remove pins (5) (3 used), first stage planetary

gears (9) (3 used), thrust plates (7) (6 used), and
needle bearings (8) (3 used) from first stage
carrier (21).

16. Remove thrust plate (4) from first stage carrier

(21).

17. Disassemble second stage carrier (17) assembly

referring to steps 14 to 16 above. (Note that no
needle bearings are used on the second stage
planetary gears).
W2-6-16 EX255-EX285
EX285

SWING DEVICE

ASSEMBLE SWING DEVICE (EX285)

3 6
5

1
32 8
2
21 9
4 7
19 12
20 14
10
17
13
18
11
16
4
15
22

30
31

33
26
24
25
29

23

28 27

SM5103

1 - Swing Motor 12 - Spring Pin (3 Used) 23 - Drain Plug

2 - Socket Bolt (8 Used) 13 - Thrust Plate (6 Used) 24 - Bolt (10 Used)
3 - First Stage Sun Gear 14 - Second Stage Planetary Gear (3 Used) 25 - Oil Seal
4 - Thrust Plate (2 Used) 15 - Bearing 26 - Cover
5 - Pin (3 Used) 16 - Retaining Ring 27 - Shaft
6 - Spring Pin (3 Used) 17 - Second Stage Carrier 28 - O-Ring
7 - Thrust Plate (6 Used) 18 - O-Ring 29 - Sleeve
8 - Needle Bearing (3 Used) 19 - Ring Gear 30 - Bearing
9 - First Stage Planetary Gear (3 Used) 20 - Second Stage Sun Gear 31 - Housing
10 - Socket Bolt (12 Used) 21 - First Stage Carrier
11 - Pin (3 Used) 22 - Drain Pipe
EX255-EX285
EX285 W2-6-17

SWING DEVICE

Assemble Swing Device

1. Install needle bearing (8) in each of first stage WARNING

planetary gears (9) (3 used). Housing weight: 107 kg (236 lb)

IMPORTANT - Set thrust plate (4) with the grooved 9. Attach housing (31) to a crane using eye bolts.
side upwards. Lift and mount housing (31) onto shaft (27).

2. Install thrust plate (4) in first stage carrier (21). 10. Install bearing (15) into housing (31) using a
press.

IMPORTANT - Set thrust plates (7) with the grooved

sides facing toward the planetary gear end. Also, set 11. Install retaining ring (16) onto shaft (27).
the thrust plates so that the bent parts fit along the
periphery of the carrier flange.

3. Install first stage planetary gears (9) (3 used) and

thrust plates (7) (6 used) into first stage carrier
(21).

4. Aligning the hole on pin (5) with spring pin hole on

first stage carrier (21), drive pins (5) (3 used) into
first stage carrier (21).

5. Tap spring pins (6) (3 used) into first stage carrier

(21) and pin (5).

NOTE - Be sure that the slit part of spring pin (6) faces
upwards as shown.when driving it into the first stage
carrier and the pin.

6 Slit

6. Assemble second stage carrier (17), referring to

steps 2 to 5 above.

NOTE - Thrust plates (13) do not have any bent parts.

7. Install O-ring (28) on sleeve (29). Install sleeve

(29) onto shaft (27).

8. Install bearing (30) onto shaft (27) using a press.

W2-6-18 EX255-EX285
EX285

SWING DEVICE

32
21

19
20
10
17

18

31

33
26
24
25

27

SM5103
EX255-EX285
EX285 W2-6-19

SWING DEVICE

12. Apply THREEBOND 1215 to oil seal (25) mount- 18. Install first stage carrier (21) and O-ring (32) into
ing part of cover (26). Install oil seal (25) and O- ring gear (19).
ring (33) onto cover (26).
19. Install first stage sun gear (3) into first stage
carrier (21).
13. Apply THREEBOND 1215 on cover (26) mount-
ing part of housing (31).
IMPORTANT - Be sure to position the sun gear with
the stepped end facing downward.
WARNING
Total weight assembled so far
(Housing, shaft, etc.): Approx. 190 kg (420 lb)

IMPORTANT - Be sure that the lip part of oil seal (25)

does not come into contact with the tooth end of shaft
(27) when installing the cover.

14. Turn over housing (31). Install cover (26) using

bolts (24).
: 19 mm
: 88 N m (9 kgf m, 65 lbf ft)

WARNING
Second stage carrier weight: 35 kg (77 lb)

15. Turn over housing (31). Install second stage

carrier (17) assembly into housing (31). Install O-
ring (18) on housing (31).

16. Install second stage sun gear (20) into second

stage carrier (17).

WARNING
Ring gear weight: 35 kg (77 lb)

17. Attach ring gear (19) to a crane using eye bolts

(M12 Pitch 1.75).
Lift and install ring gear (19) into housing (31).
Tighten socket bolts (10).

NOTE - Be sure to align the matching mark on ring

gear (19) with that on housing (31).

: 14 mm
: 205 N m (21 kgf m, 152 lbf ft)
W2-6-20 EX285
EX255-EX285

SWING DEVICE

1
2

19

22

31

23

SM5103
EX255-EX285
EX285 W2-6-21

SWING DEVICE

20. Install drain plug (23) on drain pipe (22). Install

drain pipe (22) onto housing (31).
: 10 mm
: 49 N m (5 kgf m, 36 Ibf ft)
: 27 mm
: 93 N m (9.5 kgf m, 69 Ibf ft)

21. Fill the swing reduction gear with proper oil.

Proper Oil: 17.0 L (18 US qt)

22. Apply THREEBOND 1102 to the swing motor

mounting surface of ring gear (19).

WARNING
Swing motor weight: Approx. 70 kg (154 lb)

23. Lift and mount motor (1) onto ring gear (19).
Tighten socket bolts (2).

NOTE - Be sure to align the matching mark on motor

(1) with that on ring gear (19).

: 10 mm
: 88 N m (9 kgf m, 65 Ibf ft)
W2-6-22 EX255-EX285
EX255

SWING DEVICE

DISASSEMBLE SWING MOTOR (EX255)

4
5
6
3 7
8 9
2
10
11
1 12

13

14
15

33
16 32
17 31
17 34
18
30
17
27
35
29
28
19 26 36
25
20 24
37
21
38
22
23 39
40

41
42

SM1027

43

1 - Roller Bearing 11 - Brake Piston 22 - Spring 33 - O-Ring

2 - O-Ring 12 - O-Ring 23 - Spool 34 - Plunger (9 Used)
3 - Valve Casing 13 - Friction Plate (3 Used) 24 - Plug (3 Used) 35 - Retainer Plate
(Brake Valve) 14 - Relief Valve (2 Used) 25 - Spool 36 - Thrust Plate
4 - Socket Bolt (4 Used) 15 - Pin (2 Used) 26 - Spring 37 - Shaft (Output Shaft)
5 - Poppet (2 Used) 16 - Push Rod (12 Used) 27 - Rotor 38 - Spacer
6 - Spring (2 Used) 17 - Spacer (3 Used) 28 - O-Ring 39 - Roller Bearing
7 - O-Ring (2 Used) 18 - Holder 29 - Plug 40 - Oil Seal
8 - Plug (2 Used) 19 - Socket Bolt (2 Used) 30 - Spring 41 - Seal Cover
9 - Valve Plate 20 - Cover 31 - Retaining Ring 42 - Retaining Ring
10 - Spring (18 Used) 21 - O-Ring 32 - Plate (4 Used) 43 - Casing
EX255-EX285
EX255 W2-6-23

SWING DEVICE

Disassemble Swing Motor

• Be sure to thoroughly read “Precautions for Disas-
sembly and Assembly” on page W1-1-1 before
starting the disassembly work.
WARNING
Weight of swing motor assembly:
approx. 60 kg (130 Ib)
1. Remove relief valves (14) (2 used) from valve
casing (3).
NOTE - Never attempt to disassemble relief valves
(14).
: 36 mm
5. Remove valve casing (3) from casing (43).
NOTE - Valve plate (9) may be stuck on the bottom of
valve casing (3). Take care not to drop valve plate (9)
when removing valve casing (3).
6. If valve plate (9) has not been removed in the
previous step, remove it. Then, remove springs
(10) (18 used ).
IMPORTANT - If a screwdriver or similar tool is used
to separate (pry) valve plate (9) from the rotor side,
take care not to damage the sealing surfaces. (Note
that the top surface of the valve plate differs from the
bottom surface.)

2. Remove plugs (8) (2 used). 7. Apply two hooks to the notch A and pull the hooks
to remove brake piston (11).
: 14 mm

8. Remove O-rings (12), (33) from casing (43).

3. Remove springs (6) (2 used) and poppets (5) (2
used).

4. Put align marks on valve casing (3) and casing

(43). Loosen and remove socket bolts (4) (4 used).
A
: 17 mm 11

43
NOTE - Note that valve casing (3) will be raised by
springs (10) as socket bolts (4) are loosened.
SM1028
W2-6-24 EX255-EX285
EX255

SWING DEVICE

13

16 32
17 31
17 34
18
30
17
27
35
29
19 26 36
25
20
37
21
38
22
23 39
40

41
42

SM1027

43
EX255-EX285
EX255
SWING DEVICE
9. Lay casing (43) on its side. Pull out rotor (27) from
shaft (37).
10. Remove plates (32) (4 used) and friction plates
(13) (3 used) from casing (43).
11. Remove thrust plate (36).
12. Lay casing (43) on its side. Drive shaft (37) out of
casing (43) using a plastic hammer.
13. Remove retaining ring (42) and seal cover (41)
from casing (43).
14. Remove oil seal (40) from casing (43).
15. Remove the outer race of roller bearing (39) from
casing (43) using a metal bar and a plastic ham-
mer.
16. Remove the inner race of roller bearing (39), from
shaft (37) using a press. Remove spacer (38) from
shaft (37).
17. Remove plungers (34) (9 used), retainer plate (35),
holder (18), spacer (17), push rods (16)
(12 used) from rotor (27).
W2-6-25
WARNING
Be sure to press and hold spacer (17) using a press
when removing retaining ring (31).
Attempting to remove retaining ring (31) without
pressing the spacer down may cause the spacer
and/or retaining ring (31) to spring up, possibly
resulting in personal injury.
18. Press and hold spacer (17) using a press, and
remove retaining ring (31).
19. Remove spacer (17), spring (30), and spacer (17).
20. Remove plug (29), spring (26), and spool (25) from
casing (43).
: 6 mm
21. Remove socket bolts (19), cover (20) and O-ring
(21).
: 4 mm
22. Remove spring (22) and spool (23) from casing
(43).
NOTE - Although a filter and an orifice are install in
spool (23), do not attempt to remove them unless
restriction or deformation is found.
W2-6-26 EX255-EX285
EX255

SWING DEVICE

ASSEMBLE SWING MOTOR (EX255)

3 4 8 7 6 5

14
Y Y
29

28

30 17 31 1 9 15 10

2
Cross Section Y-Y
26 11
24 12
19
33
20
13
21 25 32

35 27
22
36 16
23
17 34
18
38

40 41 37 42 39 43 SM1029

1 - Roller Bearing 11 - Brake Piston 22 - Spring 33 - O-Ring

2 - O-Ring 12 - O-Ring 23 - Spool 34 - Plunger (9 Used)
3 - Valve Casing 13 - Friction Plate (3 Used) 24 - Plug (3 Used) 35 - Retainer Plate
(Brake Valve) 14 - Relief Valve (2 Used) 25 - Spool 36 - Thrust Plate
4 - Socket Bolt (4 Used) 15 - Pin (2 Used) 26 - Spring 37 - Shaft (Output Shaft)
5 - Poppet (2 Used) 16 - Push Rod (12 Used) 27 - Rotor 38 - Spacer
6 - Spring (2 Used) 17 - Spacer (3 Used) 28 - O-Ring 39 - Roller Bearing
7 - O-Ring (2 Used) 18 - Holder 29 - Plug 40 - Oil Seal
8 - Plug (2 Used) 19 - Socket Bolt (2 Used) 30 - Spring 41 - Seal Cover
9 - Valve Plate 20 - Cover 31 - Retaining Ring 42 - Retaining Ring
10 - Spring (18 Used) 21 - O-Ring 32 - Plate (4 Used) 43 - Casing
EX255-EX285
EX255 W2-6-27

SWING DEVICE

Assemble Swing Motor

1. Install spacer (38) onto shaft (37). 10. Attach plungers (34) (9 used) on retainer plate (35).
Install the inner race of roller bearing (39) onto shaft Insert plungers (34) into rotor (27).
(37) using a press.

2. Install retaining ring (42) onto casing (43). IMPORTANT - Be sure to apply a film of hydraulic oil
Install the inner race of roller bearing (1) onto shaft on the rotor bore surface before inserting plungers (43).
(37) using a press.

11. Lay casing (43) on its side.

IMPORTANT - Be sure that the lip part of oil seal (40) Install rotor (27) assembly onto shaft (37).
faces upwards when installing it.

IMPORTANT - On each of plate (32) periphery is a

3. Turnover casing (43). Install seal cover (41) into
casing (43). Install oil seal (40) into casing (43)
using a protection plate and a press.
4. Install the outer race of roller bearing (39) onto
casing (43) a metal bar and a hammer.
5. Lay casing (43) on its side. Install shaft (37) into
casing (43).
series of tab-like protrusions with four of the protru-
sions missing at an interval. Likewise, four teeth are
missing on each friction plate. When installing plates
(32) and friction plates (13), be sure to align these
missing parts.
12. Stand casing (43) upright. Install plates (32)
(4 used) and friction plates (13) (3 used) one by one
alternately.
13. Install O-rings (12) and (33) on casing (43).

6. Stand casing (43) upright. Install thrust plate (36)

into casing (43). 14. Install brake piston (11) into casing (43). If brake
piston (11) does not enter the casing smoothly due
to the installation of the O-rings above, tap the
7. Install spacer (17), spring (30), and spacer (17) into periphery of the brake piston evenly with a plastic
rotor (27), in that order. hammer.

8. Press down spacer (17) to give enough clearance

for retaining ring (31) installation. Install retaining 15. Install spring (10) (18 used ) on brake piston (11).
ring (31).

9. Insert push rods (16) (12 used) into rotor (27).

Install spacer (17) and holder (18) onto rotor (27), in
that order.
W2-6-28 EX255
EX255-EX285

SWING DEVICE

3 4 8 7 6 5

14
Y Y
29

28

1 9

2
Cross Section Y-Y
26

19
20
21 25

22
23

43 SM1029
EX255-EX285
EX255 W2-6-29

SWING DEVICE

21. Install spool (25) and spring (26) into casing (43).
IMPORTANT - Be sure that the model stamped end of Tighten attached plug (29), O-ring (28).
roller bearing faces upwards when installing.
: 6 mm
: 36 N m (3.7 kgf m, 27 lbf ft)
16. Install roller bearing (1) into valve casing (3) using
a plastic hammer.
22. Install spool (23) and spring (22) into casing (43).

17. Install O-ring (2) and valve plate (9) on valve 23. Install O-ring (21) and cover (20) onto casing (43).
casing (3). Tighten socket bolts (19).
: 4 mm
NOTE - Be sure to apply grease to the contact surface
of valve plate (9) so as to prevent it from dropping when : 7 N m (0.7 kgf m, 5 lbf ft)
installing valve casing (3) onto the casing.

IMPORTANT - Take care not to drop valve plate (9). IMPORTANT - Be sure to fill the swing motor with
Also, be sure to align the matching marks on valve hydraulic oil after installing it.
casing (3) and casing (43).

18. Install valve casing (3) onto casing (43). Tighten

valve casing (3) onto casing (43) using socket
bolts (4)(4 used).
: 17 mm
: 430 N m (44 kgf m, 320 lbf ft)

19. Insert poppets (5) (2 used) and springs (6)

(2 used) into valve casing (3). Tighten attached
plugs (8), O-ring (7).
: 14 mm
: 330 N m (34 kgf m, 245 lbf ft)

20. Install relief valves (14) (2 used) into valve casing

(3).
: 36 mm
: 175 Nm (18 kgf m, 130 lbf ft)
W2-6-30 EX255-EX285
EX285

SWING DEVICE

DISASSEMBLE SWING MOTOR (EX285)

1 2 3 4

9
10
11
12
13
5 6 7 8

14
44 15 19
16 33
34 31
17 45 32
18 30
38

27 46

35 43

36

37

39

40
41
42
47 SM5507

45
47
48

1 - Roller Bearing 10 - Spring (24 Used) 30 - Spring 40 -

Oil Seal
2 - O-Ring 11 - Brake Piston 31 - Retaining Ring 41 -
Seal Cover
3 - Valve Casing 12 - O-Ring 32 - Plate (3 Used) 42 -
Retaining Ring
(Brake Valve) 13 - Friction Plate (2 Used) 33 - O-Ring 43 -
Casing
4 - Socket Bolt (4 Used) 14 - Relief Valve (2 Used) 34 - Plunger (9 Used) 44 -
Retaining Ring
5 - Poppet (2 Used) 15 - Pin (2 Used) 35 - Retainer Plate 45 -
Spacer (3 Used)
6 - Spring (2 Used) 16 - Push Rod (12 Used) 36 - Thrust Plate 46 -
Parking Brake
7 - O-Ring (2 Used) 17 - Spacer 37 - Shaft (Output Shaft) Release Valve
8 - Plug (2 Used) 18 - Holder 38 - Spacer 47 - Retaining Ring (2 Used)
9 - Valve Plate 19 - Socket Bolt (3 Used) 39 - Roller Bearing 48 - O-Ring
EX255-EX285
EX285 W2-6-31

SWING DEVICE

Disassemble Swing Motor

• Be sure to thoroughly read “Precautions for Disas- 6. Remove valve casing (3) from casing (43).
sembly and Assembly” on page W1-1-1 before
starting the disassembly work.
NOTE - Valve plate (9) may be stuck on the bottom of
valve casing (3). Take care not to drop valve plate (9)
WARNING when removing valve casing (3).
Weight of swing motor assembly:
Approx. 70 kg (155 Ib)
7. If valve plate (9) has not been removed in the
previous step, remove it. Then, remove springs
1. Remove relief valves (14) (2 used) from valve (10) (24 used ).
casing (3).

NOTE - Never attempt to disassemble relief valves IMPORTANT - If a screwdriver or similar tool is used
(14). to separate (pry) valve plate (9) from the rotor side,
take care not to damage the sealing surfaces. (Note
: 36 mm that the top surface of the valve plate differs from the
bottom surface.)

2. Remove plugs (8) (2 used).

8. Apply two hooks to the notch A and pull the hooks
: 14 mm to remove brake piston (11).

3. Remove springs (6) (2 used) and poppets (5) (2 9. Remove O-rings (12), (33) from casing (43).
used).

4. Loosen socket bolts (19) to remove parking brake

release valve (46) from casing (43).
A
: 10 mm 11

43
5. Put align marks on valve casing (3) and casing
(43). Loosen and remove socket bolts (4) (4 used).
SM1028
: 17 mm

NOTE - Note that valve casing (3) will be raised by

springs (10) as socket bolts (4) are loosened.
W2-6-32 EX285
EX255-EX285

SWING DEVICE

1 2 3 4

9
10
11
12
13
5 6 7 8

14
44 15 19
16 33
34 31
17 45 32
18 30
38

27 46

35 43

36

37

39

40
41
42
47 SM5507

45
47
48
EX255-EX285
EX285 W2-6-33

SWING DEVICE

10. Lay casing (43) on its side. Pull out rotor (27) from
shaft (37). WARNING
Be sure to press and hold spacer (45) using a press
when removing retaining ring (31).
11. Remove plates (32) (3 used) and friction plates
Attempting to remove retaining ring (31) without
(13) (2 used) from casing (43).
pressing the spacer down may cause the spacer
and/or retaining ring (31) to spring up, possibly
resulting in personal injury.
12. Remove thrust plate (36).

19. Press and hold spacer (45) using a press, and

remove retaining ring (31).
13. Remove retaining ring (42) and seal cover (41)
from casing (43).
20. Remove spacer (45), spring (30), and spacer (38).

21. Remove the outer race of roller bearing (1), from

14. Remove oil seal (40) from seal cover (41).
valve casing (3), using a bearing puller.

15. Lay casing (43) on its side. Drive shaft (37) out of
casing (43) using a plastic hammer.

16. Remove retaining rings (44) and (47) (2 used).

Remove the outer race of roller bearing (39) from
casing (43) using a metal bar and a plastic ham-
mer.

17. Remove the inner races of roller bearings (39) and

(1), from shaft (37) using a press. Remove spacer
(45) from shaft (37).

18. Remove plungers (34) (9 used), retainer plate (35),

holder (18), spacer (17), push rods (16) (12 used)
from rotor (27).
W2-6-34 EX255-EX285
EX285

SWING DEVICE

ASSEMBLE SWING MOTOR (EX285)

3 44

1 9
31 15
45 11
2
12
10
33
30
38 13
32
19 27
46 18
34 35
16
17 36
47 43

45
39
48
41

37 40 42

6 4

5
14

SM5508

1 - Roller Bearing 11 - Brake Piston 31 - Retaining Ring 42 -

Retaining Ring
2 - O-Ring 12 - O-Ring 32 - Plate (4 Used) 43 -
Casing
3 - Valve Casing 13 - Friction Plate (2 Used) 33 - O-Ring 44 -
Retaining Ring
(Brake Valve) 14 - Relief Valve (2 Used) 34 - Plunger (9 Used) 45 -
Spacer (3 Used)
4 - Socket Bolt (4 Used) 15 - Pin (2 Used) 35 - Retainer Plate 46 -
Parking Brake
5 - Poppet (2 Used) 16 - Push Rod (12 Used) 36 - Thrust Plate Release Valve
6 - Spring (2 Used) 17 - Spacer 37 - Shaft (Output Shaft) 47 - Retaining Ring (2 Used)
7 - O-Ring (2 Used) 18 - Holder 38 - Spacer 48 - O-Ring
8 - Plug (2 Used) 19 - Socket Bolt (3 Used) 39 - Roller Bearing
9 - Valve Plate 27 - Rotor 40 - Oil Seal
10 - Spring (24 Used) 30 - Spring 41 - Seal Cover
EX255-EX285
EX285 W2-6-35

SWING DEVICE

Assemble Swing Motor

1. Install retaining ring (47) and spacer (45) onto
shaft (37).
Install the inner race of roller bearing (39) onto
shaft (37) using a press.
Install spacer (45) and retaining ring (47) onto
shaft (37).
11. Attach plungers (34) (9 used) on retainer plate (35).
Insert plungers (34) into rotor (27).
IMPORTANT - Be sure to apply a film of hydraulic oil
on the rotor bore surface before inserting plungers (34).

2. Install the inner race of roller bearing (1) onto shaft

(37) using a press. Install retaining ring (44) onto 12. Lay casing (43) on its side.
shaft (37). Install thrust plate (36) onto rotor (27). Install them
onto shaft (37).

IMPORTANT - Be sure that the lip part of oil seal (40)

faces upwards when installing it.
3. Install oil seal (40) onto seal cover (41) using a
protection plate and a press.
IMPORTANT - On each of plate (32) periphery is a
series of tab-like protrusions with four of the protru-
sions missing at an interval. Likewise, four teeth are
missing on each friction plate. When installing plates
(32) and friction plates (13), be sure to align these
missing parts.

4. Install the outer race of roller bearing (39) onto

casing (43) a metal bar and a hammer. 13. Stand casing (43) upright. Install plates (32)
(3 used) and friction plates (13) (2 used) one by one
alternately.

5. Lay casing (43) on its side. Install shaft (37) into

casing (43). 14. Install O-rings (12) and (33) on casing (43).

6. Stand casing (43) upright. Install O-ring (48) into
casing (43).
7. Install seal cover (41) into casing (43). Secure
with retaining ring (42).
15. Install brake piston (11) into casing (43). If brake
piston (11) does not enter the casing smoothly due
to the installation of the O-rings above, tap the
periphery of the brake piston evenly with a plastic
hammer.

8. Install spacer (38), spring (30), and spacer (45) 16. Install spring (10) (24 used ) on brake piston (11).
into rotor (27), in that order.

9. Press down spacer (45) to give enough clearance

for retaining ring (31) installation. Install retaining
ring (31).

10. Insert push rods (16) (12 used) into rotor (27).
Install spacer (17) and holder (18) onto rotor (27),
in that order.
W2-6-36 EX285
EX255-EX285

SWING DEVICE

3 44

1 9
31 15
45 11
2
12
10
33
30
38 13
32
19 27
46 18
34 35
16
17 36
47 43

45
39
48
41

37 40 42

6 4

5
14

SM5508

8
EX255-EX285
EX285 W2-6-37

SWING DEVICE

22. Install parking brake release valve (46) onto cas-

IMPORTANT - Be sure that the model stamped end of
ing (43) using socket bolts (19) (3 used).
roller bearing faces upwards when installing.
: 10 mm
: 9.8 N m (1 kgf m, 2 lbf ft)
17. Install the outer race of roller bearing (1) into valve
casing (3) using a plastic hammer.

IMPORTANT - Be sure to fill the swing motor with

hydraulic oil after installing it.
18. Install O-ring (2) and valve plate (9) on valve
casing (3).

NOTE - Be sure to apply grease to the contact surface

of valve plate (9) so as to prevent it from dropping when
installing valve casing (3) onto the casing.

IMPORTANT - Take care not to drop valve plate (9).

Also, be sure to align the matching marks on valve
casing (3) and casing (43).

19. Install valve casing (3) onto casing (43). Tighten

valve casing (3) onto casing (43) using socket
bolts (4)(4 used).
: 17 mm
: 430 N m (44 kgf m, 320 lbf ft)

20. Insert poppets (5) (2 used) and springs (6)

(2 used) into valve casing (3). Tighten attached
plug (8) O-ring (7).
: 14 mm
: 330 N m (34 kgf m, 245 lbf ft)

21. Install relief valves (14) (2 used) into valve casing

(3).
: 36 mm
: 175 Nm (18 kgf m, 130 lbf ft)
W2-6-38 EX285
EX255-EX285

SWING DEVICE

DISASSEMBLE AND ASSEMBLE

PARKING BRAKE RELEASE VALVE (EX285)

40 34 39 41

38 33
37
42
36
32
35

31 43
SM5106

31 - Housing 36 - Filter 41 - O-Ring (2 Used)

32 - Spool 37 - Spacer 42 - Steel Ball
33 - Spring 38 - Orifice 43 - Bolt (3 Used)
34 - Plunger 39 - Spring
35 - Bushing 40 - O-Ring
EX255-EX285 W2-6-39

SWING DEVICE

MAINTENANCE STANDARD

Swing motor

1. Plunger and rotor bore clearance (d, D) d

Unit: mm (in)
Standard Clearance Allowable Limit
EX255 0.027 (0.00106) 0.052 (0.00205)
EX285 0.032 (0.00126) 0.062 (0.00244) SM1030

D D

SM1031

2. Plunger and shoe clearance (a)

Unit: mm (in)
Standard Clearance Allowable Limit
0 0.3 (0.012)

SM1032

SM1033
W2-6-40 EX255-EX285

SWING DEVICE

3. Thickness of shoe (t)

Unit: mm (in)
Standard Clearance Allowable Limit
EX255 5.5 (0.216) 5.3 (0.209)
EX285 6.0 (0.236) 5.8 (0.228)
t

SM1034

4. Thickness of friction plate

Unit: mm (in)
Standard Clearance Allowable Limit
EX255 1.8 (0.071) 1.6 (0.063)
EX285 4 (0.157) 3.6 (0.142) SM1035

5. Total clearance of retainer plate (1) and holder (2): 2

(H - h) 1
Unit: mm (in)
Standard Clearance Allowable Limit
EX255 5.5 (0.216) 5.0 (0.197)
EX285 7.0 (0.276) 6.5 (0.256)
h H
If the dimension is reduced to below allowable limit,
SM1036
replace retainer plate (1) and holder (2).
EX255-EX285 W2-7-1

PILOT VALVE

REMOVE AND INSTALL RIGHT PILOT VALVE

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface. 2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.

Removal
1 2 3
1. Loosen screws (6) (2 used), (1) (2 used) and (5) (2 4
used) to remove cover (7) and frame (2).
Loosen screws (4) (4 used) to dislocate boot (3). 5

7
SM1105

2. Confirm that the console is in the forefront position.

If not, position the console in the forefront position.
Loosen bolts (8) (2 used) to disconnect the joints.
Raise stand (9).
: 17 mm

8 9 SM1106

3. Remove screws (10) and (12). Dislocate cover (11)

to the right.

10

11

12 SM1107
W2-7-2 EX255-EX285

PILOT VALVE

4. Loosen screw joint (13) to remove the lever.

: 24 mm

IMPORTANT - Attach an identification tag on each 13 14

hose to aid in reassembly.

5. Disconnect hoses (15) to (20).

: 22 mm
15
NOTE - Attach a cap on each of disconnected hose
16
ends.
17
6. Loosen bolts (14) to remove the pilot valve.
: 13 mm

15 - Hose H : (To the bucket roll-out section in the control

valve)
16 - Hose P3 : (From the pilot control shut-off valve)
17 - Hose A : (To the boom raise section in the control
valve)
18 - Hose G : (To the bucket roll-in section in the control
valve)
20 19 18 SM1108
19 - Hose T6 : (To the hydraulic oil tank)
20 - Hose B : (To the boom lower section in the control
valve)

Installation

1. Mount the pilot valve using bolts (14).

13 14
: 13 mm
: 9.8 N m (1.0 kgf m, 7.2 lbf ft)

2. Connect hoses (15) to (20).

: 22 mm 15
: 39 N m (4.0 kgf m, 29 lbf ft)
16

3. Attach the lever. Tighten screw joint (13) to secure 17

the lever.
: 24 mm
: 88 N m (9.0 kgf m, 65 lbf ft)

15 - Hose H : (To the bucket roll-out section in the control

valve)
16 - Hose P3 : (From the pilot control shut-off valve)
17 - Hose A : (To the boom raise section in the control valve)
18 - Hose G : (To the bucket roll-in section in the control valve)
20 19 18 SM1108

19 - Hose T6 : (To the hydraulic oil tank)

20 - Hose B : (To the boom lower section in the control valve)
EX255-EX285 W2-7-3

PILOT VALVE

4. Install cover (11) using screws (10) and (12).

10

11

12 SM1107

5. Secure stand (9) using bolts (8) (2 used).

: 17 mm
: 49 N m (5.0 kgf m, 36 lbf ft)

8 9 SM1106

1 2 3
6. Install frame (2) using screws (1) (2 used) and
screws (5) (2 used). 4
Install cover (7) using screws (6) (2 used).
Set the boot in position, and secure it using screws 5
(4) (4 used).

IMPORTANT - After completing installation: 7

Check hydraulic oil level. Add oil if necessary. Run the SM1105
engine. Check the components for any oil leakage.
W2-7-4 EX255-EX285

PILOT VALVE

REMOVE AND INSTALL LEFT PILOT VALVE

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface. 2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.

Removal
3
1. Loosen screw (2) (2 used), to remove cover (1).
Loosen screws (4) (4 used) to dislocate boot (3). 4

2
1

SM5515
2. Remove pad (13).To remove pad, disengage the
13 14
two latches while pressing and pushing pad (13) in
the direction indicated by arrow. Then, slide the pad
to the opposite of the direction indicated by arrow
to remove it. 15
16
➡
3. Loosen screws (15) (2 used) and screws (16) 16
(2 used) to remove cover (14).

SM1109

4. Confirm that the console is in the forefront position.

If not, position the console in the forefront position.
Loosen bolts (8) (2 used) to disconnect the joints.
Raise stand (9).
: 17 mm

8 9 SM1106
EX255-EX285 W2-7-5

PILOT VALVE

5. Loosen screws (10) and (12) to dislocate cover (11)

to the right.
10

11

12 SM1107
6. Loosen screw joint (17) to remove the lever.
17 18
: 24 mm

IMPORTANT - Attach an identification tag on each

hose to aid in reassembly. 19

7. Disconnect hoses (19) to (24). 20

: 22 mm
21
NOTE - Attach a cap on each of the disconnected hose
ends.

8. Loosen bolts (18) to remove the pilot valve.

: 13 mm

19 - Hose D : (To the right swing section in the control valve)

20 - Hose P2 : (From the pilot control shut-off valve)
21 - Hose E : (To the arm roll-in section in the control valve)
22 - Hose C : (To the left swing section in the control valve) SM1110
23 - Hose T5 : (To the hydraulic oil tank)
24 - Hose F : (To the arm roll-out section in the control valve) 24 23 22

Installation 17 18

1. Mount the pilot valve using bolts (18).

: 13 mm
: 9.8 N m (1.0 kgf m, 7 lbf ft) 19

2. Connect hoses (19) to (24). 20

: 22 mm
21
: 39 N m (4.0 kgf m, 29 lbf ft)

3. Attach the lever. Tighten screw joint (17) to secure

the lever.
: 24 mm
: 88 N m (9.0 kgf m, 65 lbf ft)

19 - Hose D : (To the right swing section in the control valve)

20 - Hose P2 : (From the pilot control shut-off valve)
21 - Hose E : (To the arm roll-in section in the control valve)
22 - Hose C : (To the left swing section in the control valve) SM1110
23 - Hose T5 : (To the hydraulic oil tank) 24 23 22
24 - Hose F : (To the arm roll-out section in the control valve)
W2-7-6 EX255-EX285

PILOT VALVE

4. Install cover (11) using screws (10) and (12).

10

11

12 SM1107

5. Secure stand (9) using bolts (8) (2 used).

: 17 mm
: 49 N m (5.0 kgf m, 36 lbf ft)

8 9 SM1106

6. Install cover (14) using screws (15) (2 used) and

screws (16) (2 used). 13 14

7. Install pad (13) on cover (14).

16 15

16

SM1109

8. Set boot (3) in position, and secure it using screws 3

(4) (4 used).
4

9. Install cover (1) using screws (2) (2 used).

2
IMPORTANT - After completing installation: 1
Check hydraulic oil level. Add oil if necessary. Run the
SM5515
engine. Check the components for any oil leakage.
EX255-EX285 W2-7-7

PILOT VALVE

REMOVE AND INSTALL TRAVEL PILOT VALVE

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface. 2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.

Removal
IMPORTANT - After completing installation:
Check hydraulic oil level. Add oil if necessary. Run the
1. Loosen bolt (2) to remove pedal (1).
engine. Check the components for any oil leakage.
: 17 mm

IMPORTANT - Attach an identification tag on each

hose to aid in reassembly.

2. Disconnect hoses (3) to (8).

: 22 mm

NOTE - Attach a cap on each of disconnected hose

ends. 1

3. Loosen bolts (9) to remove the pilot valve.

: 17 mm 2

Installation 3

1. Mount the pilot valve using bolts (9). 8 4

: 17 mm
9
: 49 Nm (5.0 kgf m, 36 lbf ft)
7
5
6
SM1111
2. Connect hoses (3) to (8).
: 22 mm 3 - Hose 12: (To the right reverse travel section in the control
valve)
: 39 N m (4.0 kgf m, 29 lbf ft)
4 - Hose 10: (To the left reverse travel section in the control
valve)
5 - Hose P1: (From the pilot control shut-off valve)
3. Mount pedal (1) using bolts (2). 6 - Hose 9 : (To the left forward section in the control valve)
7 - Hose 11: (To the right forw. section in the control valve)
: 17 mm 8 - Hose T4 : To the hydraulic oil tank

: 49 N m (5.0 kgf m, 36 lbf ft)

W2-7-8 EX255-EX285

PILOT VALVE

DISASSEMBLE RIGHT AND LEFT PILOT VALVE

1
25

23
24 2

22
21
21 3
20
20
19

19 4
18
18

5 5
17 6
6

7
12

11 8
16

10 9
15

14

13

SM1112

1 - Screw Joint 10 - Spring Guide B (2 Used) 19 - Spool (4 Used)

2 - Cam 11 - Pusher B (2 Used) 20 - Spacer (4 Used)
3 - Universal Joint 12 - Bushing B (2 Used) 21 - Shim (20 Used)
4 - Plate 13 - Socket Bolt 22 - Return Spring A (2 Used)
5 - Oil Seal (4 Used) 14 - Plate 23 - Balance Spring A (2 Used)
6 - O-Ring (4 Used) 15 - O-Ring 24 - Return Spring B (2 Used)
7 - Bushing A (2 Used) 16 - Seal Washer 25 - Balance Spring B (2 Used)
8 - Pusher A (2 Used) 17 - Casing
9 - Spring Guide A (2 Used) 18 - Piston (4 Used)
EX255-EX285 W2-7-9

PILOT VALVE

Disassemble Right and Left Pilot Valve

• Be sure to thoroughly read “Precautions for Disas- 10. Remove spools (19) (4 used) from casing (17).
sembly and Assembly” on page W1-1-1 before
starting the disassembly work. 11. Compress balance spring A (23) or B (25) to
• As casing (17) and spools (19) are precision parts remove spacers (20) from each spool (19).
specially made to fit each other, they must be Remove balance spring A (23) or B (25) and shims
replaced as a set. Do not attempt to replace these (21) from each spool (19).
parts individually.
• Note that return spring A (22) and balance spring 12. Remove spring guide A (9) or B (10), and return
A (23), which are used in ports 1 and 3, differ from spring A (22) or B (24) from each seat.
return spring B (24) and balance spring B (25),
which are used in ports 2 and 4.
• For this reason, be sure to indicate the port number
from which it is removed. Port numbers are
stamped on casing (17).

1. Remove screw joint (1) and cam (2).

: 19 mm, 32 mm

2. Temporarily tighten plate (4) using two bolts (M8,

Pitch 1.25). Loosen universal joint (3) to remove it
from casing (17).

3. Turn over casing (17) and place it in a vise.

Remove socket bolt (13).

: 10 mm

4. Pull out plate (14) using a pulling bolt (M16, Pitch

2). Remove O-ring (15) from the plate. Remove
seal washer (16) from casing (17).

5. Remove piston (18) from spool (19) in each port. 75301512

(Four pistons in total)

6. Turn over casing (17). Attach special tool

(75301512) to the universal joint connecting hole. 4
Tighten plate (4) using the special tool.
17
7. Remove the bolts (2 used) temporarily installed in
the step 2. Gradually loosen the special tool until
pushers A (8), B (11) and plate (4) are fully raised,
unloading spring compresssion. SM1113

8. Remove plate (4) and pushers A (8), B (11) from

casing (17).

9. Remove pusher A (8), O-ring (6), and oil seal (5)

from each bushing A (7). Remove pusher B (11),
O-ring (6), and oil seal (5) from each bushing B
(12).
W2-7-10 EX255-EX285

PILOT VALVE

ASSEMBLE RIGHT AND LEFT PILOT VALVE

1
11
2

8
12

4 7

20 6

10
9
25
23
24
22
21

19

17

18

13 14 16 15
SM5516

1 - Screw Joint 10 - Spring Guide B (2 Used) 19 - Spool (4 Used)

2 - Cam 11 - Pusher B (2 Used) 20 - Spacer (4 Used)
3 - Universal Joint 12 - Bushing B (2 Used) 21 - Shim (20 Used)
4 - Plate 13 - Socket Bolt 22 - Return Spring A (2 Used)
5 - Oil Seal (4 Used) 14 - Plate 23 - Balance Spring A (2 Used)
6 - O-Ring (4 Used) 15 - O-Ring 24 - Return Spring B (2 Used)
7 - Bushing A (2 Used) 16 - Seal Washer 25 - Balance Spring B (2 Used)
8 - Pusher A (2 Used) 17 - Casing
9 - Spring Guide A (2 Used) 18 - Piston (4 Used)
EX255-EX285 W2-7-11

PILOT VALVE

Assemble Right and Left Pilot Valve

1. Insert special tool (75301504) into each port on

casing (17). Be sure to insert the smaller end of the
special tool first.

IMPORTANT - The number of shims (21) has been

determined during the perfomance test at the factory.
Take care not lose them. Install spacer (20) with its
concave side facing the spring.

2. Install shims (21) (20 used) and balance spring A

(23) (2 used) or B (25) (2 used) onto each spool (19) SM1115
75301504
(4 used). While compressing balance spring A (23)
(2 used) or B (25) (2 used), insert spacer (20) (4
used) onto the neck part of each spool (19) (4
used).

IMPORTANT - Install spring guide A (9) or B (10) with

its concave side facing the spring.

3. Install spring guide A (9) (2 used) or B (10)

(2 used) and return spring A (22) (2 used) or B (24)
(2 used) onto each spool (19) (4 used).

IMPORTANT - Be sure to confirm the applicable port

number for each spool (19) before inserting.

4. Insert spools (19) into casing (17).

5. Install oil seal (5) (4 used) and O-ring (6) (4 used)

onto each bushing A (7) (2 used) or B (12)
(2 used). Insert pusher A (8) (2 used) or B (11)
(2 used) into each bushing A (7) or B (12), respec-
tively.

Oil Seal Driving Tool: 75301503 75301512

6. Put each of the pusher assemblies onto the re-

spective spool assembly.

7. Install plate (4) on bushings A (7) and B (12). Install

special tool (75301512) into the universal joint
connecting hole on casing (17).

8. Gradually tighten the special tool until the bottom

of bushings A (7) and B (12) is flush with the top
surface of casing (17). Remove special tool
(75301504) from each casing port.
SM1116
9. Temporarily secure plate (4) using two bolts (M8,
Pitch 1.25). Remove special tool (75301512).
W2-7-12 EX255-EX285

PILOT VALVE

1
11
2

19

17

18

13 14 16 15
SM1114
EX255-EX285 W2-7-13

PILOT VALVE

10. Insert piston (18) into each spool (19), with the
smaller end first.

11. Install seal washer (16) on casing (17).

Install O-ring (15) onto plate (14).

12. Secure plate (4) onto casing (17) using socket bolt
(13).
: 10 mm
: 49 N m (5 kgf m, 36 lbf ft)

13. Turn over casing (17). Apply LOCTITE 262 to

universal joint (3). Install universal joint (3) into
casing (17).
: 17 mm
: 24.5 N m (2.5 kg m, 18.1 lbf ft)

14. Sufficiently apply grease to the joint part of univer-

sal joint without giving any air gaps. Apply grease
to the top of pushers A (8) (2 used) and B (11) (2
used).

15. Install cam (2) onto universal joint (3).

16. Tighten screw joint (1) while keeping the clearance

between pushers A (8) and B (11) and cam (2) to
0 to 0.2 mm (0 to 0.008 in).
Remove the two temporarily installed bolts.

Filler Gauge
: 17 mm, 32 mm
: 69 to 88 N m
(7 to 9 kgf m, 50 to 65 lbf ft)
W2-7-14 EX255-EX285

PILOT VALVE

DISASSEMBLE TRAVEL PILOT VALVE

10 5
24
11
8
10 23

22

21

6 20
8
7 19

17

16
9
18

15

14

25

13

12

SM1117

1 - Cover 10 - Bushing (2 Used) 19 - Balance Spring (4 Used)

2 - Sems Bolt (2 Used) 11 - Bushing (2 Used) 20 - Spring Guide (4 Used)
3 - Spring Pin (2 Used) 12 - Plug 21 - Pusher (4 Used)
4 - Spring Pin (2 Used) 13 - O-Ring 22 - Bushing (4 Used)
5 - Cam (2 Used) 14 - Casing 23 - O-Ring (4 Used)
6 - Socket Bolt (2 Used) 15 - Spool (4 Used) 24 - Oil seal (4 Used)
7 - Spring Washer (2 Used) 16 - Spacer (4 Used) 25 - Plate
8 - Pin (2 Used) 17 - Shim
9 - Holder 18 - Return Spring (4 Used)
EX255-EX285 W2-7-15

PILOT VALVE

Disassemble Travel Pilot Valve

• Be sure to thoroughly read “Precautions for Dis-

assembly and Assembly” on page W1-1-1 before
starting the disassembly work.
• As casing (14) and spools (15) are precision parts
specially made to fit each other, they must be
replaced as a set. Do not attempt to replace these
parts individually.

1. Remove sems bolts (2) (2 used) to remove cover

(1) from holder (9).
: 10 mm

2. Turn over casing (14), and put it in a vise. Remove

plug (12) from casing (14). Remove O-ring (13)
from plug (12).
75301513
3. Turn over casing (16), and put it in a vise. Remove
one of two socket bolts (6). Install special tool
(75301513) into the bolt hole.
: 8 mm

4. Remove the other socket bolt (6). Install special

tool (75301513) into the bolt hole.
: 8 mm

5. Loosen (operate) both special tools (75301513) SM1118

evenly at the same time. Remove holder (9) from
casing (14).

6. Put holder (9) in a vise. Remove spring pins (3) (2

Used) and (4) (2 Used) using special tool
(75301487).

7. Remove pin (8) (2 Used) and cam (5) (2 Used)

from holder (9). Do not remove bushings (10) and
(11) unless they are damaged.

8. Remove the pusher assemblies (4 Used). Re-

move pusher (21), O-ring (23), oil seal (24), from
each bushing (22).

9. Remove spools (15) (4 used) from casing (14).

10. Compress balance spring (19) to remove spring

guide (20) from each spool (15). Remove balance
spring (19), shims (17) and spacers (16) from
each spool (15). Remove return spring (18) from
each port.
W2-7-16 EX255-EX285

PILOT VALVE

ASSEMBLE TRAVEL PILOT VALVE

8 10 11 6-7 1 3-4 5 9

21

24

22

23
25
20
14
19

18

17

16

15

SM1119
12-13

1 - Cover (2 Used) 10 - Bushing (2 Used) 19 - Balance Spring (4 Used)

2 - Sems Bolt (2 Used) 11 - Bushing (2 Used) 20 - Spring Guide (4 Used)
3 - Spring Pin (2 Used) 12 - Plug 21 - Pusher (4 Used)
4 - Spring Pin (2 Used) 13 - O-ring 22 - Bushing (4 Used)
5 - Cam (2 Used) 14 - Casing 23 - O-ring (4 Used)
6 - Socket Bolt (2 Used) 15 - Spool (4 Used) 24 - Oil seal (4 Used)
7 - Spring Washer (2 Used) 16 - Spacer (4 Used) 25 - Plate
8 - Pin (2 Used) 17 - Shim
9 - Holder 18 - Return Spring (4 Used)
EX255-EX285 W2-7-17

PILOT VALVE

Assemble Travel Pilot Valve

IMPORTANT - The number of shims (17) has been

determined during the perfomance test at the factory.
Take care not lose them. Install spring guide (20) with
its concave side facing the spring.

1. Attach shims (17) spacer (16) (4 used) and balance

spring (19) (4 used) onto each spool (15) (4 used).
While compressing balance spring (19), insert
spring guide (20) (4 used) onto the neck part of each
spool (15).

2. Turn over casing (14), and clamp with a vise.

3. Install O-ring (13) onto plug (12), and install plugs

(12) onto casing (14).
: 8 mm
: 34 N m (3,5 kgf m, 25 lbf ft)

4. Turn over casing (14) and clamp with a vise. Insert

return springs (18) (4 used) into casing (14).

IMPORTANT - Be sure to confirm the applicable port

number for each spool (15) before inserting.

5. Insert spool (15) (4 used) assemblies into casing

(14).

6. Install oil seal (24) and O-ring (23) onto each

bushing (22). Insert pusher (21) into of each bush-
ing (22) (4 used).

7. Put each of the pusher (21) assemblies onto the

respective spool (15) (4 used) assembly.
75301513
8. Install holder (9) on the pusher (21) (4 used)
assembly. Install special tools (75301513) (2 used)
into the bolt holes on casing (14).

9. Gradually tighten the special tools until the bottom

of bushings (22) is flush with the top surface of
casing (14).

SM1120
W2-7-18 EX255-EX285

PILOT VALVE

8 6-7 1 3-4 5 9

21

SM1119
EX255-EX285 W2-7-19

PILOT VALVE

10. Remove one of special tools (75301513). Tem-

porarily tighten spring washer (7) and socket bolt 75301513
(6).

11. Remove the other special tool (75301513). Tem-

porarily tighten the other spring washer (7) and
socket bolt (6). Tighten both socket bolts (6) (2
used) to specification.
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)

IMPORTANT - When inserting pin (8), the spring pin

hole nearer to the pin end must be facing outerwards. SM1121

12. Apply grease to the top of pushers (21) (4 used).

Place cam (5) (2 used) on holder (9), aligning the
pin holes. Insert pin (8) (2 used) into the pin hole.

IMPORTANT - Be sure to drive spring pins (3) and (4)

until they extrude approx. 3 mm (0.12 in) down from the
bottom of cam (5). Then, mushroom the spring pin
ends at the top of the cam to prevent them from coming
out.

13. Insert spring pins (3) and (4) using special tool
(75301487).

14. Install cover (1) onto holder (9) using sems bolts
(2) (2 used).
: 10 mm
: 2 N m (0.2 kgf m, 1.5 lbf ft)
W2-7-20 EX255-EX285

PILOT VALVE

POSITIONING PILOT VALVE

(triple articulation version)

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface. 2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.

Removal

1. Loosen bolts (2) to remove pedal (1).

IMPORTANT - After completing installation:
: 17 mm Check hydraulic oil level. Add oil if necessary. Run
the engine. Check the components for any oil
IMPORTANT - Attach an identification tag on each leakage.
hose to aid in reassembly.

2. Disconnect hoses (4) to (7).

: 22 mm

NOTE - Attach a cap on each of disconnected hose

ends.

3. Loosen bolts to remove the pilot valve (3).

: 17 mm

Installation

1. Mount the pilot valve (3) using bolts.

: 17 mm
: 44 N m (5.0 kgf m, 36 lbf ft)

SM3520
2. Connect hoses (4) to (7).
: 22 mm
: 39 N m (4.0 kgf m, 29 lbf ft) 4 (Hose T7) - To hydraulic oil tank
5 (Hose H) - To connection upper extra control valve
6 (Hose I) - To connection lower extra control valve
7 (Hose R4) - From hydraulic oil tank
3. Mount pedal (1) using bolts (2).
: 17 mm
: 49 N m (5.0 kgf m, 36 lbf ft)
EX255-EX285 W2-7-21

PILOT VALVE

11B
11C 35

11 11A

11E

11D 31

13 30

2 29

27
1
39 28
6

5 25
38

15
24
40

37
36
16
17
SM3521

1 - Return spring 11C- O-Ring 24 - Plate 35 - Screw

2 - Balance spring 11D- Piston 25 - Socket Bolt 36 - Plug
5 - Spacer 11E - Oil seal 27 - Cam 37 - O-Ring
6 - Shim 13 - Spring guide 28 - Pin 38 - Spool
11 - Tappet 15 - Plunger 29 - Spring pin 39 - Bushing
11A- Bushing 16 - O-Ring 30 - Spring pin 40 - Body
11B- Dust seal 17 - Plug 31 - Cover
W2-7-22 EX255-EX285

PILOT VALVE

Disassemble positioning pilot valve

1. Remove the two screw (35) and cover (31).

35

31

SM3523

2. Remove plug (17) and (36) and extract O-rings (16)

and (37).

37

36

16

17
SM3524

3. Remove plunger (15).

15
SM5518
EX255-EX285 W2-7-23

PILOT VALVE

4. Pull-out the two spring pins (29) and (30), pin (28) 30
and remove cam (27), bushings (39) and plate (24). 29

27

39 28

24
5. Remove one of the socket bolt (25) from the valve SM3526
body, and install tool 75298319 in the valve body.

6. Remove the other socket bolt (25) and install

another tool 75298319 in the valve body.
25
7. Loosen progressively the two tools 75298319 until
the force of the springs is neutralized.

24
SM3527

8. Remove the two tools 75298319 from the valve 75298319

body.

SM3528
W2-7-24 EX255-EX285

PILOT VALVE

9. Extract the two tappet assemblies (11).

Separate piston (11D) from bushing (11A).

11A

11D

SM3529

10. Remove O-ring (11C) from bushing (11A).

11C

11A

SM3530

11. Remove dust seal (11B). 11B

11A

SM3531

12. Remove oil seal (11E).

11A

11E
SM3532
EX255-EX285 W2-7-25

PILOT VALVE

13. Remove the two spool assemblies.

Remove spacer (5) from spool (38) pushing on
balance spring (2).
5 2

38

SM3533

14. Pull-out balance spring (2) and shims (6) from

spool (38).
2

38

SM3534

15. Remove spring guide (13) and return spring (1)

from seat. 13

40

SM3537
W2-7-26 EX255-EX285

PILOT VALVE

Assemble positioning pilot valve

1. Clean all components and lubricate with clean

hydraulic oil all inner parts.

SM3535

2. Insert shims (6) and balance spring (2) into spool

(38).
2

NOTE - The quantity of shims is established during the 6

performance test.

38

SM3534

3. Will pressing spring (2) insert spacer (5).

5 2
NOTE - Make sure that the spacer is positioned with
the spring seat toward the spring.

SM5517

4. Mount tool 75298321 in the two lower holes of the

valve body.

75298321
SM3536
EX255-EX285 W2-7-27

PILOT VALVE

5. Insert return spring (1) and spring guide (13) into

body (40). 13

NOTE - Make sure that the spring seat is positioned

toward the spring. 1

40

SM3537

6. Insert the spool assemblies into spring guide (13).

NOTE - Insert the single assemblies making reference to

the cylinder number.
13

SM3538

7. Position dust seal (11B) in bushing (11A) with 75298322

some grease, using tool 75298322.

11B

11A

SM3539

8. Position oil seal (11E) in bushing (11A).

11A

11E

SM3532
W2-7-28 EX255-EX285

PILOT VALVE

9. Mount O-ring (11C) in bushing (11A).

11C

11A

SM3530

10. Insert piston (11D) into bushing (11A) from the oil
seal side (11E).

11A
NOTE - Smear some grease inside the bushing.

11D

SM3529

11. Position the two tappet assemblies into their 75298319

seats, install plate (24) and mount the two tools
75298319 in the valve body. 24

Tighten the two tools until the lower surface of the

bush is in line with the upper surface of the valve
body.

SM3528
EX255-EX285 W2-7-29

PILOT VALVE

12. Remove tool 75298319 from the left side and 75298319
temporary tighten socket bolt (25).
25

SM3541

13. Remove other tool 75298319 and temporary

tighten other socket bolt (25). 25
Tightening both socket bolts (25).

Tightening torque: 39 N m (4 kgf m, 29 lbf ft).

SM3542

14. Remove the two tools 75298321 from the bottom

of the valve body.

75298321
SM3540
W2-7-30 EX255-EX285

PILOT VALVE

15. Lock the valve body into a vise and insert plunger
(15).

15
SM5518

16. Position O-rings (37) and (16) on plugs (36) and

(17).

37

36

16
17. Install plugs (36) and (17).
17
SM3524
Tightening torque: 49 N m (5 kgf m, 36 lbf ft)

35
18. Install cover (31) using screw (35).

31

SM3523
EX255-EX285 W2-7-31

PILOT VALVE

SPECIAL TOOLS

Special Tools for Right and Left Pilot Valve 2

1

SM5519

ITEM Tools No. Tool Name Remarks

2 75301504 Guide for assembling plate For assembling spools and holder

1 75301512 Valve holder For disassembling and assembling plate

Special Tools for Travel Pilot Valve

SM1123 SM1124

ITEM Tools No. Tool Name Remarks

1 75301513 Valve holder assembly For disassembling and assembling valve

2 75301487 Spring pin driving guide For tapping in/out spring pin

Special tools for Positioning Pilot Valve (Triple articulation version):

ITEM Tools No. Tool Name Remarks

1 75298319 Valve holder assembly For disassembling and assembling valve

2 75298321 Spring pin driving guide (q.ty 4) For tapping in/out spring pin

3 75298322 Inserting tool For inserting dust seal

W2-7-32 EX255-EX285

PILOT VALVE

NOTES:
EX255-EX285 W2-8-1

PILOT SHUT-OFF VALVE

REMOVE AND INSTALL PILOT SHUT-OFF VALVE

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure
to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal

1. Remove the outer panel located under the driver's

compartment, by removing the six securing 1 2 3
screws.
: 17 mm
5
2. Remove ball joint (10).
: 13 mm

NOTE - Attach labels or tags to hoses and pipes, to aid

in assembly. 11

3. Disconnect pilot hoses (1 to 9).

: 17, 19, 22 mm

4. Remove bolts (11) to remove the pilot shut-off

valve. 4
: 8 mm

Installation
SM1311

1. Install the pilot shut-off valve using bolts (11). 10 9 8 7 6

2. Connect pilot hoses (1 to 9).
3. Install ball joint (10).
1 - Hose P2 : (To Swing and Arm Pilot Valve)
2 - Hose P1 : (To Travel Left and Right Pilot Valve)
4. Install the outer panel.
3 - Hose P3 : (To Boom and Bucket Pilot Valve)
4 - Hose T6 : (From Bucket and Boom Pilot Valve)
Wrench size Tightening Torque Remark 5 - Hose DP : (To Solenoid Valve Unit)
(mm) N m kgf m lbf ft 6 - Hose PF : (From Pilot Relief Valve)
7 - Hose T5 : (From Swing and Arm Pilot Valve)
: 13 10 1 7 Nut 8 - Hose T4 : (From Travel Left and Right Pilot Valve)
9 - Hose A4 : (To Shockless Valve)
: 22 39 4 29 Hoses 10 - Ball Joint
11 - Bolt
:8 20 2 15 Bolt
: 17 49 5 36 Bolt
: 19 29 3 22 Hoses
W2-8-2 EX255-EX285

PILOT SHUT-OFF VALVE

DISASSEMBLE PILOT SHUT-OFF VALVE

1
2
3
4

5
6
7
8

14
13
12

11

10
SM1312

1 - Retaining Ring 5 - O-Ring 9 - Spring Pin 13 - Steel Ball

2 - Washer 6 - Backup Ring 10 - Lever 14 - Body
3 - Backup Ring 7 - Washer 11 - Spool
4 - O-Ring 8 - Retaining Ring 12 - Socket Bolt
EX255-EX285 W2-8-3

PILOT SHUT-OFF VALVE

Disassemble Pilot Shut-Off Valve

• Before disassembling, be sure to read and under-

stand all the "Precautions for Disassembly and
Assembly" on page W1-1-1.

1. Remove retaining ring (1) and washer (2) and

pull out spool (11).

NOTE - Mark spool (11) and lever (10) for alignment

when installing.

2. Pull out spring pin (9) from spool (11), and

remove lever (10).

3. Remove washer (7) and retaining ring (8) from

spool (11).

4. Remove backup ring (3), (6) and O-ring (4), (5)

from body (14).

5. Loosen socket bolt (12) from body (14).

: 6 mm
W2-8-4 EX255-EX285

PILOT SHUT-OFF VALVE

ASSEMBLE PILOT SHUT-OFF VALVE

SM1313

1 - Retaining Ring 5 - O-Ring 9 - Spring Pin 13 - Steel Ball

2 - Washer 6 - Backup Ring 10 - Lever 14 - Body
3 - Backup Ring 7 - Washer 11 - Spool
4 - O-Ring 8 - Retaining Ring 12 - Socket Bolt
EX255-EX285 W2-8-5

PILOT SHUT-OFF VALVE

Assemble Pilot Shut-Off Valve

IMPORTANT - Apply a film of grease to O-rings (4) and

(5), and backup rings (3) and (6).

1. Install O-rings (4) and (5), backup rings (3) and (6)
to body (14).

2. Install washer (7) and retaining ring (8) to spool (11).

3. Drive spring pin (9) alignmenting spool (11) and

lever (10). (Alignment marks made when disas-
sembling.)

IMPORTANT - Be sure to apply a film of hydraulic oil

to spool (11).

4. Install spool (11) to body (14).

5. Install washer (2) and retaining ring (1) to spool (11).

6. Install and tighten socket bolt (12).

: 6 mm
: 44 N m (4.5 kgf m, 33 lbf ft)
W2-8-6 EX255-EX285

PILOT SHUT-OFF VALVE

NOTES:
EX255-EX285 W2-9-1

SHOCKLESS VALVE

REMOVE AND INSTALL SHOCKLESS VALVE

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal Installation

IMPORTANT - Attach labels or tags to hoses to aid in 1. Apply LOCTITE to bolts (10), then install
assembly. shockless valve with bolts (10).

1. Disconnect hoses (1 to 9, 13 to 20). 2. Install pressure switch (11) and pressure sensor
(12).
: 19, 22 mm
3. Connect hoses (1 to 9, 13 to 20).
2. Remove pressure switch (11) and pressure sensor
(12). Wrench Tightening
Size Torque Remark
: 24 mm
(mm) Nm kgf m lbf ft

3. Remove bolts (10) to remove shockless valve. : 17 20 2 14.5 Bolt

: 17 mm : 19 29 3 21.7 Hose
: 22 39 4 29 Hose
Pressure sensor
: 24 78 8 58
and Switch

1 - Hose (To left swing control valve)

2 - Hose (To right swing control valve) 19 20
18
3 - Hose (To bucket roll-out control valve) 17 11
4 - Hose (To bucket roll-in control valve) 16
5 - Hose (To boom raise control valve) 15 1
6 - Hose (To boom lower control valve) 14
7 - Hose (To arm roll-in control valve)
8 - Hose (To arm roll-out control valve)
9 - Hose (From pilot shut-off valve)
10 - Bolt
11 - Pressure switch (for boom raise)
12 - Pressure sensor (for arm roll-in) 13
13 - Hose (From arm roll-in pilot valve) 2
14 - Hose (From arm roll-out pilot valve) 12 3
15 - Hose (From boom lower pilot valve)
4
16 - Hose (From boom raise pilot valve) 10
17 - Hose (From bucket roll-in pilot valve)
5
18 - Hose (From bucket roll-out pilot valve) 6
19 - Hose (From right swing pilot valve) 9 8 7 SM1314

20 - Hose (From left swing pilot valve)

W2-9-2 EX255-EX285

SHOCKLESS VALVE

DISASSEMBLE AND ASSEMBLE

SHOCKLESS VALVE

1
14
2
11
3

4
10

13 7
7 4
8
15 3

9 2
9

10
10
11
11
12
12
SM1315
EX255-EX285 W2-9-3

SHOCKLESS VALVE

Section V Section X
5 6

1
1

2 2

4 6 3 10 4 6 3

11 10 9 15 7 10

11
12
14 Z

1
A4

Z V X
W Y

2 3 6 4
Section W
11 10 9 8 7 10

11
12
13 14
1
Section Z-Z

2 3 6 4

Section Y

SM1316
W2-9-4 EX255-EX285

SHOCKLESS VALVE

Item Part Name Q.ty Wrench Size Torque Specification Remark

(mm) Nm kgf m lbf ft

1 Plug 4 :5 10 1 7.2 PF 1/8

2 O-ring 4
3 Spring 4
4 Steel Ball 4
5 Body 1
6 Steel Ball 5
7 Ring 2
8 Orfice 1
9 Plunger 2
10 Spring 4
11 O-ring 4
12 Plug 2 :8 49 5 36 PF 3/8
13 Orifice 1 :5 10 1 7.2 PF 1/8
14 Plug 2 :8 49 5 36 PF 3/8
15 Orifice 1
EX255-EX285 W2-10-1

SOLENOID VALVE UNIT

REMOVE AND INSTALL SOLENOID VALVE UNIT

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal
1
1. Remove all wire harnesses for solenoid valves 2
from connectors. 3
4
2. Disconnect pilot lines (1 to 6, 8 to 11, 16). 5
16
: 17, 19, 22 mm 6
15
3. Remove bolts (7) to remove solenoid valve unit.
14
: 8 mm

11

10
Installation
13 12 9 8 7
1. Install solenoid valve unit with bolts (7). SM1037

2. Connect pilot lines (1 to 6, 9, to 11, 16).

3. Connect all wire harnesses for solenoid valves to 1 - Hose PE: (To pump control valve (4-spool))
connectors. 2 - Pipe DE: (From bucket flow control valve)
3 - Pipe PH: (To pump control valve (5-spool))
4 - Hose PG: (To swing parking brake)
5 - Pipe DP: (From pilot shut-off valve)
Wrench Size Tightening Torque Remark 6 - Hose DS: (To hydraulic oil tank)
7 - Socket Bolt
(mm) Nm kgf m lbf ft 8 - Hose SG: (To main relief valve)
9 - Hose SI: (To travel speed change)
: 17 44 4,5 32.5 Hose 10 - Pipe SD: (To pump regulator valve (Pump 1 and 2))
11 - Pipe SC: (To arm regenerative valve)
: 19 29 3 22 Pipe 12 - Solenoid Valve (SG)
13 - Solenoid Valve (SI)
: 22 59 6 43 Hose
14 - Solenoid Valve (SD)
:8 20 2 16 Bolt 15 - Solenoid Valve (SC)
16 - Hose F: (From pilot shut-off valve)
W2-10-2 EX255-EX285

SOLENOID VALVE UNIT

DISASSEMBLE PROPORTIONAL SOLE-

NOID VALVE

1
2 3

4
5

7
8
9
10 13
11 14
12 15

16
17
18

SM1038

1 - Socket Bolt (2 Used) 6 - Solenoid 11 - Washer 16 - Sleeve

2 - Lock Nut 7 - Spring 12 - Spring 17 - Plate
3 - O-Ring 8 - O-Ring 13 - O-Ring 18 - Washer
4 - Adjusting Screw 9 - Diaphragm 14 - O-Ring
5 - Spring 10 - Spool 15 - O-Ring
EX255-EX285 W2-10-3

SOLENOID VALVE UNIT

Disassemble Proportional Solenoid Valve

1. Loosen socket bolts (1) and remove solenoid (6).

IMPORTANT - Take care not to lose spring (7) pro-

vided in the groove of solenoid (6) when removing
solenoid (6). Do not remove pressure control lock nut
(2) and adjusting screw (4).

: 3 mm

2. Pull out spool (10) and remove washer (11), spring

(12) and diaphragm (9) from spool (10).

3. Pull sleeve (16) out of the housing and remove

O-rings (13), (14) and (15) from sleeve (16), and
then take washer (18), plate (17) out of the housing.
W2-10-4 EX255-EX285

SOLENOID VALVE UNIT

ASSEMBLE PROPORTIONAL SOLENOID

VALVE

4 2 6 1 8 16 13 14 10 15 18

9 7 11 12 17

SM1039

1 - Socket Bolt (2 Used) 6 - Solenoid 11 - Washer 16 - Sleeve

2 - Lock Nut 7 - Spring 12 - Spring 17 - Plate
3 - O-Ring 8 - O-Ring 13 - O-Ring 18 - Washer
4 - Adjusting Screw 9 - Diaphragm 14 - O-Ring
5 - Spring 10 - Spool 15 - O-Ring
EX255-EX285 W2-10-5

SOLENOID VALVE UNIT

Assemble Proportional Solenoid Valve

16
15
IMPORTANT - Apply a film of grease to O-rings (13),
14
(14) and (15).
Install sleeve (16) together with plate (17) and washer 13
(18).
Apply a film of hydraulic oil to sleeve (16).
When inserting sleeve (16), be sure to align the ports
of the sleeve with the ports of the housing.

1. Install washer (18) and plate (17) into the housing.

Install O-rings (13), (14) and (15) onto sleeve (16) SM1040
and insert into the housing.

IMPORTANT - Take care not to damage the bore 10

edges of sleeve (16) when inserting the spool assem-
bly.
After inserting spool (10) to check that spool (10) 9
slides in and out smoothly without any restriction
about 3 to 5 mm (0.12 to 0.20 in).

2. Install diaphragm (9), washer (11) and spring (12) to 16

spool (10). Apply a film of hydraulic oil to the spool 12
SM1041
11

10

SM1042

3. Install solenoid (6) with tightening socket bolts (1).

6
IMPORTANT - Lock nut (2) and adjusting screw (4)
should not be removed during disassembly, so they
are not required to be reassembled.

IMPORTANT - Be careful not to allow spring (7) to fall

out when installing solenoid (6). 7

: 3 mm
: 3 N m (0.3 kgf m, 2.2 lbf ft)
1 SM1043
W2-10-6 EX255-EX285

SOLENOID VALVE UNIT

NOTES
EX255-EX285 W2-11-1

PILOT RELIEF VALVE UNIT

REMOVE AND INSTALL PILOT RELIEF VALVE UNIT

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal
1
1. Disconnect hoses (1, 2, 3 and 6).
: 22 mm, 27 mm
2

2. Remove bolts (4) to remove relief valve unit.

: 17 mm 6

5
3
Installation

1. Install relief valve unit with bolts (4). 4

2. Connect hoses (1, 2, 3 and 6).

SM4225

Wrench Size Tightening Torque Remark

mm Nm kgf m lbf ft
: 17 49 5 36 Bolt
1 - Hose TA: (To hydraulic oil tank)
: 22 39 4 29 Hose 2 - Hose PI: (To control valve (4-Spool)
3 - Hose PD:(To Pilot shut-off valve)
: 27 70 7 50 Hose 4 - Bolt
5 - Pilot Relief Valve
: 19 39 4 29 Hose 6 - Hose PA:(From pilot pump)
W2-11-2 EX255-EX285

PILOT RELIEF VALVE UNIT

DISASSEMBLE PILOT RELIEF VALVE

2
Port A

Port P

Port PI
4

Port T

SM4226

1 - Plug 3 - Body 5 - Spring 7 - O-Ring

2 - O-Ring 4 - Poppet 6 - Shim 8 - Plug
EX255-EX285 W2-11-3

PILOT RELIEF VALVE UNIT

Disassemble Pilot Relief Valve

1. Loosen plug (1) and remove O-ring (2) from body

(3).

: 8 mm

2. Loosen plug (8) and remove O-ring (7), shim (6),

spring (5), and poppet (4) from body (3).

: 36 mm
W2-11-4 EX255-EX285

PILOT RELIEF VALVE UNIT

ASSEMBLE PILOT RELIEF VALVE

B A

A
B

1 2

4
P PI
A 5

7
T

8
6
Section Section
A-A B-B

SM4277

1 - Plug 3 - Body 5 - Spring 7 - O-Ring

2 - O-Ring 4 - Poppet 6 - Shim 8 - Plug
EX255-EX285 W2-11-5

PILOT RELIEF VALVE UNIT

Assemble Pilot Relief Valve

1. Install poppet (4) and spring (5) into body (3).

IMPORTANT - Be sure to check if poppet (4) moves

smoothly.

2. Install shim (6) and O-ring (7) to plug (8) and tighten
plug (8) to body (3).
: 36 mm
: 49 N m (5 kgf m, 36 lbf ft)

3. Install O-ring (2) to plug (1) and tighten plug (1) to

body (3).
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)
W2-11-6 EX255-EX285

PILOT RELIEF VALVE UNIT

IMPORTANT - When pilot filter (3) for pilot relief valve

unit (1) is replaced or disassembled, correctly tighten
socket bolt (2).

: 6 mm
: 20±2 N m (2±0.2 kgf m, 14.5±1.5 lbf ft)

SM4225

1 - Pilot Relief Valve Unit

2 - Socket Bolt
3 - Pilot Filter
SECTION 3 EX255-EX285

UNDERCARRIAGE

CONTENTS

Group 1 - Swing Bearing Group 5 - Front Idler

Remove and Install
Swing Bearing ...................................... W3-1-1
Group 2 - Travel Device
Remove and Install Travel Device ......... W3-2-1
Travel Device Components (EX255) ...... W3-2-2
Travel Motor Removal (EX255) .............. W3-2-3
Disassemble Travel
Reduction Gear (EX255) ....................... W3-2-4
Reassembly (EX255) ............................ W3-2-9
Assemble Travel
Reduction Gear (EX255) ..................... W3-2-10
Travel Motor Installation (EX255) ........ W3-2-16
Disassemble Travel Device (EX285) ... W3-2-18
AssembleTravel Device (EX285) ......... W3-2-24
Disassemble Travel Motor (EX255) ..... W3-2-30
Assemble Travel Motor (EX255) .......... W3-2-34
Disassemble Brake Valve (EX255) ..... W3-2-42
Assemble Brake Valve (EX255) .......... W3-2-44
Disassemble Travel Motor (EX285) ..... W3-2-46
Assemble Travel Motor (EX285) .......... W3-2-50
Disassemble Brake Valve (EX285) ...... W3-2-58
Assemble Brake Valve (EX285) .......... W3-2-60
Maintenance Standard ........................ W3-2-62
Remove and Install Front Idler ............. W3-5-1
Disassemble Front Idler (EX255) .......... W3-5-2
Assemble Front Idler (EX255) .............. W3-5-6
Disassemble Front Idler (EX285) .......... W3-5-8
Assemble Front Idler (EX285) ............ W3-5-12
Maintenance Standard ....................... W3-5-14
Group 6 - Upper and Lower Roller
Remove and Install Upper Roller .......... W3-6-1
Remove and Install Lower Roller .......... W3-6-4
Disassemble Upper Roller .................... W3-6-7
Disassemble Lower Roller .................... W3-6-8
Assemble Lower Roller ...................... W3-6-10
Maintenance Standard ....................... W3-6-12
Gruppo 7 - Tracks
Remove and Install Tracks ................... W3-7-1
Maintenance Standard ......................... W3-7-7

Group 3 - Center Joint

Remove and Install Center Joint .......... W3-3-1
Disassemble Center Joint .................... W3-3-2
Assemble Center Joint ......................... W3-3-4
Maintenance Standard ......................... W3-3-7

Group 4 - Track Adjuster

Remove and Install
Track Adjuster ...................................... W3-4-1
Disassemble Track Adjuster ................. W3-4-2
Assemble Track Adjuster ................... W3-4-10
EX255-EX285 W3-1-1

SWING BEARING

REMOVE AND INSTALL SWING BEARING

Before removing the swing bearing, the upperstructure

must be removed first. For removal and installation of
the upperstructure, refer to “Remove and Install Main
Frame” section. In this section, the procedure starts
on the premise that the upperstructure has already
been removed.

Mark
Removal

1. Put alignment marks on swing bearing (1) and track

frame (2).

1 2
SM1307

2. Remove bolts (3) (36 used).

: 32 mm

3 SM1308

WARNING
Swing bearing weight: 331 kg (730 lb)

3. Attach lifting tools (75298793), hoist swing bearing

(4) and remove it.

SM1309
4
W3-1-2 EX255-EX285

SWING BEARING

Installation

Clean the matching surfaces of swing bearing and the

frame.

1. Apply THREEBOND 1102 to the matching sur-

faces of swing bearing and track frame.

WARNING
Swing bearing weight: 331 kg (730 lb)
SM1309

Front
Frontside
Side “S” ÒSÓ
Soft Zone
Soft Zone
IMPORTANT - Inner race soft zone (S) and the ball Marking
MarkingPosition
Position
filler port should be placed on the same position (right
side of the frame).

10.5°
2. Hoist the swing bearing.
Align the swing bearing with the alignment mark on
the track frame and install the swing bearing.
PositionofofPlug
Position Plug

SM3517

3. Install bolts (3) (36 used) and tighten to specifica-

tion.
: 32 mm
: 700 N m (71 kgf m, 514 lbf ft)

3 SM1308
EX255-EX285 W3-2-1

TRAVEL DEVICE

REMOVE AND INSTALL TRAVEL DEVICE

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal
The procedure starts on the premise that the track
link has already been removed.
1. Loosen bolts (7) to remove cover (6). Disconnect
hoses (2) to (5).
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
: 22 mm
: 177 N m (18 kgf m, 130 lbf ft)
: 27 mm
: 93 N m (9.5 kgf m, 69 lbf ft)
: 36 mm
: 157 N m (16 kgf m, 116 lbf ft)
NOTE - Install caps on all disconnected hose and line
ends.
Installation
1. Install the travel device using bolts (1).
2. Connect hoses (2) to (5).
3. Install cover (6) using bolts (7).
IMPORTANT - After completing travel motor installa-
tion, be sure to fill the travel motor with hydraulic oil.
After completing installation of the travel motor or the
travel device, be sure to perform test driving to prevent
motor seizure. Test drive as follows:
1. Run the engine with the engine control dial in the
slow idle position.
2. Turn the travel speed mode switch to the slow
speed position.
3. Test drive the machine back-and-forth for 0.5 m to
1 m (19.7 to 39.37 in) in each direction five times
or more.

2. Attach the travel device to a crane using a wire

rope. Remove any slack from the wire rope so as 5 1
to secure the travel device when the mounting
bolts are removed. 4

3
WARNING
Travel device weight: 2
EX255: Approx. 315 kg (694 Ib)
EX285: Approx. 441 kg (972 lb)

3. Remove bolts (1). Remove the travel device using

the crane. 7
: 30 mm 6
SM5500
: 590 N m (60 kgf m, 434 lbf ft)
W3-2-2 EX255-EX285
EX255

TRAVEL DEVICE

TRAVEL DEVICE COMPONENTS (EX255)

SM3022
EX255-EX285
EX255 W3-2-3

TRAVEL DEVICE

TRAVEL MOTOR REMOVAL

• Oil draining
Unscrew the plugs (2) and let the oil flow.

SM1270

1. Unscrew the 4 socket head screws M16x80

(22) grade 12.9, which fix the hydraulic motor to
the gearbox. 22

SM1271

2. Remove the hydraulic motor from the gearbox.

SM1272

3. Remove the O-ring (21) from the hydraulic

motor seat.
21

SM1273
W3-2-4 EX255
EX255-EX285

TRAVEL DEVICE

DISASSEMBLE TRAVEL REDUCTION GEAR (EX255)

1
7
W3-2-20PGS˜

10 9 8
14
15
16
3 2

5
6
17
4
18
19 11
20 12
21 13

SM3515
22

1 - Screw (10 used) 7 - 1st stage sun gear 13 - Ring nut 18 - Half seal
2 - Plug (2 used) 8 - 1st reduction assembly 14 - Screw (18 used) 19 - Centering ring
3 - Washer (2 used) 9 - 2nd reduction assembly 15 - Spring washer 20 - Hub
4 - Cover 10 - Circlip (18 used) 21 - O-ring
5 - O-ring 11 - Planetary gear (5 used) 16 - Sprocket 22 - Screw (4 used)
6 - Plug 12 - Spacer (5 used) 17 - Gearbox housing
EX255-EX285
EX255 W3-2-5

TRAVEL DEVICE

1. Loosen screws (14). Remove sprocket (16) from

gearbox housing (17) using a craine.

: 30 mm

WARNING
Sprocket weight: approx. 47 kg (104 lb)

2. Turn the gearbox upside down, unscrew and re-

move the 2 plugs M22x1,5 (2) and the 2 washers (3)
from the end cover (4).

SM1275

3. Unscrew and remove the 10 socket head screws

M10x25 (1), grade 12.9, from the end cover (4).

SM1276

4. Remove the end cover (4) using 2 screws M22x1.5

tightened to the oil plugs holes.
4

SM1277
W3-2-6 EX255-EX285
EX255

TRAVEL DEVICE

5. Remove the O-ring (5) from its seat in the end cover
(4).
5

SM1278

6. Remove the 1st stage sun gear (7).

SM1279

8
7. Remove the 1st reduction assembly (8).

SM1280

9
8. Remove the 2nd reduction assembly (9).

SM1281
EX255-EX285
EX255 W3-2-7

TRAVEL DEVICE

9. Using pliers remove the 5 circlips (10) from their

seats placed in the pins of the flanged hub (20). 10

SM1282

10. Use a puller to remove the 5 planet assemblies of

the 3rd reduction (11) from the flanged hub (20).
11

SM1283

11. Remove the 5 spacer (12).

12

SM1284

12. By means of a punch, remove the riveting in the 13

edge of the ring nut (13).
Using the tool 75301526, unscrew the nut M230x2
(13).

SM1285
W3-2-8 EX255
EX255-EX285

TRAVEL DEVICE

13. Remove the centering ring from (19) from the

flanged hub (20).

NOTE - The above operation must be executed only in

case the hub must be replaced.

19

SM1286

14. Using a press and a metal stopper, remove the

flanged hub (20) from the gearbox housing (17).

17

WARNING
In case of oil leakages, it might be necessary to
check and eventually replace the lifetime seal (18),
which means both the metal rings parts and the
O-rings.

20
SM1287

15. Use a screwdriver to remove the 1st half-seal (18)

from the flanged hub (20).

18
SM1288

18
16. Use a screwdriver to remove the 2nd half-seal (18)
from the gearbox housing (17).

SM1289
EX255
EX255-EX285 W3-2-9

TRAVEL DEVICE

REASSEMBLY (EX255)

1. Important notes before reassembly

When proceeding with the gearbox reassembly, it is

necessary to follow the rules listed below:

a) In case of damaged gears, for example a planet, do

not replace the single gear, but the whole reduction
stage.

b) Replace always the O-rings of the part to be

reassembled after having carefully cleaned the
seats and having butterd some grease on the seats
themselves and on the O-rings to make easier the
reassembly.

2. Instructions for the installation of the half seals

To follow these instructions at the time of fitting, in

order to obtain the correct seal:

a) Carefully clean the seats (1) and (2) using, if neces- 2

1
sary, metal brushes or solvent (surfaces in contact
with or (3) must be perfectly clean and dry).

6 6
b) Make sure that sealing surface (4) of metal rings (5)
are free from scratches, dinges or foreign sub-
stances; metal ring surfaces (6) must be perfectly
3 3
clean and dry.

5 5
c) Carefully clean the lapped surface (4) of metal rings
(5) and remove dust or fingersprints. Then
lubrificate them with a thin oil film, taking care not 4 4
to oil the other components.
SM1290
W3-2-10 EX255
EX255-EX285

TRAVEL DEVICE

ASSEMBLE TRAVEL REDUCTION GEAR (EX255)

W3-2-25PGS
16
13

15 12
11
19 14 10
21 18 9
20
1
22
23
4

8
7
6

3
2
5

17

SM3023

1 - Screw (10 used) 7 - 1st stage sun gear 13 - Ring nut 18 - Half seal
2 - Plug (2 used) 8 - 1st reduction assembly 14 - Screw (18 used) 19 - Centering ring
3 - Washer (2 used) 9 - 2nd reduction assembly 15 - Spring washer 20 - Hub
4 - Cover 10 - Circlip (18 used) 21 - O-ring
5 - O-ring 11 - Planetary gear (5 used) 16 - Sprocket 22 - Screw (4 used)
6 - Plug 12 - Spacer (5 used) 17 - Gearbox housing 23 - Travel motor
EX255-EX285
EX255 W3-2-11

TRAVEL DEVICE

1. Assemble the 1st half seal (18) on the tool

75301527. 75301527

18
SM1291

2. Assemble the 1st half seal (18) on the gearbox

housing (17).

SM1292

3. Assemble, by using the same tool 75301527, the

2nd half seal (18) on the flanged hub (20).
Clean carefully the metal faces of the half-seals.

SM1293

4. Lube the metallic face of the half seal (18) with a

thin oil film.

SM1294
W3-2-12 EX255-EX285
EX255

TRAVEL DEVICE

5. Fit the lower ball row (d) into the gearbox housing
(17), holding the inner ring (c) with spacers (a, b). d

a
b

SM1295

6. Remove the spacer (b). g

Place the bearing spacer (e).
Drop the upper ball row (f). f
Assemble the inner raceway (g). e

a
b

SM1296

7. Place the flanged hub (20) inside the gearbox

housing (17).
Using a press and a metallic stopper, push the
flanged hub (20) against the shoulder of the gear-
box housing (17) until assembly of the unit is 20
complete.

17

SM1297

8. Turn the gearbox upside down. Place the centering

ring (19) on the flanged hub (20) and using a press
and a metal stopper push it against the shoulder
until assembly is complete.

SM1298
EX255-EX285
EX255 W3-2-13

TRAVEL DEVICE

9. Using the tool 75301526 screw-in a new ring nut 13

M230x2 (13) at a torque of 375-425 da N m.

SM1285

10. Deform the ring nut (13) next to a space on the

flanged hub (20).

SM1311
SM1299

11. Assemble correctly the 5 spacers (12) on the pins

of the flanged hub (20).

12

SM1312 SM1284

WARNING
12.Place correctly the 5 planet assemblies of the
3rd reduction (11) on the pins of the flanged hub
(20), checking that the groove side is turned to
the end cover (see figure).

SM1313
W3-2-14 EX255-EX285
EX255

TRAVEL DEVICE

13. Use a press and the metal stopper 75301528, to

push the 5 planet assemblies of the 3rd reduction
(11) against the flanged hub shoulder (20) until
assembly is complete.

SM1304

14. Use pliers to assemble the 5 circlips (10) in the 10

flanged hub pin seats (20).

SM1282

15. Assemble the 2nd reduction assembly (9).

SM1281

8
16. Assemble the 1st reduction assembly (8).

SM1280
EX255-EX285
EX255 W3-2-15

TRAVEL DEVICE

17. Insert the 1st stage sun gear (7).

SM1279

18. Mount the O-ring (5) into its seat in the end cover
(4). 5

SM1278

4
19. Place the end cover (4) on the gearbox housing
(17).

SM1305

20. Fix the end cover (4) to the gearbox housing (17)
throught 10 socket head screws M10x25 (1),
grade 12.9, tightened by a torque wrench at
7.5 daN m torque.

21. Install sprocket (16) onto gearbox housing (17).

Tighten screws (14) with spring washer (15).
: 30 mm
: 470 N m (48 kgf m, 346 lbf ft)
SM1276
W3-2-16 EX255
EX255-EX285

TRAVEL DEVICE

TRAVEL MOTOR INSTALLATION (EX255)

IMPORTANT - Before mounting the hydraulic motor,

verify, use a depth slide gauge to measure the axial
distance from the input side of the flanged hub (20) to
the 1st stage sun gear (7).
Axial dimension = 115 ± 2 mm.

SM1306

1. Fit the O-ring (21) into the seat of the hydraulic

motor.

21

SM1273

2. Place the hydraulic motor on the gearbox.

SM1272

3. Fix the hydraulic motor to the gearbox through 4

socket head screws M16x80 (22), grade 12.9, 22
tightened by a torque wrench at 27 da N m torque.

SM1271
EX255-EX285
EX255 W3-2-17

TRAVEL DEVICE

4. Fill the gearbox with the lubricant oil.

Loosen the filling oil plug and put fill with proper oil.
Approximate oil capacity 4,5 liters ± 10 %.
Insert the washers (3) and the plugs M22x1.5 (2)
into the oil draing-filling holes of the end cover (4).
Tighten the plugs by a torque wrench at
3-4 daNm torque.

SM1276
W3-2-18 EX285
EX255-EX285

TRAVEL DEVICE

DISASSEMBLE TRAVEL DEVICE (EX285)

36
31
32

31

30 46
44 45
42
29
35

37
43
10
9
8
23
2 18
8
1
7 22
34 19
33
20
21
19
24
6
3
5 17
4
3
25 12 41
26 40
27 14
28
27
26
11 16
15
38
SM5107

13

1 - Third Stage Carrier 17 - Plug (3 Used) 32 - Drum

2 - Third Stage Sun Gear 18 - Spring Pin (3 Used) 33 - Spring Washer (20 Used)
3 - Thrust Plate (6 Used) 19 - Thrust Plate (6 Used) 34 - Bolt (20 Used)
4 - Second Stage 20 - Needle Bearing (3 Used) 35 - Spring Washer (4 Used)
Planetary Gear (3 Used) 21 - First Stage Planetary 36 - Bearing Nut
5 - Needle Bearing (3 Used) Gear (3 Used) 37 - Bolt (4 Used)
6 - Pin (3 Used) 22 - Pin (3 Used) 38 - Sprocket
7 - Spring Pin (3 Used) 23 - Second Stage Carrier 40 - Retaining Ring
8 - Spacer (2 Used) 24 - Spring Pin (3 Used) 41 - Bearing
9 - Second Stage Sun Gear 25 - Pin (3 Used) 42 - O-Ring
10 - First Stage Carrier 26 - Thrust Plate (6 Used) 43 - Spacer
11 - Propeller Shaft 27 - Needle Bearing (6 Used) 44 - Housing
12 - Ring Gear 28 - Third Stage Planetary 45 - Lock Plate
13 - Bolt (24 Used) Gear (3 Used) 46 - Bolt (2 Used)
14 - Stopper Pin 29 - Motor
15 - Cover 30 - Floating Seal
16 - Bolt (12 Used) 31 - Roller Bearing (2 Used)
EX285
EX255-EX285 W3-2-19

TRAVEL DEVICE

Disassemble Travel Device

• Be sure to thoroughly read “Precautions for Disas-

sembly and Assembly” on page W1-1-1 before
starting the disassembly work.

WARNING
Pressure may remain in the travel device. Slowly
loosen the air bleed plug to completely release the
residual pressure. Then, remove the drain plug to
drain gear oil into a container. If the air bleed plug
is loosened quickly, the plug may fly off and/or gear
oil may spout. Position your face and body away
from the plug.
29
1. Stand the travel device upright with the motor on
the top. Install spacer (75301498) on the frame
mounting surface on motor (29) using two bolts
(M20, Pitch 2.5).
: 30 mm

75301498
WARNING
SM1079
Travel device weight: 441 kg (972 lb)

2. Turn over the travel device. (Stand the travel

device upright with the spacer (75301498) side on
a work bench.)

NOTE - If the spacer (75301498) is not available, use

a device to stand the travel device securely so that the
brake valve does not come into contact with the work
bench.

3. Remove bolts (16) to remove cover (15).

: 19 mm

NOTE- For easy separation of cover (15), apply a

chisel between cover (15) and ring gear (12) and
lightly tap on the end of the chisel.
Do not remove stopper pin (14) unless it is damaged
or excessively worn.

4. Remove propeller shaft (11) and first stage carrier

(10) assembly.
5. Remove second stage sun gear (9) and second 75301485 13
stage carrier (23) as an assembly. Remove third
stage sun gear (2).

WARNING
Ring gear weight: 50 kg (110 Ib)

6. Remove bolts (13). Attach eye bolt (75301485) to

ring gear (12). Remove ring gear (12) using a crane.
: 24 mm SM1080
W3-2-20 EX255-EX285
EX285

TRAVEL DEVICE

36
31
32

31

30 46
44 45
42
29
35

37

10

18

17

SM5107
EX255-EX285
EX285 W3-2-21

TRAVEL DEVICE

WARNING
Weight of third stage carrier assembly:
Approx. 45 kg (99 lb) 46

45
7. Remove third stage carrier (1) assembly.
36
8. Remove lock bolt (46), and lock plate (45), from
bearing nut (36).

9. Remove bearing nut (36) using special tools.

Special Tools: 75301495, 75301496, 75301497
SM5109
Bolt: M16 (60 to 90 mm in length): 2 pieces

WARNING
Weight of drum and sprocket combined: 75301496
130 kg (290 lb)
75301497

10. Attach eye bolt (75301486) to drum (32). Remove 75301495

drum (32) from housing (44) using a crane.

11. Remove the inner race of roller bearing (31) from 36

drum (32).
SM1082
12. Remove the half of floating seal (30) from drum
(32).

13. Remove the other half of floating seal (30) from

housing (44).
75301486
NOTE - Do not attempt to remove the inner race of
roller bearing (31) which remained in housing (44) side
unless it is to be replaced.

14. Apply a metal bar to the outer race of roller bearing

on drum (32) side, and tap the bar end with a
hammer to drive the outer race out.

SM1083

15. Apply a round bar to spring pin (18), and tap the end
of the bar to drive spring pin (18) out of first stage
carrier (10) assembly.
W3-2-22 EX285
EX255-EX285

TRAVEL DEVICE

32

44

43
10

8
23
18

8
1
22
34 19
33
20
21
19

38
SM5107
EX255-EX285
EX285 W3-2-23

TRAVEL DEVICE

16. Remove pin (22). Remove first stage planetary

gears (21), needle bearings (20), and thrust plates
(19).

17. Remove spacer (43) from first stage carrier (10)

assembly.

18. Disassemble second stage carrier (23) assembly

following steps 16 to 18 above.

19. Disassemble third stage carrier (1) assembly fol-

lowing steps 16 to 18 above.

WARNING
Sprocket weight: Approx. 65 kg (143 lb)

20. Loosen bolts (34). Remove sprocket (38) from

drum (32) using a crane.
: 30 mm
W3-2-24 EX285
EX255-EX285

TRAVEL DEVICE

ASSEMBLE TRAVEL DEVICE (EX285)

29 42 44 8 13 12 1 2 23 8 9 10 43

17

11
15
14

41
40
21
20
22
18
19
16

30 31 32 45 46 28 27 25 26 24 3 4 5 6 7

36 38 33-34
SM5108

1 - Third Stage Carrier 16 - Bolt (12 Used) 30 - Floating Seal

2 - Third Stage Sun Gear 17 - Plug (3 Used) 31 - Roller Bearing (2 Used)
3 - Thrust Plate (6 Used) 18 - Spring Pin (3 Used) 32 - Drum
4 - Second Stage 19 - Thrust Plate (6 Used) 33 - Spring Washer (20 Used)
Planetary Gear (3 Used) 20 - Needle Bearing (3 Used) 34 - Bolt (20 Used)
5 - Needle Bearing (3 Used) 21 - First Stage Planetary 35 - Spring Washer (4 Used)
6 - Pin (3 Used) Gear (3 Used) 36 - Bearing Nut
7 - Spring Pin (3 Used) 22 - Pin (3 Used) 37 - Bolt (4 Used)
8 - Spacer (2 Used) 23 - Second Stage Carrier 38 - Sprocket
9 - Second Stage Sun Gear 24 - Spring Pin (3 Used) 40 - Retaining Ring
10 - First Stage Carrier 25 - Pin (3 Used) 41 - Bearing
11 - Propeller Shaft 26 - Thrust Plate (6 Used) 42 - O-Ring
12 - Ring Gear 27 - Needle Bearing (6 Used) 43 - Spacer
13 - Bolt (24 Used) 28 - Third Stage Planetary 44 - Housing
14 - Stopper Pin Gear (3 Used) 45 - Lock Plate
15 - Cover 29 - Motor 46 - Bolt (2 Used)
EX255-EX285
EX285 W3-2-25

TRAVEL DEVICE

Assemble Travel Device

1. If replacing roller bearing (31), warm the inner race
50 to 70 °C (122 to 158 °F) using a heater, then
install it into housing (44). Wait for the inner race to
cool. Then, drive it in position completely using a
metal bar and a hammer.
7. Install bearing nut (36) to housing (44), with the
uneven surface side towards the hub and tighten
manually.
8. Secure the travel device immovable. Attach the
special tools to bearing nut (36). Then, tighten it
using a torque wrench.

Special Tools: 75301495, 75301496, 75301497

2. Install one half of floating seal (30) on housing (29).
Bolt: M16 (60 to 90 mm in length): 2 pieces

NOTE - For easier insertion of floating seal O-ring, use : 785 N m (80 kgf m, 580 lbf ft)
wooden spatula to guide it along the periphery.

3. Install the outer race of roller bearing (31) on drum

(32) in position completely using a metal bar and a
hammer.
Install the halt floating seal (30) into drum (32).
75301496

75301497

75301495
WARNING
Sprocket weight: Approx. 65 kg (143 lb)
36

4. Mount sprocket (38) on drum (32). Apply LOCTITE SM1082

262 to bolts (34). Tighten bolts (34) and spring
washer (33).
: 30 mm
: 470 N m (48 kgf m, 350 lbf ft)

WARNING
Weight of drum and sprocket combined:
Approx. 130 kg (290 lb)

5. Attach eyebolt (75301486) to drum (32) then install

drum (32) onto housing (44) with motor (29), using
a hoist.

6. Warm the inner race of roller bearing (31) 50 to

70 °C (122 to 158 °F) using a heater. Install it
between drum (32) and housing (44). Wait for the
inner race to cool. Then, drive it into position
completely using a metal bar and a hammer.
W3-2-26 EX285
EX255-EX285

TRAVEL DEVICE

44 8 13 12 1

30 31 32 45 46 28 27 25 26 24

36 38
SM5108
EX255-EX285
EX285 W3-2-27

TRAVEL DEVICE

9. Tap on drum (32) using a plastic hammer to secure

appropriate play. Then, rotate sprocket (38) three
turns clockwise and then counterclockwise.

10. Repeat step 9 above. Then, tighten bearing nut 75301496

(36) to specification.
75301497
Special Tools: 75301495, 75301496, 75301497
Bolt: M16 (60 to 90 mm in length): 2 pieces 75301495

: 785 N m (80 kgf m, 580 lbf ft)

36
11. Install lock plate (45). Apply LOCTITE 262 to the
thread of bolts (46) (2 used), then tighten them to
SM1082
specification.
: 19 mm
: 88 N m (9 kgf m, 65 lbf ft)

12. Install two needle bearings (27) into each third

stage planetary gear (28).

13. Putting thrust plates (26) on both ends of each 46

third stage planetary gears (28), install them into
third stage carrier (1). Install thrust plates (8) into 45
third stage carrier (1).
36

14. Drive pin (25) into third stage carrier (1), aligning
the spring pin holes.

15. Drive spring pin (24) into the spring pin hole on third SM5109

stage carrier (1) and pin (25).

NOTE - Be sure that the slit part of spring pin (24) faces
upwards in relation to the end of pin (25), as shown.
25

WARNING 24 Spaccatura
Third stage carrier assembly weight:
Approx. 45 kg (99 lb)
SM1085

16. Install third stage carrier (1) assembly, aligning

splines with housing (44).

17. Install third stage sun gear (2) into third stage
carrier (1). Be sure that the lower tooth end faces
upwards.

18. Clean (decrease) ring gear mounting surface of

drum (32). Apply THREEBOND 1215 to the
mounting surface.
W3-2-28 EX255-EX285
EX285

TRAVEL DEVICE

29 42 44 8 13 12 1 2 23 8 9 10 43

17

11
15
14

41
40
21
20
22
18
19
16

30 31 32

SM5108
EX255-EX285
EX285 W3-2-29

TRAVEL DEVICE

WARNING WARNING
Ring gear weight: Approx. 50 kg (110 lb) Travel device weight: Approx. 441 kg (972 lb)

18. Install ring gear (12) onto drum (32) using a crane.
30. Turn over the travel device. Remove spacer
Tighten bolts (13).
(75301498).
: 24 mm
: 265 N m ( 27 kgf m, 195 lbf ft)
IMPORTANT - Be sure to fill the travel device with the
19. Install spacer (8) into second stage carrier (23). specified amount of gear oil after installing it on the
machine.
20. Assemble second stage carrier (23) referring to
steps 12 to 15.

21. Install second stage carrier (23) assembly into ring

gear (12).

22. Install second stage sun gear (9) into second

stage carrier (23).

23. Install spacer (43) into first stage carrier (10).

24. Assemble first stage carrier (10) referring to steps

12 to 15.

25. Install first stage carrier (10) assembly into ring

gear (12), aligning splines between first stage
carrier (10) and second stage sun gear (9).

26. Add lubricant oil to gear box. (Refer to the Opera-

tor’s Manual for the type of lubricant oil to be used.)

Oil capacity: 7.8 L (2.1 US gal)

27. Insert propeller shaft (11). Be sure that the propel-

ler shaft correctly meshes with first stage plan-
etary gears (21) and the shaft of motor (29).

28. Clean (degrease) the cover mounting surface of

ring gear (12). Apply THREEBOND 1215 to the
mounting surface. Install cover (15). Tighten bolts
(16).
: 19 mm
: 108 N m (11 kgf m, 80 lbf ft)

29. Wrap seal tape around plugs (17). Install plugs (17)
into cover (15).
: 10 mm
: 49 N m (5 kgf m, 36 lbf ft)
W3-2-30 EX255
EX255-EX285

TRAVEL DEVICE

DISASSEMBLE TRAVEL MOTOR (EX255) 14

13

12

11
10
9
8
7
6
5
4
3
2
1
15
16
17
18
19
20
21 25
22
26

27

23 28
24
29

30

31

32

40 39 38 37 36 33
SM3513
34

35

1 - O-Ring 15 - O-Ring 29 - Valve Plate

2 - Disc Spring 16 - Baring Nut 30 - Plate
3 - D-Ring 17 - Plunger (7 Used) 31 - Knock Pin (2 Used)
4 - Piston 18 - Rotor 32 - Socket Bolt (8 Used)
5 - D-Ring 19 - Plug (2 Used) 33 - Brake Valve
6 - Plate (5 Used) 20 - Friction Plate (4 Used) 34 - O-Ring
7 - Spacer 21 - Link 35 - Plug
8 - Drive Disc 22 - Reamer Bolt 36 - Servo Piston
9 - Bearing 23 - Plug 37 - Piston Ring (2 Used)
10 - Spacer 24 - O-Ring 38 - O-Ring
11 - Bearing 25 - Pin 39 - Cover
12 - Housing 26 - Center Shaft 40 - Socket Bolt (4 Used)
13 - Oil Seal 27 - Center Spring
14 - Retaining Ring 28 - Bushing
EX255-EX285
EX255 W3-2-31

TRAVEL DEVICE

Disassemble Travel Motor

• Be sure to thoroughly read “Precautions for Disas-

sembly and Assembly” on page W1-1-1 before
starting the disassembly work.

WARNING
Brake valve weight: 30 kg (66 lb)

1. Loosen socket bolts (32), and remove brake valve

(33) using hoist from the motor.
: 14 mm

2. Loosen socket bolts (40) and remove cover (39) 22

and O-ring (38).
: 10 mm

3. Turn over brake valve (33).

SM1087
Remove drain plug (23). Insert a hexagon wrench
from drain plug hole to remove reamer bolt (22).
: 8, 10 mm

4. Remove servo piston (36) to remove valve plate

(29) and link (21).

IMPORTANT - Remove plug (19), only necessary.

19

5. Remove O-rings (1, 15) from housing (12).

SM1088

6. Remove rotor (18) from housing (12).

Make matching mark on rotor (18) and plungers
(17).

7. Remove center spring (27) and center shaft (26).

8. Remove plungers (17) one by one. First, grab

plunger (17) upright against drive disc (8). Then,
turn it at an angle against the drive disc while
slightly raising the bottom of the plunger to remove
the plunger. (to disconnect the joint).

IMPORTANT - Make matching mark on the plungers

(17) and drive disc (8).

9. Remove disc spring (2).

W3-2-32 EX255-EX285
EX255

TRAVEL DEVICE

14
13

12

11
10
9
8
7
6
5
4
3

16

20

SM3513
EX255-EX285
EX255 W3-2-33

TRAVEL DEVICE

WARNING
Be sure to reduce air pressure to 98 to 196 kPa
(1 to 2 kgf/cm2, 14 to 28 psi) when using com-
pressed air. Cover piston (4) with cloths when
removing the piston using compressed air to avoid 4
12
sudden flying off.

10. Remove piston (4) from housing while supplying

98 to 196 kPa (1 to 2 kgf/cm2, 14 to 28 psi) air
pressure to the brake releasing hydraulic circuit
using an air pump.

11. Remove D-rings (3, 5) from piston (4).

12. Remove plates (6), friction plates (20) and spacer SM1089
(7) from housing (12).

WARNING
Housing+drive disc+etc weight: 50 kg (110 lb)

13. Turn over housing (12), then tap with plastic 75301492
hammer to remove drive disc (8) assembly.
75301499
14. Remove retaining ring (14) from housing (12). Pull
out oil seal (13). 8

15. Attach drive disc (8) assembly to special tool SM1090

(75301492 and 75301499). Remove bearing nut
(16).

16. Place support wooden blocks under the outer

race, as illustrated. Press drive disc (8) using a
press to pull out bearing (11) and spacer (10). 10
9
17. Remove the outer race of bearing (11) from spacer 11
(10). Pista

18. Place support wooden blocks under the inner race

of bearing (9). Push drive disc (8) out using a
press.

IMPORTANT - If the inner race of bearing (9) is SM1091

removed, do not reuse it.
W3-2-34 EX255-EX285
EX255

TRAVEL DEVICE

ASSEMBLE TRAVEL MOTOR (EX255)

35 30 28 29 15 2 18 27 25 26

Cross Section A-A

33
22 21 19

A
14
B
C
8

12
A

23
13

37
16
39
40
11

38 36 32 17 1 4 3 5 20 6 7 9 10 SM3519

1 - O-Ring 15 - O-Ring 29 - Valve Plate

2 - Disc Spring 16 - Baring Nut 30 - Plate
3 - D-Ring 17 - Plunger (7 Used) 31 - Knock Pin (2 Used)
4 - Piston 18 - Rotor 32 - Socket Bolt (8 Used)
5 - D-Ring 19 - Plug (2 Used) 33 - Brake Valve
6 - Plate (5 Used) 20 - Friction Plate (4 Used) 34 - O-Ring
7 - Spacer 21 - Link 35 - Plug
8 - Drive Disc 22 - Reamer Bolt 36 - Servo Piston
9 - Bearing 23 - Plug 37 - Piston Ring (2 Used)
10 - Spacer 24 - O-Ring 38 - O-Ring
11 - Bearing 25 - Pin 39 - Cover
12 - Housing 26 - Center Shaft 40 - Socket Bolt (4 Used)
13 - Oil Seal 27 - Center Spring
14 - Retaining Ring 28 - Bushing
EX255-EX285
EX255 W3-2-35

TRAVEL DEVICE

Assemble Travel Motor

1. Warm the inner race of bearing (9) to 70 to 90 °C

(160 to 194 °F) in an oil bath or using a dryer. Then,
install it onto drive disc (8) using special tool
10
75298960 and a press.
9
2. Put the outer race on the inner race of bearing (9).

3. Install the outer race of bearing (11) onto spacer

(10) by tapping with a plastic hammer.

4. Put spacer (10) on the outer race of bearing (9).

Confirm that the oil groove side of the spacer faces Oil groove SM1093

bearing (9).

5. Warm the inner race of bearing (11) to 70 to 90 °C

(160 to 194 °F) in an oil bath or using a dryer. Then,
install it onto drive disc (8) using special tool and a
press. Apply a metal bar to the inner race. Tap the
end of the bar to completely install it in position (or
to confirm that it has been completely installed in
position).

6. Fix drive disc (8) in special tool (75301499). 16

Tighten bearing nut (16) while applying lubricants
until the specified shaft starting torque is obtained.
75301499

8
7. Measure shaft starting torque.
: 2 ± 0.5 N m (0.2 ± 0.05 kgf m,
1.5 ± 0.4 lbf ft)
SM1090

IMPORTANT - Take care not to damage oil seal (13).

8. Install oil seal (13) into housing (12) using a press.

Install retaining ring (14).

WARNING
Housing weight: 46 kg (101 lb)

9. Turn over housing (12). Install drive disc (8) assem-

bly into housing (12) by tapping with a plastic
hammer.

SM1094
W3-2-36 EX255
EX255-EX285

TRAVEL DEVICE

30 15 2 18 27 25 26

Cross Section A-A

33

23

17 1 4 3 5 20 6 7 10 SM3519
EX255-EX285
EX255 W3-2-37

TRAVEL DEVICE

10. Install spacer (7) into housing (12) with the oil
groove side facing downward, aligning the oil
groove and the hole on housing (12).

11. Install plates (6) (5 used) and friction plates (20) (4

used) one by one alternately, aligning notches of
each plate and friction plate. Be sure to install
plates (6) to housing (12) side and friction plates
(20) to drive disc (8) side.

12. Attach D-rings (3) and (5) onto piston (4). Install
piston (4) into housing (12).

NOTE - Tap the end of piston (4) with a plastic hammer

for easy insertion.
17 8

13. Install disc spring (2) onto housing (12) with the
larger diameter side facing upward.

14. Aligning matching marks, install plungers (17) into

the spherical joints on drive disc one by one.
Confirm that plungers (17) move smoothly in the
joints.
SM1095
15. Install center shaft (26) onto drive disc (8). Attach
center spring (27) onto center shaft (26).

16. Insert the top part of center shaft (26) into the
center hole on rotor (18), aligning pin (25) on center
shaft (26) with the groove on rotor (18).
18
17. Insert plungers (17) into rotor (18) one by one,
aligning the matching marks. Be sure that the
groove on rotor (18) comes over pin (25) on shaft
(26).

18. Install O-rings (1) and (15) onto housing (12).

19. Add hydraulic oil into housing (12).

Hydraulic oil:1.2 L (1.27 US qt) 26 25
SM1096
20. Remove plug (23) from brake valve (33).

21. Install plate (30) on brake valve (33).

W3-2-38 EX255
EX255-EX285

TRAVEL DEVICE

35 30 28 29
Cross Section A-A

33
22 21 19

23

37
39
40

38 36 SM3519
EX255-EX285
EX255 W3-2-39

TRAVEL DEVICE

22. Attach piston rings (37) onto servo piston (36).

Then, attach them to special tool (75301530). 36

23. Insert servo piston (36) into brake valve (33).

24. If replacing bushing (28), drive it into valve plate

(29) using special tool (75301494).

NOTE - Note the facing direction of the oil groove side

when removing the bushing.

25. Apply LOCTITE 262 to plugs (19). Install link (21) 75301530 SM1097
on valve plate (29) using plugs (19).
: 6 mm
: 49 N m (5 kgf m, 36 lbf ft) 29 21

26. Install link (21) and valve plate (29) to fit into the
groove on plate (30). Align the groove of link (21)
with servo piston (36).

27. Align the holes on link (21) and on servo piston (36)
by inerting the aligning tool (75301500) through
plug (23) hole.

28. Apply extreme-pressure grease to the tip of

reamer bolt (22) to prevent seizure between parts.
Install reamer bolt (22) into link (21) and servo
piston (36) through the other plug (23) hole on the 19 SM1098
opposite side.
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft) 36 75301500 21

29. Remove plug (35) from brake valve (33). Secure

valve plate (29) using a fastening device.

30. Install O-ring (38) on cover (39). Install cover (39)

on brake valve (33) using socket bolts (40).
: 10 mm
: 88 N m (9 kgf m, 65 lbf ft)

SM1099
22
W3-2-40 EX255
EX255-EX285

TRAVEL DEVICE

35 26
Cross Section A-A

33

A
B
C

12
A

23

32 SM3519
EX255-EX285
EX255 W3-2-41

TRAVEL DEVICE

31. Attach special tool (75301501) to the top of center

shaft (26).

32. Remove plug (A) from brake valve (33). Remove

spool (B) and spring (C).
: 8 mm
75301501
26
WARNING
Brake valve weight: 30 kg (66 Ib)

33. Attach brake valve (33) to a crane. Lift brake valve SM1092

(33) and align special tool (75301501) with plug (A) 12

hole. Then, install brake valve (33) onto housing
(12).

34. Remove special tool (75301501) and the fastening

device from brake valve (33).

35. Install plugs (23) and (35), spool (B), spring (C),
and plug (A) to brake valve (33).
: 5 mm
: 15 N m (1.5 kgf m, 11 lbf ft)

: 8 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
: 10 mm
: 118 N m (12 kgf m, 90 lbf ft)

36. Install socket bolts (32).

: 12 mm
: 215 N m (22 kgf m, 160 lbf ft)
W3-2-42 EX255-EX285
EX255

TRAVEL DEVICE

DISASSEMBLE BRAKE VALVE (EX255)

4 1- 2
8 5

9 6
10 7
11
12

21

20

19 13

18 7
12 1- 2
14 6

15 11 5

16
4
17 10

9 SM1101

1 - O-Ring (2 Used) 8 - Plug (2 Used) 15 - Seat (2 Used)

2 - Overload Relief Valve (2 Used) 9 - O-Ring (2 Used) 16 - O-Ring (2 Used)
3 - Casing 10 - Spring (2 Used) 17 - Plug (2 Used)
4 - Plug (2 Used) 11 - Spring (2 Used) 18 - Plug
5 - O-Ring (2 Used) 12 - Stopper (2 Used) 19 - O-Ring
6 - Spring (2 Used) 13 - Spool 20 - Spool
7 - Poppet (2 Used) 14 - Ball (2 Used) 21 - Spring
EX255-EX285
EX255 W3-2-43

TRAVEL DEVICE

Disassemble Brake Valve • Parking Brake Release Valve

• Be sure to thoroughly read “Precautions for Disas- 9. Remove plug (17) and O-ring (16) from casing
sembly and Assembly” on page W1-1-1 before (3).
starting the disassembly work.
: 6 mm

10. Remove seat (15) and tilt casing (3) to remove

• Counterbalance Valve
ball (14).
1. Remove plug (8) and O-ring (9) from casing (3). : 5 mm
: 36 mm
• Reducing Valve
2. Remove springs (10), (11) and stopper (12).
11. Remove plug (18) and O-ring (19) from casing
3. Remove spool (13) from casing (3).
(3).
: 8 mm
• Overload Relief Valve
12. Remove spool (20) and spring (21).
4. Remove overload relief valve (2) from casing
(3).
: 27 mm

• Check Valve

5. Remove plug (4) and O-ring (5) from casing (3).

: 12 mm

6. Remove spring (6) and poppet (7).

• Servo Piston Operating Shuttle Valve

7. Remove plug (17) and O-ring (16) from casing

(3).
: 6 mm

8. Remove seat (15) and tilt casing (3) to remove

ball (14).
: 5 mm
W3-2-44 EX255-EX285
EX255

TRAVEL DEVICE

ASSEMBLE BRAKE VALVE (EX255)

Cross Section C-C

6 7 1 2

A 14 19 20 21
15
5
18
17
4 16
C

10

11

12

3
B

13

A
Cross Section A-A

14
15 Cross Section B-B
SM1102
17
16

1 - O-Ring (2 Used) 8 - Plug (2 Used) 15 - Seat (2 Used)

2 - Overload Relief Valve (2 Used) 9 - O-Ring (2 Used) 16 - O-Ring (2 Used)
3 - Casing 10 - Spring (2 Used) 17 - Plug (2 Used)
4 - Plug (2 Used) 11 - Spring (2 Used) 18 - Plug
5 - O-Ring (2 Used) 12 - Stopper (2 Used) 19 - O-Ring
6 - Spring (2 Used) 13 - Spool 20 - Spool
7 - Poppet (2 Used) 14 - Ball (2 Used) 21 - Spring
EX255-EX285
EX255 W3-2-45

TRAVEL DEVICE

Assemble Brake Valve 5. Install O-ring (16) to plug (17), then install it
to casing (3).
• Reducing Valve
: 6 mm
1. Insert spring (21) and spool (20) into casing (3), : 34 N m (3.5 kgf m, 25 lbf ft)
and tighten plug (18) with O-ring (19) to casing
(3).
• Check Valve
: 8 mm
: 69 N m (7 kgf m, 51 lbf ft) 6. Insert poppet (7) with spring (6) into casing (3),
and tighten plug (4) with O-ring (5) to casing
(3).
• Parking Brake Relief Valve
: 12 mm
(Cross Section C-C)
: 235 N m (24 kgf m, 175 lbf ft)
2. Tilt casing (3) and insert ball (14). Apply
LOCTITE 262 to seat (15) and tighten it to
casing (3). • Overload Relief Valve
: 5 mm
7. Install overload relief valve (2) to casing (3).
: 14.5 N m (1.5 kgf m, 11 lbf ft)
: 27 mm
: 540 N m (55 kgf m, 400 lbf ft)
IMPORTANT - Before inserting ball (14), put ball (14)
on seat (15) and tap on the ball with a hammer to obtain
tight fitting between ball (14) and seat (15). Also, after • Counterbalance Valve
inserting ball (14) and before tightening seat (15),
insert a metal bar into the plug hole to apply its end to 8. Insert spool (13) into casing (3).
ball (14), then tap the other end of the bar to obtain tight
fitting between ball (14) and the casing.
IMPORTANT - Apply film of hydraulic oil to spool
(13).
3. Install O-ring (16) to plug (17), then install it to
casing (3). 9. Install springs (10), (11) to stopper (12), then
insert it into casing (3).
: 6 mm
: 34 N m (3.5 kgf m, 25 lbf ft) 10. Install O-ring (9) to plug (8), then install to
casing (3).
: 36 mm
• Servo Piston Operating Shuttle Valve
(Cross Section B-B) : 215 N m (22 kgf m, 160 lbf ft)

4. Tilt casing (3) and insert ball (14). Apply

LOCTITE 262 to seat (15) and tighten it to IMPORTANT - Be sure to fill the travel device with
casing (3). hydraulic oil after installing it.
: 5 mm
: 14.5 N m (1.5 kgf m, 11 lbf ft)

IMPORTANT - Before inserting ball (14), put ball (14)

on seat (15) and tap on the ball with a hammer to obtain
tight fitting between ball (14) and seat (15). Also, after
inserting ball (14) and before tightening seat (15),
insert a metal bar into the plug hole to apply its end to
ball (14), then tap the other end of the bar to obtain tight
fitting between ball (14) and the casing.
W3-2-46 EX285
EX255-EX285

TRAVEL DEVICE

DISASSEMBLE TRAVEL MOTOR (EX285)

12

10
9

8
7
20 13 14

5
4
3
1 2
11 16 15

25

6 26
27
17

19 18

21 28

22 29
19

23 30
32 24

31

40 33
39 38 37 36

SM5110

34
35

1 - O-Ring 15 - O-Ring 29 - Valve Plate

2 - Disc Spring 16 - Bearing Nut 30 - Plate
3 - D-Ring 17 - Plunger (7 Used) 31 - Knock Pin (2 Used)
4 - Piston 18 - Rotor 32 - Socket Bolt (4 Used)
5 - D-Ring 19 - Plug (2 Used) 33 - Brake Valve
6 - Plate (5 Used) 20 - Friction Plate (4 Used) 34 - O-Ring
7 - Spacer 21 - Link 35 - Plug
8 - Drive Disc 22 - Reamer Bolt 36 - Servo Piston
9 - Bearing 23 - Plug 37 - Piston Ring (2 Used)
10 - Spacer 24 - O-Ring 38 - O-Ring
11 - Bearing 25 - Pin 39 - Cover
12 - Housing 26 - Center Shaft 40 - Socket Bolt (4 Used)
13 - Oil Seal 27 - Center Spring
14 - Retaining Ring 28 - Bushing
EX255-EX285
EX285 W3-2-47

TRAVEL DEVICE

Disassemble Travel Motor

• Be sure to thoroughly read “Precautions for Disas-

sembly and Assembly” on page W1-1-1 before
starting the disassembly work.

WARNING
Brake valve weight: 43 kg (95 lb)

1. Loosen socket bolts (32), and remove brake valve

(33) using hoist from the motor.
: 14 mm

2. Loosen socket bolts (40) and remove cover (39) 22

and O-ring (38).
: 10 mm

3. Turn over brake valve (33).

SM1087
Remove drain plug (23). Insert a hexagon wrench
from drain plug hole to remove reamer bolt (22).
: 8, 10 mm

4. Remove servo piston (36) to remove valve plate

(29) and link (21).

IMPORTANT - Remove plug (19), only necessary.

19
5. Remove O-rings (1), (15) from housing (12).
SM1088

6. Remove rotor (18) from housing (12).

Make matching mark on rotor (18) and plungers
(17).

7. Remove center spring (27) and center shaft (26).

IMPORTANT - Make matching mark on the plungers

(17) and drive disc (8).

8. Remove plungers (17) one by one. First, grab

plunger (17) upright against drive disc (8). Then,
turn it at an angle against the drive disc while
slightly raising the bottom of the plunger to remove
the plunger. (to disconnect the joint)

9. Remove disc spring (2).

W3-2-48 EX285
EX255-EX285

TRAVEL DEVICE

12

10
9

8
7
20 13 14

5
4
3
11 16

SM5110
EX285
EX255-EX285 W3-2-49

TRAVEL DEVICE

WARNING
Be sure to reduce air pressure to 98 to 196 kPa
(1 to 2 kgf/cm2, 14 to 28 psi) when using com-
pressed air. Cover piston (4) with cloths when
removing the piston using compressed air to avoid
12 4
sudden flying off.

10. Remove piston (4) from housing while supplying

98 to 196 kPa (1 to 2 kgf/cm2, 14 to 28 psi) air
pressure to the brake releasing hydraulic circuit
using an air pump.

11. Remove D-rings (3, 5) from piston (4).

12. Remove plates (6), friction plates (20) and spacer SM1089
(7) from housing (12).

WARNING
Housing+drive disc+etc weight: 50 kg (110 lb)

13. Turn over housing (12), then tap with plastic 75301492
hammer to remove drive disc (8) assembly.
75301499
14. Remove retaining ring (14) from housing (12). Pull
out oil seal (13). 8

15. Attach drive disc (8) assembly to special tool SM1090

75301492 and 75301499. Remove bearing nut
(16).

16. Place support wooden blocks under the outer

race, as illustrated. Press drive disc (8) using a
press to pull out bearing (11) and spacer (10). 10
9
17. Remove the outer race of bearing (11) from spacer 11
(10). Pista

18. Place support wooden blocks under the inner race

of bearing (9). Push drive disc (8) out using a
press.

IMPORTANT - If the inner race of bearing (9) is

SM1091
removed, do not reuse it.
W3-2-50 EX255-EX285
EX285

TRAVEL DEVICE

ASSEMBLE TRAVEL MOTOR (EX285)

34,35 28 1 15 2 3 4 5 6 7 8 9

30 Cross Section A
29
31
10
33
11

12

13 22 21 19
14

18

25

16
17
37
20

39

SM5111

36 38 40 24,23 32 27 26

1 - O-Ring 15 - O-Ring 29 - Valve Plate

2 - Disc Spring 16 - Bearing Nut 30 - Plate
3 - D-Ring 17 - Plunger (7 Used) 31 - Knock Pin (2 Used)
4 - Piston 18 - Rotor 32 - Socket Bolt (4 Used)
5 - D-Ring 19 - Plug (2 Used) 33 - Brake Valve
6 - Plate (5 Used) 20 - Friction Plate (4 Used) 34 - O-Ring
7 - Spacer 21 - Link 35 - Plug
8 - Drive Disc 22 - Reamer Bolt 36 - Servo Piston
9 - Bearing 23 - Plug 37 - Piston Ring (2 Used)
10 - Spacer 24 - O-Ring 38 - O-Ring
11 - Bearing 25 - Pin 39 - Cover
12 - Housing 26 - Center Shaft 40 - Socket Bolt (4 Used)
13 - Oil Seal 27 - Center Spring
14 - Retaining Ring 28 - Bushing
EX285
EX255-EX285 W3-2-51

TRAVEL DEVICE

Assemble Travel Motor

1. Warm the inner race of bearing (9) to 70 to 90 °C

(160 to 194 °F) in an oil bath or using a dryer. Then,
install it onto drive disc (8) using special tool
10
75298960 and a press.
9
2. Put the outer race on the inner race of bearing (9).

3. Install the outer race of bearing (11) onto spacer

(10) by tapping with a plastic hammer.

4. Put spacer (10) on the outer race of bearing (9).

Confirm that the oil groove side of the spacer faces Oil groove
SM1093

bearing (9).

5. Warm the inner race of bearing (11) to 70 to 90 °C

(160 to 194 °F) in an oil bath or using a dryer. Then,
install it onto drive disc (8) using special tool and a
press. Apply a metal bar to the inner race. Tap the
end of the bar to completely install it in position (or
to confirm that it has been completely installed in
position).

6. Fix drive disc (8) in special tool (75301499). 16

Tighten bearing nut (16) while applying lubricants
until the specified shaft starting torque is obtained.
75301499

8
7. Measure shaft starting torque.
: 3 ± 0.5 N m (0.3 ± 0.05 kgf m,
2.2 ± 0.4 lbf ft)
SM1090

IMPORTANT - Take care not to damage oil seal (13).

8. Install oil seal (13) into housing (12) using a press.

Install retaining ring (14).

WARNING
Housing weight: 46 kg (101 lb)

9. Turn over housing (12). Install drive disc (8) assem-

bly into housing (12) by tapping with a plastic
hammer.

SM1094
W3-2-52 EX255-EX285
EX285

TRAVEL DEVICE

34,35 28 1 15 2 3 4 5 6 7 8 9

30 Cross Section A
29
31
10
33
11

12

13
14

18

25

16
17

20

SM5111

36 38 40 24,23 32 27 26
EX285
EX255-EX285 W3-2-53

TRAVEL DEVICE

10. Install spacer (7) into housing (12) with the oil
groove side facing downward, aligning the oil
groove and the hole on housing (12).

11. Install plates (6) (5 used) and friction plates (20) (4

used) one by one alternately, aligning notches of
each plate and friction plate. Be sure to install
plates (6) to housing (12) side and friction plates
(20) to drive disc (8) side.

12. Attach D-rings (3) and (5) onto piston (4). Install
piston (4) into housing (12).

NOTE - Tap the end of piston (4) with a plastic hammer

for easy insertion.

17 8

13. Install disc spring (2) onto housing (12) with the
larger diameter side facing upward.

14. Aligning matching marks, install plungers (17) into

the spherical joints on drive disc one by one.
Confirm that plungers (17) move smoothly in the
joints.
SM1095
15. Install center shaft (26) onto drive disc (8). Attach
center spring (27) onto center shaft (26).

16. Insert the top part of center shaft (26) into the
center hole on rotor (18), aligning pin (25) on center
shaft (26) with the groove on rotor (18).
18
17. Insert plungers (17) into rotor (18) one by one,
aligning the matching marks. Be sure that the
groove on rotor (18) comes over pin (25) on shaft
(26).

18. Install O-rings (1) and (15) onto housing (12).

19. Add hydraulic oil into housing (12).

Hydraulic oil:1.3 L (1.37 US qt) 26 25
SM1096
20. Remove plug (23) from brake valve (33).
: 10 mm

21. Install plate (30) on brake valve (33).

W3-2-54 EX285
EX255-EX285

TRAVEL DEVICE

34,35 28

30 Cross Section A
29
31
33

22 21 19

37

39

SM5111

36 38 40 24,23
EX255-EX285
EX285 W3-2-55

TRAVEL DEVICE

22. Attach piston rings (37) onto servo piston (36).

Then, attach them to special tool (75301530). 36

23. Insert servo piston (36) into brake valve (33).

24. If replacing bushing (28), drive it into valve plate

(29) using special tool (75301494).

NOTE - Note the facing direction of the oil groove side

when removing the bushing.

25. Apply LOCTITE 262 to plugs (19). Install link (21) 75301530 SM1097
on valve plate (29) using plugs (19).
: 6 mm
: 49 N m (5 kgf m, 36 lbf ft) 29 21

26. Install link (21) and valve plate (29) to fit into the
groove on plate (30). Align the groove of link (21)
with servo piston (36).

27. Align the holes on link (21) and on servo piston (36)
by inerting the aligning tool (75301500) through
plug (23) hole.

28. Apply extreme-pressure grease to the tip of

reamer bolt (22) to prevent seizure between parts.
Install reamer bolt (22) into link (21) and servo
piston (36) through the other plug (23) hole on the 19 SM1098
opposite side.
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft) 36 75301500 21

29. Remove plug (35) from brake valve (33). Secure

valve plate (29) using a fastening device.

30. Install O-ring (38) on cover (39). Install cover (39)

on brake valve (33) using socket bolts (40).
: 10 mm
: 88 N m (9 kgf m, 65 lbf ft)

SM1099
22
W3-2-56 EX255-EX285
EX285

TRAVEL DEVICE

34,35 28 1 15 2 3 4 5 6 7 8 9

30 Cross Section A
29
31
10
33
11
12

13

14

18
25

16

17
20

SM5111

36 38 40 24,23 32 27 26
EX255-EX285
EX285 W3-2-57

TRAVEL DEVICE

31. Attach special tool (75301501) to the top of center

shaft (26).

32. Remove plug (A) from brake valve (33). Remove

spool (B) and spring (C).
: 8 mm
75301501
26
WARNING
Brake valve weight: 43 kg (95 Ib)

33. Attach brake valve (33) to a crane. Lift brake valve SM1092

(33) and align special tool (75301501) with plug (A) 12

hole. Then, install brake valve (33) onto housing
(12).

34. Remove special tool (75301501) and the fastening

device from brake valve (33).

35. Install plugs (23) and (35), spool (B), spring (C),
and plug (A) to brake valve (33).
: 5 mm
: 15 N m (1.5 kgf m, 11 lbf ft)

: 8 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
: 10 mm
: 118 N m (12 kgf m, 90 lbf ft)

36. Install socket bolts (32).

: 14 mm
: 390 N m (40 kgf m, 290 lbf ft)
W3-2-58 EX285
EX255-EX285

TRAVEL DEVICE

DISASSEMBLE BRAKE VALVE (EX285)

9
A
10

12 4

17 5
13
16
6
15
14 4 1,2

12
21
10 7
20
6
14
15 9 5
19 16 8 1,2
18 17 4

SM5112

A - Parking Brake Shuttle Valve 7 - Poppet (2 Used) 16 - O-Ring (2 Used)

B - Servo Piston Shuttle Valve 8 - Plug (2 Used) 17 - Plug (2 Used)
1 - O-Ring (2 Used) 9 - O-Ring (2 Used) 18 - Plug
2 - Overload Relief Valve (2 Used) 10 - Spring (2 Used) 19 - O-Ring
3 - Casing 12 - Stopper (2 Used) 20 - Spool
4 - Plug (2 Used) 13 - Spool 21 - Spring
5 - O-Ring (2 Used) 14 - Ball (2 Used)
6 - Spring (2 Used) 15 - Seat (2 Used)
EX285
EX255-EX285 W3-2-59

TRAVEL DEVICE

Disassemble Brake Valve • Reducing Valve

• Be sure to thoroughly read “Precautions for Dis- 11. Remove plug (18) and O-ring (19) from
assembly and Assembly” on page W1-1-1 before casing (3).
starting the disassembly work.
: 8 mm

12. Remove spool (20) and spring (21).

• Counterbalance Valve

1. Remove plug (8) and O-ring (9) from casing

(3).
: 41 mm

2. Remove spring (10) and stopper (12).

3. Remove spool (13) from casing (3).

• Overload Relief Valve

4. Remove overload relief valve (2) from cas

ing (3).
: 27 mm

• Check Valve

5. Remove plug (4) and O-ring (5) from casing

(3).
: 12 mm

6. Remove spring (6) and poppet (7).

• Servo Piston Operating Shuttle Valve

7. Remove plug (17) and O-ring (16) from

casing (3).
: 6 mm

8. Remove seat (15) and tilt casing (3) to

remove ball (14).
: 5 mm

• Parking Brake Release Shuttle Valve

9. Remove plug (17) and O-ring (16) from

casing (3).
: 6 mm

10. Remove seat (15) and tilt casing (3) to

remove ball (14).
: 5 mm
W3-2-60 EX255-EX285
EX285

TRAVEL DEVICE

ASSEMBLE BRAKE VALVE (EX285)

14
15

16

14 17
15
16 17
Section B
Section C

2 1 7 6 19 20 21

18

3
4
5

8
9

13 12 10 Section A-A

SM5113

1 - O-Ring (2 Used) 8 - Plug (2 Used) 16 - O-Ring (2 Used)

2 - Overload Relief Valve (2 Used) 9 - O-Ring (2 Used) 17 - Plug (2 Used)
3 - Casing 10 - Spring (2 Used) 18 - Plug
4 - Plug (2 Used) 12 - Stopper (2 Used) 19 - O-Ring
5 - O-Ring (2 Used) 13 - Spool 20 - Spool
6 - Spring (2 Used) 14 - Ball (2 Used) 21 - Spring
7 - Poppet (2 Used) 15 - Seat (2 Used)
EX285
EX255-EX285 W3-2-61

TRAVEL DEVICE

Assemble Brake Valve 5. Install O-ring (16) to plug (17), then install it to
casing (3).
• Reducing Valve
: 6 mm
1. Insert spring (21) and spool (20) into casing (3), : 34 N m (3.5 kgf m, 25 lbf ft)
and tighten plug (18) with O-ring (19) to casing
(3).
• Check Valve
: 8 mm
: 69 N m (7 kgf m, 51 lbf ft) 6. Insert poppet (7) with spring (6) into casing (3),
and tighten plug (4) with O-ring (5) to casing
(3).
• Parking Brake Relief Valve
: 12 mm
(Cross Section C-C)
: 235 N m (24 kgf m, 175 lbf ft)
2. Tilt casing (3) and insert ball (14). Apply
LOCTITE 262 to seat (15) and tighten it to
casing (3). • Overload Relief Valve
: 5 mm
7. Install overload relief valve (2) to casing (3).
: 14.5 N m (1.5 kgf m, 11 lbf ft)
: 27 mm
: 540 N m (55 kgf m, 400 lbf ft)
IMPORTANT - Before inserting ball (14), put ball (14)
on seat (15) and tap on the ball with a hammer to obtain
tight fitting between ball (14) and seat (15). Also, after • Counterbalance Valve
inserting ball (14) and before tightening seat (15),
insert a metal bar into the plug hole to apply its end to 8. Insert spool (13) into casing (3).
ball (14), then tap the other end of the bar to obtain tight
fitting between ball (14) and the casing.
IMPORTANT - Apply film of hydraulic oil to spool (13).

3. install O-ring (16) to plug (17), then install it to

casing (3). 9. Install spring (10) to stopper (12), then insert it
into casing (3).
: 6 mm
: 34 N m (3.5 kgf m, 25 lbf ft)

10. Install O-ring (9) to plug (8), then install to

• Servo Piston Operating Shuttle Valve casing (3).
(Cross Section B-B)
: 41 mm
4. Tilt casing (3) and insert ball (14). Apply : 340 N m (35 kgf m, 250 lbf ft)
LOCTITE 262 to seat (15) and tighten it to
casing (3).
IMPORTANT - Be sure to fill the travel device with
: 5 mm
hydraulic oil after installing it.
: 14.5 N m (1.5 kgf m, 11 lbf ft)

IMPORTANT - Before inserting ball (14), put ball (14)

on seat (15) and tap on the ball with a hammer to obtain
tight fitting between ball (14) and seat (15). Also, after
inserting ball (14) and before tightening seat (15),
insert a metal bar into the plug hole to apply its end to
ball (14), then tap the other end of the bar to obtain tight
fitting between ball (14) and the casing.
W3-2-62 EX255-EX285

TRAVEL DEVICE

MAINTENANCE STANDARD

Sprocket

E
A
SM1103

IMPORTANT - Consult FIAT-HITACHI for any inqueries concerning welding procedures.

Standard (mm) Allowable Limit

mm (in) mm (in) Remedy

EX255 EX285 EX255 EX285

A 72.0 (2.83) 93.0 (3.66) 64 (2.52) 75 (2.95)

B 579.6 (22.82) 616.5 (24.27) 570 (22.42) 602 (23.70) Build up and
finishing
PCD644.6 PCD689.4
C (25.38) (27.50) – –
704.0
D 658.4 (25.92) (27.72) 648 (25.51) 694 (27.32)
203.2
E 190.0 (7.48) (8.0) – –
EX255-EX285 W3-2-63

TRAVEL DEVICE

Parking Brake

E A B

C D
SM1104

Standard (Thickness) Allowable Limit

of Height (Thickness)
Part Name mm (in) mm (in) Remedy
EX255 EX285

A Friction Plate 3.3 (3.25) 3.25

B Spacer 8.5 (0.33) 9.0 (0.35) -

C Disk Spring 6.2 (0.24) 6.5 (0.26) 6.10 (0.24)

D Piston *41.5 (1.63) *46.0 (1.81) -

E Plate 1.8 (0.070) 1.75 (0.069)

Remark The spacer and piston do not wear down. New friction plates are
made with a marginal tolerance of plus (+) 0.1 mm in thickness.

NOTA - * Piston thickness (D) is the distance (width) between the disc spring (C) contacting left end of the piston
and the brake plate (E) contacting right end of the piston.
W3-2-64 EX255-EX285

TRAVEL DEVICE

NOTES
EX255-EX285 W3-3-1

CENTER JOINT

REMOVE AND INSTALL CENTER JOINT

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation
1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hy-
draulic oil tank.
NOTE - Be sure to run the vacuum pump continu-
ously while working.

Removal Installation

NOTE - Attach labels or tags to hoses and adapters, NOTE - Refer to “Removal” section above for wrench
to aid in assembly. sizes and tightening torque.

1. Disconnect hoses (1), (2), and (5) to (16). 1. Install the center joint and lift it, then tighten bolts
Remove the adapters. (17).
Loosen bolts (3) and remove lock plate (4). 2. Install adapters and hoses (1), (2), (5) to (16).
: 19 mm 3. Install lock plate (4) and tighten bolts (3).
: 34 N m (3.5 kgf m, 25 lbf ft)
: 22 mm 1 2 3 4
: 39 N m (4.0 kgf m, 29 lbf ft)
: 27 mm 8
: 93 N m (9.5 kgf m, 69 lbf ft)
: 36 mm
5
: 175 N m (18 kgf m, 130 lbf ft)

SM1141

NOTE - Plug all disconnected ends. 7 6

2. Attach the center joint to a hoist. 9

17
3. Remove bolts (17) and lower the hoist to remove 10
the center joint. 16
11
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft) 15

14 12
WARNING
Weight of center joint: 26.5 kg (58.5 lb) 13

SM1148
W3-3-2 EX255-EX285

CENTER JOINT

DISASSEMBLE CENTER JOINT

12

10 11

SM1149

1 - Plug 5 - Bushing 9 - Cover

2 - Spindle 6 - Body 10 - Retaining Ring
3 - Dust Seal 7 - Oil Seal (6 Used) 11 - O-Ring
4 - O-Ring 8 - Bolt (4 Used) 12 - Ring
EX255-EX285 W3-3-3

CENTER JOINT

Disassemble Center Joint

IMPORTANT - Put a matching mark on body (6) and

spindle (2).

WARNING 75301505
Weight of center joint: 26.5 kg (58.5 Ib)

8
1. Remove two bolts (8) and install two eyebolts
(M10, Pitch1.5, Length18 mm). Attach hoist to the
center joint, then secure it on workbench
(75298324). 6

2. Remove eyebolts and bolts (8) to remove cover

(9) from body (6).
SM1150
: 17 mm

3. Remove O-ring (11), retaining ring (10) and ring

(12) from body (6).

4. Attach the special tool (75301505) to body (6),

using bolts (8) (2 Used) and remove body (6) from
spindle (2).
: 17 mm

IMPORTANT - Take care not to damage the spindle.

5. Remove oil seals (7) from body (6).

6
IMPORTANT - Use two picks to pry out oil seals (7),
for easy removal, as illustrated.
Take care not to damage the seal groove with the pick.
7
6. Remove dust seal (3) and O-ring (4) from body
(6).

SM1151
W3-3-4 EX255-EX285

CENTER JOINT

ASSEMBLE CENTER JOINT

1 2

12

SM1152

11 10 9 8

1 - Plug 5 - Bushing 9 - Cover

2 - Spindle 6 - Body 10 - Retaining Ring
3 - Dust Seal 7 - Oil Seal (6 Used) 11 - O-Ring
4 - O-Ring 8 - Bolt (4 Used) 12 - Ring
EX255-EX285 W3-3-5

CENTER JOINT

Assemble Center Joint

1. Install O-ring (4) and dust seal (3) into body (6).

NOTE - If bushing is removed, be sure to reinstall

bushing (5) before installing dust seal (3).

2. Install oil seals (7) (6 Used) into body (6).

3. Secure spindle (2) to workbench (75298324).

Mount body (6) on spindle (2).

NOTE - Align with the matching mark on the spindle

and body.

IMPORTANT - Take care not to damage the seals 0,1 mm

when installing.
Clearance between body (6) and spindle (2) is about
0.1 mm (0.004 in), so that body (6) must be straight
to spindle (2).

4. Tap body (6) with a soft hammer until it touches

the edge of spindle (2).

IMPORTANT - Be sure to install ring (12) with the

chamfered side down. SM1153

5. Install ring (12) and O-ring (11) to body (6).

IMPORTANT - Be sure to install retaining ring (10)

with the chamfered side down.

6. Install retaining ring (10) to spindle (2).

7. Install cover (9) and tighten bolts (8) (4 Used).

: 17 mm
: 49 N m (5 kgf m, 36 lbf ft)
W3-3-6 EX255-EX285

CENTER JOINT

When replacing the body or spindle with new one, the

following procedures are required.
75301507
Replacing Body (6)

1. Clean body (6) and bushing (5). 6

2. Press bushing (5) into body (6), using pressing

tool (75301507). 5

Pressing force: 4.9 to 14.7 kN (500 to 1500 kgf,

1100 to 3300 lbf)

SM1154

Replacing Spindle (2)

1 2
1. Clean spindle (2).

2. Insert plugs (1) into spindle (2) using pressing

tools (75301506) so that the top of the plug sleeve A
is lower than the top surface of spindle (2).

3. Insert the balls into the plug sleeves so that the top
of each ball (A) is 0.4 mm ( 0.016 in ) or more lower Sleeve
than the respective sleeve edge, as illustrated in
the detail D.

Detail D

SM1155

75301506

Balls

SM1156
EX255-EX285 W3-3-7

CENTER JOINT

MAINTENANCE STANDARD

Item Allowable Limit (basis of judgment) Remedy

Bushing 1. Wear more than 0.2 mm (0.008 in) Replace

2. Scored, abnormal wear. Replace

3. Uneven wear. Replace

(wear range is less than 180°).
Wear area

Body, Spindle Sliding Surface and Scored or something hurt it Replace

Sealed Part

1. Scored more than 0.1 mm (0.004 in). Replace

Sliding Surface
Except Sealed Part 2. Scored less than 0.1 mm (0.004 in) Repair with
deep. oil stone

1. Wear more than 0.5 mm (0.02 in) Replace

deep. Abnormal wear.

Sliding Surface 2. Wear less than 0.5 mm (0.02 in) Repair

Ring deep.

3. Scored less than 0.5 mm (0.02 in) Repair

deep and able to repair.

Cover Sliding Surface 1. Wear more than 0.5 mm (0.02 in). Replace
Ring
2. Wear less than 0.5 mm (0.02 in). Repair

3. Scored less than 0.5 mm (0.02 in) Repair

deep and able to repair.
W3-3-8 EX255-EX285

CENTER JOINT

NOTES:
EX255-EX285 W3-4-1

TRACK ADJUSTER

REMOVE AND INSTALL TRACK

ADJUSTER

Before removing the track adjuster, the tracks and the

front idler must be removed first. For removal and
installation of the tracks and the front idler, refer to
applicable removal/installation sections. In this sec-
tion, the procedure starts on the premise that the
tracks and the front idler have already been removed.

Removal

WARNING
Track adjuster weight:
EX255: 118 kg (260 lb)
EX285: 161 kg (355 lb) 1 2

1. After removing the front idler and yoke, remove

track adjuster (1) from track frame (2) by prying it
out, using a pry bar.

Installation SM1157

1. As illustrated, install track adjuster (1) into spring

guide (3) on track frame (2). Check that the end
face of track adjuster (1) comes into contact with
the face of plate (4).

2 3 3 4

SM1175 SM1158
W3-4-2 EX255-EX285

TRACK ADJUSTER

DISASSEMBLE TRACK ADJUSTER

3
4

9
10

11

17 12
16

15

14

13
SM1159

3 - Wiper Ring 10 - Cylinder

4 - Piston Rod 11 - Plug 15 - Spacer
6 - U-Ring 12 - Valve 16 - Spring
8 - Rod 13 - Nut 17 - Seal
9 - O-Ring 14 - Washer
EX255-EX285 W3-4-3

TRACK ADJUSTER

Disassemble Track Adjuster

• Be sure to thoroughly read “Precautions for Disas-

sembly and Assembly” on page W1-1-1 before
starting the disassembly work.

Be sure to use special tool (75301508) for assem-

bly / disassembly of the track adjuster. 75301508

WARNING
Prevent personal injury. The spring force of the
track adjuster is extremely large.Thoroughly in-
spect the special tool for any damage. Carefully
perform assembly work referring to the procedure
below. SM1160

WARNING
Approximate weight of the track spring holder
assembly: 225 kg (496 lb)

Plate
1. Place a jack on the bottom of the track spring
holder assembly (75301508).

2. Loosen four nuts to remove the plate.

: 46 mm

WARNING
Track adjuster weight:
EX255: 118 kg (260 lb) SM1161

EX285: 161 kg (355 lb)

3. Connect the track adjuster to a hoist using a lifting

strap.
Put the track adjuster in the track spring holder
assembly (75301508), using the hoist.
Remove the lifting strap.

SM1162
W3-4-4 EX255-EX285

TRACK ADJUSTER

11

17 12

14

13
SM1159
EX255-EX285 W3-4-5

TRACK ADJUSTER

4. Install the plate on the spring holder.

Remove valve (12) with grease fitting. Plate

SM1163

5. Set an oil jack as illustrated.

Jack up the specified amount below to compress

the spring.

NOTE
EX255 - Specified Amount: A - B = 112 mm (4.41 in).
A = Free length: 689 mm (27.13 in);
B = Set length: 577 mm (22.72 in).
SM1164
EX285 - Specified Amount: A - B = 120 mm (4.72 in).
A = Free length: 677 mm (26.65 in);
B = Set length: 557 mm (21.93 in).

13 8
6. Tighten nuts to secure the track adjuster.
: 46 mm

Operate the oil jack to compress the track adjuster

approximately 10 mm (0.4 in) until a clearance is
observed between washer (14) and nut (13).

SM1165

13 8 11

7. Remove plug (11) and nut (13).

: 5 mm
: 75 mm

SM1166
W3-4-6 EX255-EX285

TRACK ADJUSTER

3
4

10

16

15

14

SM1159
EX255-EX285 W3-4-7

TRACK ADJUSTER

8. Lower jack to release the spring force.

SM1167

9. Loosen the nuts to remove the plate. Plate

Remove washer (14).

14

WARNING
Spring assembly weight:
SM1168
EX255: 110 kg (242 lb)
EX285: 148 kg (326 lb)

10. Remove the track adjuster, using an eyebolt (M16,

Pitch1.5) and hoist.
Remove the hoist and eyebolt.

WARNING
Spring weight:
EX255: 70 kg (154 lb)
EX285: 87 kg (192 lb)

11. Remove spring (16) from rod (8).

12. Remove spacer (15) from rod (8).

SM1169

13. Pull out piston rod (4) from cylinder (10).

W3-4-8 EX255-EX285

TRACK ADJUSTER

9
10

SM1159
EX255-EX285 W3-4-9

TRACK ADJUSTER

14. Remove rod (8) and O-ring (9) from cylinder (10). 3
6

15. Remove wear ring (3), and U-ring (6) from cylinder 10
(10).

SM1170
W3-4-10 EX255-EX285

TRACK ADJUSTER

ASSEMBLE TRACK ADJUSTER

EX255
12 11 13 2 14 8 15 16 9 B 10 4 6 3 1

577 mm (free length, 689 mm)

718 mm

SM1171

EX285

12 11 13 2 14 8 15 16 9 B 10 4 6 3 1

557 mm (free length, 677 mm)

707 mm

SM1171

1 - Idler 6 - U-Ring 11 - Plug 15 - Spacer

2 - Flange 8 - Rod 12 - Valve 16 - Spring
3 - Wiper Ring 9 - O-Ring 13 - Nut
4 - Piston Rod 10 - Cylinder 14 - Washer
EX255-EX285 W3-4-11

TRACK ADJUSTER

Assemble Track Adjuster

1. Clean all parts.

Install U-ring (6), and wiper ring (3) to cylinder (10).
3
2. Apply a film of grease to O-ring (9) and install it into 6
cylinder (10).
10
Install rod (8) into cylinder (10).

3. Apply grease to U-ring (6), wiper ring (3), cylinder

(10), and to piston rod (4). Install piston rod (4) into
cylinder (10).

IMPORTANT - Fill part (B) on cylinder (10) and insert SM1170

piston rod (4) to completely bleed air from part (B) and
from the inside of rod (8).

4. Install spacer (15) on rod (8).

8

WARNING
Spring weight:
EX255: 70 kg (154 lb)
EX285: 87 kg (192 lb)

5. Install spring (16) on rod (8).

WARNING
Spring assembly weight: SM1169

EX255: 110 kg (242 lb)

EX285: 148 kg (326 lb)

6. Put the track adjuster in the spring holder, using an

eyebolt (M16, Pitch1.5) and hoist. Remove the
hoist and eyebolt.
W3-4-12 EX255-EX285

TRACK ADJUSTER

EX255

11 13 14 8 16

577 mm (free length, 689 mm)

718 mm

SM1171

EX285

11 13 14 8 16

557 mm (free length, 677 mm)

707 mm

SM1171
EX255-EX285 W3-4-13

TRACK ADJUSTER

7. Install washer (14) on spring (16).

Install the plate. Plate

14

16

SM1168

8. Align the jack and track adjuster with the hole in

plate.
Tighten the nuts to secure the track adjuster.
: 46 mm

SM1165

9. Operate the jack to compress spring (16) to

specification. 16
Compressed Length: 577 mm (1 ft 10.7 in)

SM1172

13 8 11
10. Apply LOCTITE 242 to plug (11). Install nut (13)
and plug (11) to rod (8).

: 75 mm

: 5 mm

: 14.5 N m (1.5 kgf m, 11 lbf m)

SM1166
W3-4-14 EX255-EX285

TRACK ADJUSTER

EX255

12 8

577 mm (free length, 689 mm)

718 mm

SM1171

EX285

12 8

557 mm (free length, 677 mm)

707 mm

SM1171
EX255-EX285 W3-4-15

TRACK ADJUSTER

11. Install valve (12) to rod (8).

: 24 mm
: 147 N m (15 kgf m, 110 lbf ft)

12. Lower the jack.

SM1164

Plate
13. Remove the nuts and plate.
: 46 mm

SM1163

WARNING
Track adjuster weight:
EX255: 118 kg (260 lb)
EX285: 161 kg (355 lb)

14. Remove the track adjuster from the spring holder,

using a lifting strap and a hoist.

SM1173

15. If only the spring assembly is to be transported, be

sure to use a special tool, such as the one
illustrated, to carry the spring assembly safely.
: 24 mm

SM1174
W3-4-16 EX255-EX285

TRACK ADJUSTER

NOTES
EX255-EX285 W3-5-1

FRONT IDLER

REMOVE AND INSTALL FRONT IDLER

Before removing the front idler, the tracks must be

removed first. For removal and installation of the
tracks, refer to “Remove and Install Tracks” section.
In this section, the procedure starts on the premise
that the tracks has already been removed.

SM1176

Removal

WARNING
Front idler weight: 1
EX255: 123 kg (271 lb)
EX285: 203 kg (448 lb)
3

1. Slide the front idler forward, using a pry bar.

2. Attach the front idler to a hoist, then remove front

idler (1) from track frame (3).
2
SM1177

3. To keep the front idler (1) for a time, place it on

blocks as shown.

SM1178

1
Installation

1. Attach front idle (1) to a hoist, then install it to track 3

frame (3).
Apply a film of grease to the sliding surface
between track frame (3) and yoke bearing (2).

2
SM1190
W3-5-2 EX255-EX285
EX255

FRONT IDLER

DISASSEMBLE FRONT IDLER (EX255)

2
1
3

7 4
6

6
8
5
4
3
2
1

9
10

SM1179

1 - Bearing (2 Used) 5 - Axle 9 - Yoke

2 - Elastic pin (2 Used) 6 - Bushing (2 Used) 10 - Bolt (4 Used)
3 - O-Ring (2 Used) 7 - Idler
4 - Floating Seal (2 Used) 8 - Plug (2 Used)
EX255-EX285
EX255 W3-5-3

FRONT IDLER

Disassemble Front Idler

• Be sure to thoroughly read “Precautions for Disas-

sembly and Assembly” on page W1-1-1 before
starting the disassembly work.

1. Loosen bolts (10) to remove yoke (9). Remove

plug (8) from bearing (1) to drain oil into a container.
: 24 mm
: 6 mm

2. Remove elastic pin (2).

: 16 mm
1 5

WARNING 7
Total weight including idler:
Approx. 107 kg (236 lb)

3. Set the idler assembly in a press as illustrated. SM1180

Apply the press on the axle end. Push axle (5) out
of bearing (1) using the press. Axle (5) will come
off idler (7), and the upper side bearing (1) will also
be separated from idler (7). 1

4
4. Remove floating seal (4) from bearing (1) and idler
(7). 7

IMPORTANT - For handling of floating seal (4), refer 4

to the section “Floating seal precautions” on page
W1-1-3. 3

SM1181
W3-5-4 EX255-EX285
EX255

FRONT IDLER

6
5

SM1179
EX255-EX285
EX255 W3-5-5

FRONT IDLER

5. Press out axle (5) to remove bearing (1) and

O-ring (3). 3
1

SM1182

6. Remove bushings (6), using special tool.

Special Tool: 75301510

75301510

SM1183
W3-5-6 EX255
EX255-EX285

FRONT IDLER

ASSEMBLE FRONT IDLER (EX255)

1 2 4 5 6

10

3 8 9

SM1184
7

1 - Bearing (2 Used) 5 - Axle 9 - Yoke

2 - Elastic pin (2 Used) 6 - Bushing (2 Used) 10 - Bolt (4 Used)
3 - O-Ring (2 Used) 7 - Idler
4 - Floating Seal (2 Used) 8 - Plug (2 Used)
EX255-EX285
EX255 W3-5-7

FRONT IDLER

Assemble Front Idler

1. Install bushing (6) into idler (7) using a press. 2

5
2. Install O-ring (3) (1 piece) onto axle (5). Aligning
the pin holes, install axle (5) into bearing (1) and
secure using elastic pin (2). Take care not to 1
damage O-ring (3).

IMPORTANT - The elastic pin (2) has to be fitted with

the slit oriented to the internal side of the idler.
3 SM1185

3. Install floating seal (4) (one pair) into idler (7) and
into bearing (1). 7 4 1

IMPORTANT - For handling of floating seal (4), refer

to the section “Floating seal precautions” on page
W1-1-3.

4. Insert axle (5) into idler (7) from the floating seal
installed side. Install O-ring (3) onto axle (5). 5

5. Install the other floating seal (4) (one pair) into SM1186

idler (7) and into the other bearing (1).

6. Install bearing (1) onto axle (5), aligning the pin

holes. Secure them using elastic pin (2).
1 4 3 7

1
IMPORTANT - The elastic pin (2) has to be fitted with
the slit oriented to the internal side of the idler.

7. Add engine oil via plug (8) hole on bearing (1).

Apply sealant (LOCTITE 503 or equivalent) to
plug (8). Tighten plug (8).
SM1187
: 6 mm
: 20 N m (2 kgf m, 15 lbf ft)

SAE 30 oil quantity: 265 cm3 (0.28 US qt)

2
8. Install yoke (9) and tighten bolts (10).
: 24 mm
: 206 N m (21 kgf m, 152 lbf ft) 5

SM1188
W3-5-8 EX285
EX255-EX285

FRONT IDLER

DISASSEMBLE FRONT IDLER (EX285)

2
1
4
6 3

12
8
6

4 3
2
1

11
10

SM5115

1 - Bearing (2 Used) 5 - Axle 9 -Yoke

2 - Elastic pin (2 Used) 6 - Bushing (2 Used) 10 - Bolt (4 Used)
3 - O-Ring (2 Used) 7 - Idler 11 - Washer (4 Used)
4 - Floating Seal (2 Used) 8 - Plug 12 - O-Ring
EX285
EX255-EX285 W3-5-9

FRONT IDLER

Disassemble Front Idler

• Be sure to thoroughly read “Precautions for Disas-

sembly and Assembly” on page W1-1-1 before
starting the disassembly work.

1. Loosen bolts (10) to remove yoke (9). Remove

plug (8) from bearing (1) to drain oil into a container.
: 24 mm
: 6 mm

2. Remove elastic pin (2).

: 16 mm
1 5

CAUTION 7
Total weight including idler:
Approx. 177 kg (390 lb)

3. Set the idler assembly in a press as illustrated. SM1180

Apply the press on the axle end. Push axle (5) out
of bearing (1) using the press. Axle (5) will come
off idler (7), and the upper side bearing (1) will also
be separated from idler (7). 1

4
4. Remove floating seal (4) from bearing (1) and idler
(7). 7

IMPORTANT - For handling of floating seal (4), refer 4

to the section “Floating seal precautions” on page
W1-1-3. 3

SM1181
W3-5-10 EX285
EX255-EX285

FRONT IDLER

6 3

SM5115
EX285
EX255-EX285 W3-5-11

FRONT IDLER

5. Press out axle (5) to remove bearing (1) and

O-ring (3). 3
1

SM1182

6. Remove bushings (6), using special tool.

Special Tool: 75301509

75301509

SM1183
W3-5-12 EX255-EX285
EX285

FRONT IDLER

ASSEMBLE FRONT IDLER (EX285)

1 2 4 5 8-12

10-11

SM5116

7 6 3

1 - Bearing (2 Used) 5 - Axle 9 - Yoke

2 - Elastic pin (2 Used) 6 - Bushing (2 Used) 10 - Bolt (4 Used)
3 - O-Ring (2 Used) 7 - Idler 11 - Washer (4 Used)
4 - Floating Seal (2 Used) 8 - Plug 12 - O-Ring
EX255-EX285
EX285 W3-5-13

FRONT IDLER

Assemble Front Idler

1. Install bushing (6) into idler (7) using a press. 2

5
2. Install O-ring (3) (1 piece) onto axle (5). Aligning
the pin holes, install axle (5) into bearing (1) and
secure using elastic pin (2). Take care not to 1
damage O-ring (3).

IMPORTANT - The elastic pin (2) has to be fitted with

the slit oriented to the internal side of the idler.
3 SM1185

3. Install floating seal (4) (one pair) into idler (7) and
into bearing (1). 7 4 1

IMPORTANT - For handling of floating seal (4), refer

to the section “Floating seal precautions” on page
W1-1-3.

4. Insert axle (5) into idler (7) from the floating seal
installed side. Install O-ring (3) onto axle (5).
5
5. Install the other floating seal (4) (one pair) into SM1186

idler (7) and into the other bearing (1).

6. Install bearing (1) onto axle (5), aligning the pin

holes. Secure them using elastic pin (2).
1 4 3 7

1
IMPORTANT - The elastic pin (2) has to be fitted with
the slit oriented to the internal side of the idler.

7. Add engine oil via plug (8) hole on bearing (1).

Apply sealant (LOCTITE 503 or equivalent) to
plug (8). Tighten plug (8).
: 6 mm SM1187

: 20 N m (2 kgf m, 15 lbf ft)

SAE 30 oil quantity: 380 cm3 (0.41 US qt)

2
8. Install yoke (9) and tighten bolts (10).
: 24 mm
: 225 N m (23 kgf m, 166 lbf ft) 5

SM1188
W3-5-14 EX255-EX285

FRONT IDLER

MAINTENANCE STANDARD

Front Idler

C D

A
B SM1189

Standard Allowable Limit

(mm) (in) (mm) (in) Remedy

EX255 EX285 EX255 EX285

A 84 (3.31) 101 (3.98) 66 (2.60) 92 (3.62)

B 159 (6.26) 203 (7.99) – Buildup weld

and
C 500 (19.69) 530 (20.87) 482 (18.98) 520 (20.47) finishing

D 540 (21.26) 574 (22.60) –

E 20 (0.79) 22 (0.87) –

IMPORTANT - Consult FIAT-HITACHI for any inqueries concerning welding procedures.

Axle and Bushing

Standard Allowable Limit

Remedy
(mm) (in) (mm) (in)

EX255 EX285 EX255 EX285

Axle Outside Dia. 75 (2.95) 85 (3.35) 74.2 (2.92) 84.2 (3.31)

Replace
Bushing Inside Dia. 75 (2.95) 85 (3.35) 76 (2.99) 86 (3.39)

Bushing Flange Thickness 2 (0.08) 1.2 (0.05)

EX255-EX285 W3-6-1

UPPER AND LOWER ROLLER

REMOVE AND INSTALL UPPER ROLLER

Removal

WARNING
Do not loosen valve (1) quickly or loosen it too
much as high-pressure grease in the adjusting
cylinder may spout out. Loosen carefully, keeping
body parts and face away from valve (1).
Never loosen grease fitting (2).
SM1228

IMPORTANT - When gravel or mud is packed between

sprockets and tracks, remove it before loosening. 1

1. Loosen valve (1) to drain grease.

: 24 mm

Grease Outlet SM0100

WARNING 3
Use a nonskid cloth between track frame (5) and oil
jack to prevent slipping.

2. Jack up tracks (3) heigh enough to permit upper

roller (4) removal.

SM1230
5 4

3. Insert a wooden block between tracks (3) and track

frame (5). 3

5
SM1231
W3-6-2 EX255-EX285

UPPER AND LOWER ROLLER

4. Remove bolts (2) from upper roller (1).

: 24 mm

SM1233

WARNING
Upper roller weight:
EX255: 14 kg (31 lb)
EX285: 16 kg (35 lb)
1

5. Remove upper roller (1) from track frame (3).

SM1233
3

Installation

WARNING
Upper roller weight:
EX255: 14 kg (31 lb)
EX285: 16 kg (35 lb)
1
1. Install upper roller (1) and bolts (2). 2
: 24 mm
3
: 265 N m (27 kgf m, 195 lbf ft)
SM1233

2. Remove the wooden block and jack.

SM1230
EX255-EX285 W3-6-3

UPPER AND LOWER ROLLER

3. Supply grease to valve (1) to adjust tracks tension. 1

Grease Outlet SM0100

Check the track tension measuring the track sag

(A) as indicated in the TRACKS section.
Track sag specifications (A):
EX255: 300 to 335 mm (11.8 to 13.2 in)
EX285: 340 to 380 mm (13.4 to 15.0 in)
: 24 mm
: 147 N m (15 kgf m, 108 lbf ft)

NOTE - Check track sag after thoroughly removing soil

stuck on the track area by washing.

SM1234

4. Add engine oil via plug (4) hole on cover (5). Apply
sealant (LOCTITE 503 or equivalent) to plug (4).
Tighten plug (4).
5
SAE 30 oil quantity:
EX255: 85 cm3 (0.09 US qt) 4
EX285: 75 cm3 (0.08 US qt)
: 6 mm
: 9.8 to 19.6 N m
(1 to 2 kgf m, 7.5 to 15 lbf ft)

SM1235
W3-6-4 EX255-EX285

UPPER AND LOWER ROLLER

REMOVE AND INSTALL LOWER ROLLER

Removal

1. Remove the roller guard and loosen bolts (5).

EX255 5
: 27 mm

EX285
: 30 mm
SM1236

2. Lift the one side of the track frame high enough to

remove the lower roller.
Insert wooden blocks under track frame (2).

SM1237

WARNING
Do not loosen valve (3) quickly or loosen it too
much as high-pressure grease in the adjusting
cylinder may spout out. Loosen carefully, keeping
body parts and face away from valve (3).
Never loosen grease fitting (4).

SM1228

3. Loosen valve (3) to drain grease enough to permit

the roller removal.

: 24 mm

Grease Outlet SM0100

EX255-EX285 W3-6-5

UPPER AND LOWER ROLLER

WARNING
Lower roller weight:
EX255: 35 kg (77 lb)
EX285: 56 kg (123 lb)

4. Securely hold the lower roller using a fork lift.

Remove lower roller (1).
1 SM1238

Installation 2 1
1. Securely hold the lower roller using a fork lift.
Put lower rollers (1) on the tracks as illustration.

SM1239

2. Lower track frame (2) enough to allow bolts (4) to be 2 4

installed into track frame (2).

SM1240

3. Align tapped holes in track frame (2).

Tighten bolt (4).

EX255
4
: 27 mm
: 400 N m (41 kgf m, 295 lbf ft)

EX285
: 30 mm SM1236

: 500 N m (51 kgf m, 369 lbf ft)

W3-6-6 EX255-EX285

UPPER AND LOWER ROLLER

4. Supply grease to valve (3) to adjust tracks tension.

3

Grease Outlet SM0100

Check the track tension measuring the track sag

(A) as indicated in the TRACKS section.

Track sag specifications (A):

EX255: 300 to 335 mm (11.8 to 13.2 in)
EX285: 340 to 380 mm (13.4 to 15.0 in)

: 24 mm
: 147 N m (15 kgf m, 108 lbf ft)

SM1234

NOTE - Check track sag after thoroughly removing soil

stuck on the track area by washing.
EX255-EX285 W3-6-7

UPPER AND LOWER ROLLER

DISASSEMBLE UPPER ROLLER

NOTE - Replace the upper roller as an assembly.

SM1241
W3-6-8 EX255-EX285

UPPER AND LOWER ROLLER

DISASSEMBLE LOWER ROLLER

3
2
4
5
8

6
7
6
5
4
3
2
1

SM1242

1 - Plug (2 Used) 4 - O-ring (2 Used) 7 - Roller

2 - Collar ( 2 Used) 5 - Floating Seal (2 Used) 8 - Axle
3 - Elastic pin (2 Used) 6 - Bushing (2 Used)
EX255-EX285 W3-6-9

UPPER AND LOWER ROLLER

Disassemble Lower Roller

2 5 7 5
• Be sure to thoroughly read “Precautions for Disas-
sembly and Assembly” on page W1-1-1 before
starting the disassembly work.
5 2
1. Remove plug (1) and elastic pins (3) from collars
(2), and drain oil.
: 6 mm
: 14 mm SM1243

2. Press down axle (8) until O-ring (4) comes out of

collar (2). 4 2
Remove collar (2) from axle (8).

3. Remove O-ring (4) from axle (8).

Remove axle (8) from roller (7).
8

4. Remove floating seal (5) from roller (7) and collar

(2).

5. Press out axle (8), and remove collar (2) and O-ring SM1244

(4) from axle (8)

6. In case of replacing bushings (6), remove the

bushings using a press and the special tool.

Special Tool: 75301509 75301509

SM1245
W3-6-10 EX255-EX285

UPPER AND LOWER ROLLER

ASSEMBLE LOWER ROLLER

2 7 6 5 4 3 1

8
SM1246

1 - Plug (2 Used) 4 - O-ring (2 Used) 7 - Roller

2 - Collar ( 2 Used) 5 - Floating Seal (2 Used) 8 - Axle
3 - Elastic pin (2 Used) 6 - Bushing (2 Used)
EX255-EX285 W3-6-11

UPPER AND LOWER ROLLER

Assemble Lower Roller

8 3
1. Install bushings (6) (2 used) onto roller (7) using a
press. Take care not to dent the flange surface of
bushings (6). Apply a coat of grease to O-ring (4)
and install onto axle (8).

2. Install collar (2) onto axle (8), aligning the pin holes.
Secure them using elastic pin (3). Take care not to 2 4 SM1247

damage O-ring (4).

7 5
IMPORTANT - The elastic pin has to be fitted with the
slit oriented to the internal side of the roller.

5 2
IMPORTANT - For handling of floating seal (5), refer to the
section "Floating seal precautions” on page W1-1-3.

3. Install floating seal (5) to roller (7) and to collar (2).

SM1248

4. Insert axle (8) into roller (7). Install the other floating
seal (5) to roller (7) and to collar (2). Install O-ring
(4) the other collar (2). Secure them using elastic
2 5 8 7
pin (3).

IMPORTANT - The elastic pin has to be fitted with the

slit oriented to the internal side of the roller.

5. Add oil via plug (1) hole on collar (2). Apply sealant SM1249

(LOCTITE 503 or equivalent) to plug (1). Tighten 4

plug (1).

SAE 30 oil quantity: 3 7

3
EX255: 278 cm (0.29 US qt)
3
EX285: 555 cm (0.59 US qt)
: 6 mm 1

: 9.8 to 19.6 N m
(1 to 2 kgf m, 7.5 to 15 lbf ft)

SM1250
2
W3-6-12 EX255-EX285

UPPER AND LOWER ROLLER

MAINTENANCE STANDARD

Upper Roller

SM1251

Standard Allowable Limit

Remedy
(mm) (in) (mm) (in)

EX255 EX285 EX255 EX285

A 84 (3.31) 98 (3.86) –
Replace
B 150 (5.91) 165 (6.50) –

C 120 (4.72) 110 (4.33)

Lower Roller

SM1252

Standard Allowable Limit

Remedy
(mm) (in) (mm) (in)
EX255 EX285 EX255 EX285

A 172 (6.77) 203 (7.99) 181.5 (7.15) 213 (8.39)

Buildup weld
B 218 (8.58) 256 (10.08) – and
finishing
C 23 (0.91) 26.5 (1.04) 11.5 (0.45) 18.5 (0.73)

D 155 (6.10) 175 (6.89) 139 (5.47) 165 (6.50)

IMPORTANT - Consult FIAT-HITACHI for any inqueries concerning welding procedure.

EX255-EX285 W3-6-13

UPPER AND LOWER ROLLER

Axle and Bushing

Standard Allowable Limit Remedy

(mm) (mm)
EX255 EX285 EX255 EX285

Axle Outside Dia. 65 (2.56) 75 (2.95) 64.2 (2.53) 74.2 (2.92)

Replace
Bushing Inside Dia. 65 (2.56) 75 (2.95) 66 (2.60) 76 (2.99)

Bushing Flange Thickness 2 (0.08) 1.2 (0.047)

W3-6-14 EX255-EX285

UPPER AND LOWER ROLLER

NOTES:
EX255-EX285 W3-7-1

TRACKS

REMOVE AND INSTALL TRACKS 5

Removal

1. Move the tracks so that master pin (3) is positioned 4

over front idler (4).
Put a wooden block under track shoes (5), as
shown.
3

SM1254

WARNING
Do not loosen valve (1) quickly on loosen too much
since high-pressure grease in the adjusting cylinder
may spout out.
Loosen carefully, keeping body parts and face
away from valve (1).
Never loosen grease fitting (2).

SM1253

2. To loosen the track tension, slowly turn valve (1) 1

counterclockwise one turn; grease will escape
from grease outlet.

: 24 mm

SM1255

Grease
outlet
SM0100
W3-7-2 EX255-EX285

TRACKS

WARNING
The front idler may jump out of position due to strong
spring force when the tracks is disconnected.
Especially, the strong spring force is always applied
to the bolt part of the rod. If the rod and/or the bolt
are damaged, metal fragments may fly off when the
tracks is disconnected.
Take the necessary precautions to prevent perso-
nal injuries.

SM1256

Spacer
3. Remove master pin (3) by using a special tool.

Bushing
3

SM1257
EX255 EX285
A 75294946 75294946
B 75294947 75295630 D C 3 E
C 75294964 75298429
D 75294963 75298430
E 75295757 75298428
G 75297580 75297580
G B A
SM1258

4. Slowly drive the machine in reverse until the whole

length of the removing track comes on the ground.

SM1259

5. Rotate the upperstructure 90 degrees toward the

removing track side, perpendicular to the tracks.
Operate the boom and arm so that the angle
between them is 90 to 110 degrees. Lower the 90° ÷ 110°
boom with the bucket rolled-in to jack up the
machine as illustrated.

SM1260
EX255-EX285 W3-7-3

TRACKS

Installation

1. Jack up the machine and put the track under the

lower roller. Idler side Sprocket
Be sure to position the track in correct direction, as side
illustrated.

SM1261

2. Lift the track, and place it on sprocket (1).

SM1262

3. Slowly turn the sprocket in forward direction.

SM1263

3
4. Turn sprocket (1) until end of track (4) comes on
front idler (3).
Lower the machine and put a wooden block as
illustrated.

SM1264
W3-7-4 EX255-EX285

TRACKS

IMPORTANT - Hole surfaces, link holes and Spacer

counterbore surfaces, bushing ends, shall be free from
dust and rust.

5. Install master pin (5), using a hammer and special Bushing

tool. 5

SM1257
EX255 EX285
A 75294946 75294946
B 75294947 75295630 D C 5 E
C 75294964 75298429
D 75294963 75298430
E 75295757 75298428
G 75297580 75297580
G B A
SM1258

IMPORTANT - Inject rust preventive protective (ex.

TECTYL165 G) between pin and bushing clearance.

IMPORTANT - If any links have been removed from

the track, be sure to charge the grease (es. AMBRA
MG2) into the clearance between the pin and bushing
when reconnecting the links. Also, apply a coat of
grease to the ends of the bushing.
Grease Charging Method:
- Stand the bushing on a flat plate.
- Fill the bushing bore with the grease.
- Insert the pin into the bushing while pushing the
bushing onto the plate (so that the bushing end
stays on the plate).
- Wipe off excess grease.

6. Supply grease to the cylinder through the grease

fitting to adjust the track tension.

: 24 mm

Check the track tension measuring the track sag SM1265

(A) as indicated in the pages to follow.

EX255-EX285 W3-7-5

TRACKS

Checking track sag

• Turn the upperstructure 90° and lower the bucket to

raise one track off the ground as shown.

• Keep the angle between boom and arm 90° to 110°

and rest the bucket round side (outer) onto the 90° ÷ 110°
ground.

• Place blocks under the frame to support the ma-

chine.

• Rotate the raised track in reverse two full rotations, S0012

then forward two full rotations.

• Measure track sag (A) at the middle of the frame and

from the bottom of the track frame to the back face
of the track shoe. Distance (A) should be:
EX255: 300 to 335 mm (11.8 to 13.2 in)
EX285: 340 to 380 mm (13.4 to 15.0 in)

NOTE: Check track sag after thoroughly removing dirt

stuck on the track by pressure-washing.

Precautions for adjusting track sag

• If track sag is not within specification, loosen or

tighten the track following the procedures detailed
below.

• When adjusting track sag, lower the bucket to the

ground to raise one track off the ground. Repeat this
SM1234
procedure to raise the other track. Place blocks
under the frame on the side of the raised track to
support the machine.

• After adjusting track sag of both tracks, move the

machine back and forth several times. Check track
sag again. If, after settling, this is not within
specifications repeat the above procedures until
correct sag is obtained.
W3-7-6 EX255-EX285

TRACKS

Loosening the track

2
WARNING
- Do not loosen the valve (1) quickly or too much as
grease pressure inside the cylinder might dan-
gerously eject it off its seat.
- Loosen the valve with care, keeping the body
parts and face away from the valve (1).
- Never loosen the grease fitting (2).

IMPORTANT: remove any matter such as mud or

1
gravel possibly stuck between sprockets and track OM0142
links before loosening.

• To loosen the track, slowly turn valve (1) anticlock-

wise using a 24 mm long socket. The grease will
escape from the valve base.

• 1 to 1.5 turns of the valve (1) are sufficient to loosen

the track.

• If grease does not come out evenly, slowly rotate the

raised track.

• When proper track sag is obtained, turn valve (1)

clockwise and tigthen to 14 daNm.

Tightening the track

WARNING
It is abnormal if the trac remains tight after turning
valve (1) anticlockwise or if the track is still loose
after charging grease through the grease fitting (2).
In such cases NEVER ATTEMPT TO DISASSEM-
BLE the track or the track adjuster due to danger-
ous high-pressure grease inside the track adjuster.
Contact your authorised FIAT-HITACHI Dealer im-
mediately.

• To tighten the track, inject grease from a grease gun

into fitting (2) until sag is within specification.
EX255-EX285 W3-7-7

TRACKS

MAINTENANCE STANDARD

Link Pin and Track Bushing

• Measure the length of four links, as illustrated, with

the tension on the track.
• Do not measure the master-pin included part of the
track.

SM1266
A

Standard Allowable Limit

(mm) (in) (mm) (in) Remedy

EX255 EX285 EX255 EX285 Buildup weld

and finishing
A 760.6 (29.95) 812 (31.97) 785.8(30.94) 830 (32.68) or replace

IMPORTANT - Consult FIAT-HITACHI for any inqueries concerning welding procedures.

Master Pin

SM1269

Standard Allowable Limit

(mm) (in) (mm) (in) Remedy

EX255 EX285 EX255 EX285

A 212 (8.35) 251 (9.88) – Replace

B 37.72 (1.48) 44.2 (1.74) 35.5 (1.39) 41.5 (1.63) Replace

W3-7-8 EX255-EX285

TRACKS

Master Bushing

SM1267

Standard Allowable Limit Remedy

(mm) (in) (mm) (in)

EX255 EX285 EX255 EX285

A 129.2 (5.09) 154 (6.06) –

Replace
B 38.7 (1.52) 44.45 (1.75) 41.5 (1.63) 47,3 (1.86)

C 59 (2.32) 66.675 (2.625) 54 (2.13) 63 (2.48)

Suola

SM1268

Standard Allowable Limit Remedy

(mm) (in) (mm) (in)

EX255 EX285 EX255 EX285

A 217.5 (8.56) 240 (9.45) –

Replace
B 10 (0.39) 13 (0.51) –

C 26 (1.02) 26.5 (1.04) 15 (0.59)

SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 - Front attachment
Remove and install front attachment
(monobloc version) ................................ W4-1-1
Maintenance Standard
(monobloc version) ................................ W4-1-6
Bucket teeth ......................................... W4-1-8
Standard dimensions for arm and
bucket connection ................................. W4-1-9
Remove and install front attachment
(triple articulation version) ................... W4-1-11
Maintenance Standard
(triple articulation version) ................... W4-1-16
EX255-EX285
Group 2 - Cylinders
Remove and install cylinders ................. W4-2-1
Hydraulic circuit pressure
release procedure ................................ W4-2-12
Cylinder air bleeding procedure ............ W4-2-13
Disassemble cylinders ......................... W4-2-14
Assemble cylinders ............................. W4-2-20
Maintenance Standard ........................ W4-2-26
Special Tools (EX255) ......................... W4-2-27
Special Tools (EX285) ......................... W4-2-28
EX255-EX285 W4-1-1

FRONT ATTACHMENT

REMOVE AND INSTALL FRONT ATTACHMENT

(monobloc version)

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first.
Push the air release valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on firm, level ground.

Position the front attachment as illustated and
lower the bucket to the ground.
SM1317

Removal

1. Disconnect lubrication pipes (12) from both boom 12

cylinder rod ends.
: 19 mm

2. Loosen lock nuts (1), remove bolt (2) and stop-

pers (3) from both boom cylinder rod ends.
: 30 mm
SM1318

WARNING
Boom cylinder weight:
EX255: 203 kg (448 lb) 4
EX285: 233 kg (514 lb)
4
2

WARNING 5
3
Prevent personal injury. Metal fragments may fly
off when a hammer is used to remove pins. Be
sure to wear necessary protection, such as gog- 1
gles, hardhat, etc.

3. Attach each boom cylinder to a crane. SM3502

Remove cylinder rod end pin (5) and thrust plate

(4) using a hammer and bar.
W4-1-2 EX255-EX285

FRONT ATTACHMENT

IMPORTANT - Avoid boom cylinder damage. A

grease fitting is located on the boom cylinder. Be sure
to position a wooden block so that the grease fitting
does not come in contact with the wooden block when
the boom cylinder is lowered.

4. Position a wooden block between the main frame

and the boom cylinder bottom, as illustrated.
Slowly lower the boom cylinder using the crane
onto the wooden block.

5. Stop the engine. Push the air release valve on top

of the hydraulic oil tank to release any remaining
pressure.
Completely release the residual pressure from the
hydraulic circuit by performing the “Hydraulic Cir-
cuit Pressure Release Procedure” Refer to page SM1320

W4-2-12.
Wooden Block

6. Disconnect hoses (8) and (7) of arm cylinder and

bucket cylinder.
Close all openings with plugs to keep clean.

: 36, 41 mm

7 8

SM3504

7. Remove bolts (10) and lock plate (9) from main

frame.
: 30 mm

10

9
11

SM3503
EX255-EX285 W4-1-3

FRONT ATTACHMENT

WARNING
Approx. weight of front attachment assembly:
EX255: 4550 kg (10 031 lb)
EX285: 5600 kg (12 346 lb)

8. Attach the boom to a crane.

Slighty hoist the boom to take out any wire rope
slack.

SM1323

9. Pull the boom foot pin with special tool

(75301511). 75301511

SM1350

10. Lift the front attachment. Drive the base machine

away from the front attachment and the crane.

SM1325
W4-1-4 EX255-EX285

FRONT ATTACHMENT

Installation

WARNING
Approx. weight of front attachment assembly:
EX255: 4550 kg (10 031 lb)
EX285: 5600 kg (12 346 lb)

1. Install the front attachment

Install dust seals to boom foot.
Align the boom foot boss with the main frame SM1325
boss. Insert a thrust plate to both right and left
sides of the boom foot boss to take out clearance
between the boom foot boss and the main frame
boss the remaining clearance should be less than
1 mm.

2. Install boom foot pin (11) using a hammer and bar.

Install bolt (10) (2 used) and lock plate (9). 10

: 30 mm
: 540 N m (55 kgf m, 398 lbf ft) 9
11

SM3503

3 Remove the plugs from the pipes or hoses.

Connect the arm and bucket hoses (7), (8) to the
pipes.
7 8
: 41 mm
: 295 N m (30 kg m, 218 lbf ft)
: 36 mm
: 235 N m (24 kgf m, 173 lbf ft)

WARNING
Boom cylinder weight:
SM3504
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)

4. Attach the boom cylinder to a crane. Lift the boom

cylinder and align the boom cylinder rod with the
pin hole on the boom.

NOTE - For easy alignment, start the engine and use

the boom control lever.

SM1326
EX255-EX285 W4-1-5

FRONT ATTACHMENT

NOTE - Fill the hydraulic oil tank with hydraulic oil to

the specified level.
Run the engine at idle. Check hose connections for
any oil leakage

IMPORTANT - Bleed air from hydraulic circuit.

WARNING
Prevent personal injury. Metal fragments may fly
off when a hammer is used to insert pins. Be sure 4
to wear necessary protection, such as goggles,
4
hardhat, etc.
2

3 5
5. Install thrust plate (4). Drive pin (5) into the pin
hole.
1

6. Install thrust plate (4), stopper (3), tighten bolt (2)

and lock nuts (1).
SM3502
: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)
Install the other boom cylinder following the same 12
procedures.

7. Connect lubrication pipes (12) to each boom

cylinder rod. Tighten the connection to specifica-
tion.
: 19 mm
: 29 N m (3 kgf m, 22 lbf ft)
SM1318

8. Remove the pipes, with pipe fittings located in the

holes (14), from the boom foot boss.

9. Remove plug (13) and install an adeguate grease

fitting into plug (13) removed hole.
Plug tapered thread: 3/8 GAS - UNI339

10. Fill grease via grease fitting.

Remove grease fitting and re-install the plug (13)
in the original position.

11. Connect the pipes, with pipe fittings, on the boom

SM5521
foot boss.
W4-1-6 EX255-EX285

FRONT ATTACHMENT

MAINTENANCE STANDARD
(monobloc version)

F E
G
C
H
D J
A
I
K
B

SM1328

Unit: mm (in)

Parts Name Standard Allowable Limit Remedy

EX255 EX285 EX255 EX285
A Pin 100 (3.94) 99,0 (3.90)
Bushing 100 (3.94) 101,5 (4.00)

B Pin 90 (3.54) 100 (3.94) 89.0 (3.50) 99.0 (3.90)

Boss (Main Frame) 90 (3.54) 100 (3.94) 91.5 (3.60) 101.5 (4.00)
Bushing (Boom Cylinder) 90 (3.54) 100 (3.94) 91.5 (3.60) 101.5 (4.00)

C Pin 90 (3.54) 100 (3.94) 89.0 (3.50) 99.0 (3.90)

Bushing (Boom Cylinder) 90 (3.54) 100 (3.94) 91.5 (3.60) 101.5 (4.00)
Boss (Boom) 90 (3.54) 100 (3.94) 91.5 (3.60) 101.5 (4.00) Replace

D Pin 90 (3.54) 100 (3.94) 89.0 (3.50) 99.0 (3.90)

Bushing 90 (3.54) 100 (3.94) 91.5 (3.60) 101.5 (4.00)

E Pin 80 (3.15) 90 (3.54) 79.0 (3.11) 89.0 (3.50)

Boss (Arm) 80 (3.15) 90 (3.54) 81.5 (3.21) 91.5 (3.60)
Bushing (Arm Cylinder) 80 (3.15) 90 (3.54) 81.5 (3.21) 91.5 (3.60)

F Pin 80 (3.15) 90 (3.54) 79.0 (3.11) 89.0 (3.50)

Boss (Boom) 80 (3.15) 90 (3.54) 81.5 (3.21) 91.5 (3.60)
Bushing (Arm Cylinder) 80 (3.15) 90 (3.54) 81.5 (3.21) 91.5 (3.60)
EX255-EX285 W4-1-7

FRONT ATTACHMENT

Unit: mm (in)

Parts Name Standard Allowable Limit Remedy

EX255 EX285 EX255 EX285
G Pin 80 (3.15) 79.0 (3.11)
Boss (Arm) 80 (3.15) 81.5 (3.21)
Bushing (Bucket Cylinder) 80 (3.15) 81.5 (3.21)

H Pin 90 (3.54) 89.0 (3.50)

Bushing 90 (3.54) 91.5 (3.60)
Bushing (Bucket Cylinder) 90 (3.54) 91.5 (3.60)
Replace
I Pin 80 (3.15) 79.0 (3.11)
Bushing 80 (3.15) 81.5 (3.21)

J Pin 90 (3.54) 89.0 (3.50)

Bushing 90 (3.54) 91.5 (3.60)

K Pin 90 (3.54) 89.0 (3.50)

Bushing 90 (3.54) 91.5 (3.60)

IMPORTANT - Be sure to install front attachment

bushings using a press.
W4-1-8 EX255-EX285

FRONT ATTACHMENT

BUCKET TEETH

Replacement

WARNING
Keep people not involved in the maintenance work
outside the working area.
Wear adequate personal clothes and glasses with
side shields as a protection against flying debris.

• Ensure the machine is parked on a level surface.

5 1 2 3
• Rest the bucket to the ground.

• Switch off the auto-idle, fully turn the engine speed

manual control anticlockwise, stop the engine,
remove the ignition key and move the safety lever
in the locked position (LOCK).

• Using a hammer (3) and a drift (2), as shown, drive

the lock pin (1) from its seat and remove the tooth.

4
SM1329

NOTE: Hit the lock pin (1) with the drift (2) on the pin
tapered portion to drive it out of its seat.

• Clean shank (5) surface and install a new tooth (4)

onto the shank.

• Install the lock pin (1) into its seat and drive it in
using a drift (2) and a hammer (3) until it is fully
seated.
EX255-EX285 W4-1-9

FRONT ATTACHMENT

STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION

d
e
f c
b

j
o p
k
i n

h m
g l
q
Cross-section A Cross-section B
SM1330

Unit: mm (in)

EX255 EX285

a (*) 460 (181.1) 475 (187)

b (*) 5 (2) 0 (0)

c 620 (244.1) 622 (244.9)

d 580 (228.3) 600 (236.2)

e 475 (187) 475 (187)

f 1547 (609) 1588 (625.7)

g 549 (216.1) 555 (218.5)

h 430 (169.3) 430 (169.3)

i 90 (35.4) 90 (35.4)

j 470 (185) 470 (185)

k 69 (27.1) 69 (27.1)

l 549 (216.1) 555 (218.5)

m 410 (161.4) 410 (161.4)

n 90 (35.4) 90 (35.4)

o 90° 90°

p 20° 45°

q 565 (222.4) 571 (224.8)

(*) Arm: 2 950 mm (1161.4 in) (EX255), 3 750 mm (1476.4 in) (EX285)
W4-1-10 EX255-EX285

FRONT ATTACHMENT

NOTES:
EX255-EX285 W4-1-11

FRONT ATTACHMENT

REMOVE AND INSTALL FRONT ATTACHMENT

(triple articulation version)

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first.
Push the air release valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on firm, level ground.

Position the front attachment as illustated and
lower the bucket to the ground.

SM1357

Removal

1. Disconnect lubrication pipes (12) from both boom 12

cylinder rod ends.
: 19 mm

2. Loosen lock nuts (1), remove bolt (2) and stoppers

(3) from both boom cylinder rod ends.
: 30 mm

SM1318

WARNING
4
Boom cylinder weight:
EX255: 203 kg (448 lb) 4
EX285: 233 kg (514 lb) 2

3 5
WARNING
Prevent personal injury. Metal fragments may fly 1
off when a hammer is used to remove pins. Be
sure to wear necessary protection, such as gog-
gles, hardhat, etc.
SM3502

3. Attach each boom cylinder to a crane.

Remove cylinder rod end pin (5) and thrust plate
(4) using a hammer and bar.
W4-1-12 EX255-EX285

FRONT ATTACHMENT

IMPORTANT - Avoid boom cylinder damage. A

grease fitting is located on the boom cylinder. Be sure
to position a wooden block so that the grease fitting
does not come in contact with the wooden block when
the boom cylinder is lowered.

4. Position a wooden block between the main frame

and the boom cylinder bottom, as illustrated.
Slowly lower the boom cylinder using the crane
onto the wooden block.

SM1320

5. Stop the engine. Push the air release valve on top Wooden Block
of the hydraulic oil tank to release any remaining
pressure.
Completely release the residual pressure from the
hydraulic circuit by performing the “Hydraulic Cir-
cuit Pressure Release Procedure”. Refer to page
W4-2-12.
7

8
6. Disconnect hoses (8), (7) and (31) of arm cylinder
and bucket cylinder and positioning cylinder.
Close all openings with plugs to keep clean.

: 36, 41 mm
: 12 mm
31

SM1358

7. Remove bolts (10) and lock plate (9) from main

frame.
: 30 mm
10

9
11

SM3503
EX255-EX285 W4-1-13

FRONT ATTACHMENT

WARNING
Front assembly weight:
EX255: 4890 kg (10 781 lb)
EX285: 5900 kg (13 007 lb)

WARNING
Avoid wire rope damage. Be sure to position a
necessary protection between the wire rope and
boom pin hole surfaces.

8. Attach the boom to a crane.

Using the boom pin hole for front attachment sling.

WARNING
To secure the top arm with an other crane, when
remove the front attachment.

9. Slighty hoist the boom to take out any wire rope 75301511
slack.

10. Pull the boom foot pin with special tool

SM1350
(75301511).

11. Lift the front attachment. Drive the base machine

away from the front attachment and the crane.

SM1325
W4-1-14 EX255-EX285

FRONT ATTACHMENT

Installation

WARNING
Front assembly weight:
EX255: 4890 kg (10 781 lb)
EX285: 5900 kg (13 007 lb)

WARNING
To secure the top arm with an other crane, when SM1325
remove the front attachment.

1. Install the front attachment.

Install dust seals to boom foot.
Align the boom foot boss with the main frame
boss. Insert a thrust plate to both right and left 10
sides of the boom foot boss to take out clearance
between the boom foot boss and the main frame
boss the remaining clearance should be less than
1 mm.
9
11

SM3503
2. Install boom foot pin (11) using a hammer and bar.
Install bolt (10) (2 used) and lock plate (9).

7
: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)
8

3 Remove the plugs from the pipes or hoses.

Connect positioning arm and bucket hoses (31)
(7), and (8) to the pipes.
: 41 mm
: 295 N m (30 kg m, 218 lbf ft) 31
: 36 mm
: 235 N m (24 kgf m, 173 lbf ft)
SM1358

WARNING
Boom cylinder weight:
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)

4. Attach the boom cylinder to a crane. Lift the boom

cylinder and align the boom cylinder rod with the
pin hole on the boom.

NOTE - For easy alignment, start the engine and use

the boom control lever. SM1326
EX255-EX285 W4-1-15

FRONT ATTACHMENT

NOTE - Fill the hydraulic oil tank with hydraulic oil to

the specified level.
Run the engine at idle. Check hose connections for
any oil leakage

IMPORTANT - Bleed air from hydraulic circuit.

WARNING
Prevent personal injury. Metal fragments may fly
off when a hammer is used to insert pins. Be sure 4
to wear necessary protection, such as goggles, 4
hardhat, etc.
2

3 5
5. Install thrust plate (4). Drive pin (5) into the pin
hole.
1

6. Install thrust plate (4), stopper (3), tighten bolt (2)

and lock nuts (1). SM3502

: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)
12

7. Connect lubrication pipes (12) to each boom

cylinder rod. Tighten the connection to specifica-
tion.
: 19 mm
: 29 N m (3 kgf m, 22 lbf ft)

SM1318
8. Remove the pipes, with pipe fittings located in the
holes (14), from the boom foot boss.

9. Remove plug (13) and install an adeguate grease

fitting into plug (13) removed hole.
Plug tapered thread: 3/8 GAS - UNI339

10. Fill grease via grease fitting.

Remove grease fitting and re-install the plug (13)
in the original position.

11. Connect the pipes, with pipe fittings, on the boom

foot boss.
SM5521
W4-1-16 EX255-EX285

FRONT ATTACHMENT

MAINTENANCE STANDARD
(triple articulation version)

L
E
M
D G
F C

A
N

H
B

I J

K
SM1357

Unit: mm (in)

Parts Name Standard Allowable Limit

Remedy
EX255 EX285 EX255 EX285
A Pin 100 (3.94) 99.0 (3.90)
Bushing 100 (3.94) 101.5 (4.00)

B Pin 90 (3.54) 100 (3.94) 89.0 (3.50) 99.0 (3.90)

Boss (Main Frame) 90 (3.54) 100 (3.94) 91.5 (3.60) 101.5 (4.00)
Bushing (Boom Cylinder) 90 (3.54) 100 (3.94) 91.5 (3.60) 101.5 (4.00)

C Pin 90 (3.54) 100 (3.94) 89.0 (3.50) 99.0 (3.90)

Bushing (Boom Cylinder) 90 (3.54) 100 (3.94) 91.5 (3.60) 101.5 (4.00)
Boss (Boom) 90 (3.54) 100 (3.94) 91.5 (3.60) 101.5 (4.00) Replace

D Pin 100 (3.94) 99.0 (3.90)

Bushing 100 (3.94) 101.5 (4.00)

E Pin 90 (3.54) 89.0 (3.50)

Boss (Arm) 90 (3.54) 91.5 (3.60)
Bushing (Positioning Cylinder) 90 (3.54) 91.5 (3.60)

F Pin 90 (3.54) 89.0 (3.50)

Boss (Boom) 90 (3.54) 91.5 (3.60)
Bushing (Positioning Cylinder) 90 (3.54) 91.5 (3.60)
EX255-EX285 W4-1-17

FRONT ATTACHMENT

Unit: mm (in)

Parts Name Standard Allowable Limit

Remedy
EX255 EX285 EX255 EX285
G Pin 80 (3.15) 79.0 (3.11)
Boss (Arm) 80 (3.15) 81.5 (3.21)
Bushing (Bucket Cylinder) 80 (3.15) 81.5 (3.21)

H Pin 90 (3.54) 89.0 (3.50)

Bushing 90 (3.54) 91.5 (3.60)
Bushing (Bucket Cylinder) 90 (3.54) 91.5 (3.60)

I Pin 80 (3.15) 79.0 (3.11)

Bushing 80 (3.15) 81.5 (3.21)

J Pin 90 (3.54) 89.0 (3.50)

Bushing 90 (3.54) 91.5 (3.60)
Replace
K Pin 90 (3.54) 89.0 (3.50)
Bushing 90 (3.54) 91.5 (3.60)

L Pin 80 (3.15) 90 (3.54) 79.0 (3.11) 89.0 (3.50)

Boss (Positioning) 80 (3.15) 90 (3.54) 81.5 (3.21) 91.5 (3.60)
Bushing (Arm Cylinder) 80 (3.15) 90 (3.54) 81.5 (3.21) 91.5 (3.60)

M Pin 80 (3.15) 90 (3.54) 79.0 (3.11) 89.0 (3.50)

Boss (Arm) 80 (3.15) 90 (3.54) 81.5 (3.21) 91.5 (3.60)
Bushing (Arm Cylinder) 80 (3.15) 90 (3.54) 81.5 (3.21) 91.5 (3.60)

N Pin 90 (3.54) 100 (3.94) 89.0 (3.50) 99.0 (3.90)

Bushing 90 (3.54) 100 (3.94) 91.5 (3.60) 101.5 (4.00)

IMPORTANT - Be sure to Install front attachment

bushings using a press.
W4-1-18 EX255-EX285

FRONT ATTACHMENT

NOTES
EX255-EX285 W4-2-1

CYLINDERS

REMOVE AND INSTALL CYLINDERS

WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first.
Push the air release valve on top of the hydraulic oil tank to release any remaining pressure.

Preparation

1. Park the machine on firm, level ground.

Position the front attachment as illustrated and
lower the bucket to the ground.

2. Push the air release valve on top of the hydraulic

oil tank to release any remaining pressure.
SM1317

Remove Bucket Cylinder

1. Insert wooden block (15) between bucket cylinder

(1) and arm (8).
1
2. Completely release the residual pressure from the
hydraulic circuit by performing the “Hydraulic Cir-
cuit Pressure Release Procedure”. Refer to page
W4-2-12.

15
IMPORTANT - Pin (6) end of the link will drop when pin
8
(6) is removed, possibly resulting in personal injury. Be
sure to secure the link using a piece of wire before 15
removing pin (6).
SM1331

3. Loosen nuts (4) and bolt (5), in that order.

Pull out pin (6). Then, remove thrust plates (16). 16
5
: 30 mm

SM3506
6
W4-2-2 EX255-EX285

CYLINDERS

4. Use wire (14) to secure cylinder rod (13) as illus- 13 1

trated.

5. Disconnected hoses (9) (2 Used) from bucket

cylinder (1).
Put plugs on cylinder pipes and hoses.

: 10 mm
: 36 mm
14 SM1333

WARNING
Bucket cylinder weight: 17
EX255: 172 kg (379 lb)
EX285: 209 kg (461 lb)
12 10

6. Use a crane to slightly hoist bucket cylinder (1).

18
Loosen lock-nuts (11), remove screw (12) and
stopper (18) then pull-out pin (10) using a hammer 11
and a bar, so that the end of the cylinder gets free.
Recover adjusting shims (17).
: 30 mm
1
SM5522

7. Remove bucket cylinder (1).

9
9
EX255-EX285 W4-2-3

CYLINDERS

Install Bucket Cylinder

WARNING
Bucket cylinder weight:
EX255: 172 kg (379 lb) 17
EX285: 209 kg (461 lb)

12 10
1. Connect bucket cylinder (1) to a crane using a sling
belt. 18
Align the hole on the bucket cylinder tube with the
pin hole on the arm-tip bracket. 11

2. Install thrust plates (17).

Insert pin (10). Then, install bolt (12) into stopper
(18). Tighten lock nuts (11). 1
SM5522
: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)
9
3. Connect two hoses (9) to bucket cylinder (1). 9
: 10 mm
: 88 N m (9.0 kgf m, 65 lbf ft)
: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)

NOTE - Fill the hydraulic oil tank with hydraulic oil to

the specified level.
Run the engine at idle. Check hose connections for
any oil leakage.

4. Align the bucket cylinder rod with bucket links (2), 2 5 18 16

(3).
Install thrust plates (16) and pin (6).

NOTE - For easy alignment, start the engine and use

the arm control lever.

6 3 4 SM3506
5. Install bolt (5), onto pin (6) and stopper (18); tighten
lock nuts (4).
: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)

IMPORTANT - If link (3) has been disconnected from

the arm, be sure to insert thrust plate (16) when
connecting it. Bleed air from hydraulic circuit.
W4-2-4 EX255-EX285

CYLINDERS

Remove Arm Cylinder

1
1. Insert a wooden block between arm cylinder (1) and
boom (12).

2. Stop the engine. Push the air release valve on top

of the hydraulic oil tank to release any remaining
pressure.
Completely release the residual pressure from the
hydraulic circuit by performing the “Hydraulic Cir-
SM1347
cuit Pressure Release Procedure”. Refer to page 12
W4-2-12.

13
11
3. Disconnect lubricant supply pipe from pin (9). 9
Loosen lock nuts (10) and remove bolt (11).
: 30 mm 2 1

4. Remove pin (9) and thrust plate (13).

10
SM3508

5. Use wire to secure cylinder rod (2) as illustrated.

SM1337

1
6. Disconnect arm cylinder hoses (7), (16).
Put plugs on the pipe on arm cylinder (1) and hoses. 8
7
: 36 mm

7. Disconnect Iubricant supply pipe (8).

: 19 mm
16

SM3509
EX255-EX285 W4-2-5

CYLINDERS

WARNING 1
Arm cylinder weight:
EX255: 300 kg (661 lb)
EX285: 310 kg (683 lb)

8. Use a crane to slightly hoist arm cylinder (1).

SM1335

1 5 15
3
9. Loosen lock nuts (4). Remove bolt (5) and pin (3).
Then remove thrust plate (15) from arm cylinder (1).
: 30 mm

SM3510
W4-2-6 EX255-EX285

CYLINDERS

Install Arm Cylinder

WARNING
Arm cylinder weight:
EX255: 300 kg (661 lb)
EX285: 310 kg (683 lb)

1. Use a crane to install arm cylinder (1) to the boom

bracket.

2. Install thrust plates (15) stopper (18) and pin (3).

Then, install bolts (5) and lock nuts (4) into stopper 1 5 15 3
(18).
: 30 mm 8
: 540 N m (55 kgf m, 398 lbf ft)
7
3. Attach lubricant supply pipe (8) and arm cylinder
hoses (7) and (16). 18
4
: 10 mm
: 88 N m (9 kgf m, 65 lbf ft)
: 19 mm 16
SM3509
: 29 N m (3 kgf m, 21 lbf ft)
: 36 mm
: 175 N m (18 kgf m, 129 lbf ft)

NOTE - Fill hydraulic oil tank with hydraulic oil to the

specified level.
Run the engine at idle. Check hose connections for
any oil leakage.
6

2
4. Remove wire (6) from arm cylinder (1).
Slightly hoist arm cylinder (1) and align the arm
cylinder rod with arm (14).
SM1337

NOTE - For easy alignment, start the engine and use

the arm control lever.
11 13 9

5. Install thrust plate (13), pin (9) and stopper (18).

Then, install bolt (11) into stopper (18) and pin (9).
Tighten lock nuts (10). 18

: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)

IMPORTANT - Bleed air from hydraulic circuit. 10 SM3508

EX255-EX285 W4-2-7

CYLINDERS

Remove Boom Cylinder

1. Park the machine on firm, level surface and lower

the bucket teeth and arm top to the ground with the
arm and bucket cylinders fully retracted as illu-
strated.

SM1317
2. Disconnect lubricant supply pipes (1).
: 19 mm
1

WARNING
Boom cylinder weight:
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb) 3

3. Use a crane to hoist the boom cylinder.

4. Loosen lock nuts (2), remove bolt (3) and stopper

4
(4). Using bar and hammer, tap pin (5) until the
boom cylinder is free. Remove thrust plate (6). 2
SM3511
: 30 mm 6 5

5. Use a wire to secure the boom cylinder rod as

illustrated.
Lower cylinder on proper stand.

6. Stop the engine. Push the air release valve on top

of the hydraulic oil tank to release any remaining
pressure.
Completely release the residual pressure from the
hydraulic circuit by performing the “Hydraulic Cir-
cuit Pressure Release Procedure”. Refer to page
W4-2-12.
SM1342
7. Disconnect boom cylinder hoses (11) (4 used). Put
plugs on cylinder pipes.
: 36 mm
11
10 8
8. Loosen lock nuts (7), Remove bolt (8), pins (9), and
thrust plates (10).
: 30 mm

WARNING
Boom cylinder weight:
EX255: 203 kg (448 lb) 9
EX285: 233 kg (514 lb)
7
9
9. Hoist the boom cylinder with a crane.
Remove the other boom cylinder following the
SM3512
same procedures.
W4-2-8 EX255-EX285

CYLINDERS

Install Boom Cylinder

WARNING
Boom cylinder weight:
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)

1. Use a crane to install the boom cylinders to the

main frame.

2. Install thrust plate (10) and pin (9). Then, install bolt SM1342
(8) and lock nuts (7). Tighten lock nuts (7).
: 30 mm
: 540 N m (55 kgf m, 400 lbf ft) 11
10 8
3. Install the other side boom cylinder.

4. Connect the boom cylinder hoses (11) (4 used).

: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)
9
NOTE - Fill the hydraulic oil tank with hydraulic oil to
the specified level. 7
Run the engine at idle. Check hose connections for 9
any oil leakage.
SM3512
5. Hoist the boom cylinder, and align the rod side with
the boom.

NOTE - For easy alignment, start the engine and use

the boom control lever.
3

WARNING
Prevent personal injury. Metal fragments may fly
off when a hammer is used to insert pins. Be sure
to wear necessary protection, such as goggles,
hardhat, etc. 4
2
6 5 6
6. Install pin (5) using a bar and hammer, then install SM3511
thrust plates (6).

7. Install bolt (3), stopper (4), and lock nuts (2).

Tighten lock nuts (2). 1
: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)

8. Install lubricant supply pipes (1).

: 19 mm
: 29 N m (3 kgf m, 21 lbf ft)

9. Install other boom cylinder following the same

procedure.
SM1346

IMPORTANT - Bleed air from hydraulic circuit.

EX255-EX285 W4-2-9

CYLINDERS

Remove positioning cylinder

(triple articulation version)

PREPARATION

1. Park the machine on firm, level ground.

Position the front attachment as illustrated and
lower the bucket to the ground.

2. Push the air release valve on top of the hydraulic

oil tank to release any remaining pressure.
SM1357

REMOVAL
5 6
1. Insert a wooden block between positioning cylinder
and boom.

2. Completely release the residual pressure from the

hydraulic circuit by performing the “Hydraulic Cir-
cuit Pressure Release Procedure”. Refer to page 7
W4-2-12.

3. Disconnect lubrication pipe from positioning cylin-

der (rod side).
4
SM1360

4. Loosen lock nuts (4), remove bolt (5) and stopper

(7).
Using bar and hammer, tap pin (6) until the position-
ing cylinder is free and remove thrust plate. 14

: 30 mm 13

5. Use wire (14) to secure cylinder rod (13) as illus- SM1337

trated.

6. Disconnected hoses (9) (2 used) from positioning

cylinder. Put plugs on cylinder hoses.
: 12 mm
9

7. Disconnect lubrication pipe (A) from positioning

cylinder (bottom side).
A

SM1358
W4-2-10 EX255-EX285

CYLINDERS

WARNING 1
Positioning cylinder weight:
EX255-EX285: 242 kg (534 lb)

8. Use a crane to slightly hoist positioning cylinder

(1).
Loosen lock nuts (11), remove bolt (12), stopper
(15) and pin (10).
Remove thrust plate. SM1361

12 1 10
9. Remove positioning cylinder (1).

15

11
SM1362
EX255-EX285 W4-2-11

CYLINDERS

Install positioning cylinder

12 1 10
WARNING
Positioning cylinder weight:
EX255-EX285: 242 kg (534 lb)

1. Connect positioning cylinder (1) to a crane using a

sling belt. 15
Align the hole on the positioning cylinder tube with
the pin hole on the boom-tip bracket. 11
SM1362

2. Install thrust plates and insert pin (10). Then install

stopper pin (15) and bolt (12) into pin (10). Tighten
lock nuts (11).

3. Connect lubrication pipe (A) to positioning cylinder

9
(bottom side).

4. Connect two hoses (9) to positioning cylinder (1).

: 12 mm A

NOTE - Fill the hydraulic oil tank with hydraulic oil to

the specified level. Run the engine at idle. Check hose
connections for any oil leakage.

SM1358

5. Remove wire (14) from positioning cylinder (13).

6. Slightly hoist positioning cylinder and align the

14
positioning cylinder rod with positioner.
Install thrust plate and insert pin (6).
13

NOTE - For easy alignment, start the engine and use SM1337
the positioner control lever.

5 6
7. Install stopper (7) and bolt (5) onto pin (6). Tighten
lock nuts (4).

8. Connect lubrication pipe to positioning cylinder

(rod side).
7

NOTE - Bleed air from hydraulic circuit.

4
SM1360
W4-2-12 EX255-EX285

CYLINDERS

HYDRAULIC CIRCUIT PRESSURE RE-

LEASE PROCEDURE

WARNING 4 6
Be sure to slowly loosen the overload relief valves.
Quick loosening of the overload relief valves may
cause pressurized oil to spout, possibly resulting in
severe burns and/or oil penetration of skin.

Release the residual circuit pressure by slowly loosen-

ing the overload relief valve(s) for the line(s) or hose(s)
to be disconnected.
: 32 mm
: 83±5N m (8.5±0.5 kgf m, 62±3.6 lbf ft)

IMPORTANT - Be sure to loosen the valve body, not SM1348

the adjusting screw. Also, be sure to re-tighten the

overload relief valve after releasing the residual circuit
pressure.
2
7

1 - Boom Cylinder (Bottom Side)

2 - Boom Cylinder (Rod Side)
3 - Arm Cylinder (Bottom Side)
4 - Arm Cylinder (Rod Side)
5 - Bucket Cylinder (Bottom Side)
6 - Bucket Cylinder (Rod Side)
7 - Positioning Cylinder (Rod Side)
8 - Positioning Cylinder (Bottom Side)
1
5
8 3
SM1349
EX255-EX285 W4-2-13

CYLINDERS

CYLINDER AIR BLEEDING PROCEDURE

WARNING
After installing the cylinder, be sure to do the work
air bleeding procedure.
Move in the horizontal direction for boom cylinder
and arm cylinder.

Air bleeding procedure

1. Install cylinder.
2. Start engine and run at low speed (about low idle
speed + 200 min-1).
Extend and retract slowly 5 times.
(Do not extend and retract to the stroke end dur-ing
the first 4 times. On the last time extend and retract
to the stroke end.)
3. Be sure that cylinder moves smoothly.

SM6293

Air Bleeding Figure

W4-2-14 EX255-EX285

CYLINDERS

DISASSEMBLE CYLINDERS

Boom Cylinder

11 1 2 3 4 7 5 6 9 10

8
13 20 15 16 21 23 22
12

SM1350A
14 19 16 17 18 20 19 24

Bucket Cylinder

11 1 2 3 4 7 5 6 9 10

8
13 20 15 16 20 21 22
12

19 16 17 18 19 24 23
SM1351

1 - Wiper Ring 7 - Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2 - Backup Ring 8 - Socket Bolt (12 Used) 14 - Cushion Seal 20 - Slide Ring (2 Used)
3 - U-Ring 9 - Backup Ring 15 - Piston 21 - Shim
4 - Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5 - Bushing 11 - Cylinder Rod 17 - Seal Ring 23 - Steel Ball
6 - Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut
EX255-EX285 W4-2-15

CYLINDERS

Disassemble Boom and Bucket Cylinders

Be sure to thoroughly read all the “Precautions for 4. Pull-out cylinder rod (11) and secure it on special
Disassembly and Assembly” on page W1-1-1 before tool (75298623). Put matching marks between
starting the disassembly procedure. cylinder rod (11) and nut (24).

The disassembly procedure below starts on the

premise that the hydraulic lines and the line securing
bands have been removed. 75298623

WARNING
SM1365
Boom cylinder:
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)
Bucket cylinder: 5. Remove set screw (22) and steel ball (23).
EX255: 172 kg (379 lb)
EX285: 209 kg (461 lb) NOTE - Cut away its mushroomed portion using a drill
first, as set screw (22) was mushroomed with a punch
and hammer at two places after it had been screwed
in.
1. Lift and securely place the cylinder on a workbench
using a crane. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from the cylinder.
: 6 mm

6. Loosen nut (24) using special tool (75298623).

Remove shim (21), piston (15) and cushion bearing
(13).
For the boom cylinder, also remove and cushion
seal (14).
Nut (24) turning special tool:
EX255
SM1364
- (bucket and boom cylinders): 95 mm (75294752)
2. Fully extend cylinder rod (11). Secure the rod end EX285
using a crane. Remove socket bolts (8) from - (bucket and boom cylinders): 100 mm (75297716)
cylinder head (7).
: 14 mm

3. Pull out cylinder head (7) from cylinder tube (12) by

tapping with a plastic hammer. SM1366

IMPORTANT - Be sure to pull cylinder rod (11) straight 7. Remove slide rings (19), (20), backup rings (16),
so as not to damage the sliding surfaces. seal ring (17) and O-ring (18) from piston (15).

8. Remove cylinder head (7) from cylinder rod (11).

9. Remove O-rings (10), backup rings (9) and (2) from

cylinder head (7). Then remove wiper ring (1), U-
ring (3), buffer ring (4), snap ring (6), and bushing
(5).
W4-2-16 EX255-EX285

CYLINDERS

Arm Cylinder

11 1 2 3 4 7 5 6 9 10

13 20 15 16 25 26 28 24 22 12

14 19 16 17 18 20 19 27 21 23 SM1352

1 - Wiper Ring 11 - Cylinder Rod 21 -

Shim
2 - Backup Ring 12 - Cylinder Tube 22 -
Set Screw
3 - U-Ring 13 - Cushion Bearing (front) 23 -
Steel Ball
4 - Buffer Ring 14 - Cushion Seal (front) 24 -
Nut
5 - Bushing 15 - Piston 25 -
Snap Ring
6 - Snap Ring 16 - Backup Ring (2 Used) 26 -
Cushion Seal (rear)
7 - Cylinder Head 17 - Seal Ring 27 -
Cushion Bearing
8 - Socket Bolt (12 Used) 18 - O-Ring (rear)
9 - Backup Ring 19 - Slide Ring (2 Used) 28 - Stopper (2 Used)
10 - O-Ring 20 - Slide Ring (2 Used)
EX255-EX285
CYLINDERS
Disassemble Arm Cylinder
Be sure to thoroughly read all the “Precautions for
Disassembly and Dissembly” on page W1-1-1 before
starting the disassembly procedure.
The disassembly procedure below starts on the
premise that the hydraulic lines and the line securing
bands have been removed.
WARNING
Arm cylinder weight:
EX255: 300 kg (661 lb)
EX285: 310 kg (683 lb)
1. Place the cylinder horizontally on a workbench
using a crane and secure it.
Drain hydraulic oil from the cylinder.
SM1364
2. Fully extend cylinder rod (11). Secure the rod end
using a crane. Remove socket bolts (8) from
cylinder head (7).
: 17 mm
3. Pull out cylinder head (7) from cylinder tube (12) by
tapping with a plastic hammer.
IMPORTANT - Be sure to pull cylinder rod (11)
straight so as not to damage the sliding surfaces.
4. Pull out cylinder rod (11) and secure it on special
tool (75298623). Put matching marks between
cylinder rod (11) and nut (24).
75298623
SM1365
W4-2-17
5. Remove set screw (22) and steel ball (23).
NOTE - Cut away its mushroomed portion using a drill
first, as set screw (22) was mushroomed with a punch
and hammer at two places after it had been screwed
in.
: 6 mm
6. Loosen nut (24) using special tool (75298623).
Remove shim (21), piston (15), cushion bearing
(13) and cushion seal (14).
Nut (24) Turning Special Tool:
- EX255: 100 mm (75297716)
- EX285: 115 mm (75297549)
SM1366
7. Remove slide ring (19), (20), backup ring (16), seal
ring (17) and O-ring (18) from piston (15).
8. Remove cylinder head (7) from cylinder rod (11).
9. Remove O-rings (10), backup rings (9) and (2) from
cylinder head (7). Then remove wiper ring (1), U-
ring (3), buffer ring (4), snap ring (6), and bushing
(5).
10.Remove stopper (28) from cylinder rod (11) using a
screw driver. Remove cushion bearing (27), cush-
ion seal (26), and snap ring (25).
W4-2-18 EX255-EX285

CYLINDERS

Positioning Cylinder
(triple articulation version)

11 1 2 3 4 7 5 6 9 10

8
20 15 16 21 23 22
12

19 16 17 18 20 19 24
SM5523

1 - Wiper Ring 9 - Backup Ring 19 - Slide Ring (2 Used)

2 - Backup Ring 10 - O-Ring 20 - Slide Ring (2 Used)
3 - U-Ring 11 - Cylinder Rod 21 - Shim
4 - Buffer Ring 12 - Cylinder Tube 22 - Set Screw
5 - Bushing 15 - Piston 23 - Steel Ball
6 - Snap Ring 16 - Backup Ring (2 Used) 24 - Nut
7 - Cylinder Head 17 - Seal Ring
8 - Socket Bolt (12 Used) 18 - O-Ring
EX255-EX285 W4-2-19

CYLINDERS

Disassemble Positioning Cylinder

Be sure to thoroughly read all the “Precautions for
Disassembly and Assembly” on page W1-1-1 before
starting the disassembly procedure.
The disassembly procedure below starts on the
premise that the hydraulic lines and the line securing
bands have been removed.
5. Remove set screw (22) and steel ball (23).
NOTE - Cut away its mushroomed portion using a drill
first, as set screw (22) was mushroomed with a punch
and hammer at two places after it had been screwed
in.

: 6 mm
WARNING
Positioning cylinder weight:
EX255-EX285: 242 kg (534 lb)
6. Loosen nut (24) using special tool (75298623).
Remove shim (21) and piston (15).
1. Place the cylinder horizontally on a workbench Nut (24) Turning Special Tool:
using a crane and secure it. EX255-EX285: 120 mm (75298684)
Drain hydraulic oil from the cylinder.

SM1366

7. Remove slide ring (19), (20), backup ring (16), seal

SM1364 ring (17) and O-ring (18) from piston (15).

2. Fully extend cylinder rod (11). Secure the rod end

using a crane. Remove socket bolts (8) from 8. Remove cylinder head (7) from cylinder rod (11).
cylinder head (7).

: 17 mm 9. Remove O-rings (10), backup rings (9) and (2) from

cylinder head (7). Then remove wiper ring (1), U-
3. Pull out cylinder head (7) from cylinder tube (12) by ring (3), buffer ring (4), snap ring (6), and bushing
tapping with a plastic hammer. (5).

IMPORTANT - Be sure to pull cylinder rod (11)

straight so as not to damage the sliding surfaces.

4. Pull out cylinder rod (11) and secure it on special

tool (75298623). Put matching marks between
cylinder rod (11) and nut (24).

75298623

SM1365
W4-2-20 EX255-EX285

CYLINDERS

ASSEMBLE CYLINDERS

Boom Cylinder

Face the slit

toward the piston

Slit
Green
Black
1 2 3 4 5 6 7 8 9-10 18
11 12 13 14 15 16 17 19 20 21

22-23

24

SM1353
Be sure that oil groove faces the correct
direction when assembling

Bucket Cylinder

Slit
Green

1 2 3 4 5 6 7 8 9-10 18
11 12 13 15 16 17 19 20 21

22-23

24

Be sure that oil groove faces SM5524

the correct direction when assembling

1 - Wiper Ring 10 - O-Ring 19 - Slide Ring (2 Used)

2 - Backup Ring 11 - Cylinder Rod 20 - Slide Ring (2 Used)
3 - U-Ring 12 - Cylinder Tube 21 - Shim
4 - Buffer Ring 13 - Cushion Bearing 22 - Set Screw
5 - Bushing 14 - Cushion Seal 23 - Steel Ball
6 - Snap Ring 15 - Piston 24 - Nut
7 - Cylinder Head 16 - Backup Ring (2 Used)
8 - Socket Bolt (12 Used) 17 - Seal Ring
9 - Backup Ring 18 - O-Ring
EX255-EX285
CYLINDERS
Assemble Bucket and Boom Cylinder
1. Install bushing (5) to cylinder head (7) using a
press.
Special tools for bushing (5) installation:
EX255
- boom cylinder: Ø 90 mm (75301684)
- bucket cylinder: Ø 85 mm (75301685)
EX285
- boom cylinder: Ø 95 mm (75301654)
- bucket cylinder: Ø 90 mm (75301646)
IMPORTANT - Be sure that the rings are installed
correctly.
2. Install U-ring (3), backup ring (2), snap ring (6), and
buffer ring (4) to cylinder head (7).
3. Install wiper ring (1) to cylinder head (7) using a
plastic hammer.
Special tools for wiper ring installing:
EX255
- boom cylinder: (75301665)
- bucket cylinder: (75301534)
EX285
- boom cylinder: (75301533)
- bucket cylinder: (75301665)
4. Install O-rings (10) and backup ring (9) to cylinder
head (7).
5. Install O-ring (18), backup ring (16) (2 used), seal
ring (17), slide ring (19) (2 used), (20) (2 used) to
piston (15).
Special tools for seals assembly:
EX255: bucket and boom cylinder (75301670)
EX285: bucket and boom cylinder (75301659)
15
SM1367
6. Install cylinder head (7) to cylinder rod (11).
Special tools:
EX255
- boom cylinder (75301688)
- bucket cylinder (75301689)
EX285
- boom cylinder: (75301537)
- bucket cylinder: (75301693)
W4-2-21
IMPORTANT - Be sure that the cushion seal slit faces
toward the piston and that the cushion bearing oil
groove faces the correct direction.
7. Install cushion bearing (13) to cylinder rod (11).
(For boom cylinder only, install cushion seal (14).)
Install piston (15) to cylinder rod (11).
8. Install shim (21) to cylinder rod (11). Tighten nut
(24) using special tool (75298623).
75298623
SM1365
Be sure to align the machine mark on the rod with
that on the nut.
Nut (24) Turning Special Tools:
EX255: 95 mm (75294752)
: 5 440 N m (555 kgf m, 4012 lbf ft)
(boom cylinder)
8 150 N m (831 kgf m, 6011 lbf ft)
(bucket cylinder)
EX285: 100 mm (75297716)
: 6 800 N m (693 kgf m, 5015 lbf ft)
(boom cylinder)
10 200 N m (1040 kgf m, 7523 lbf ft)
(bucket cylinder)
9. Align the holes on cylinder rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
screw (22) into the hole.
Mushroom the head of set screw (22) at two places
using a punch and hammer.
: 6 mm
: 56.9±10.7 N m (5.8±1.09 kgf m,
42±7,9 lbf ft)
IMPORTANT - Be sure to align cylinder rod (11) with
the center of cylinder tube (12) when inserting, in order
to avoid damaging the rings.
10. Secure cylinder tube (12) horizontally using a work
bench. Insert cylinder rod (11) into cylinder tube
(12).
11. Install cylinder head (7) to cylinder tube (12).
Tighten socket bolts (8).
: 14 mm
: 267 N m (27.2 kgf m, 197 lbf ft) (EX255)
367 N m (37.4 kgf m, 271 lbf ft) (EX285)
W4-2-22 EX255-EX285

CYLINDERS

Arm Cylinder

Face the slit toward

the piston

Slit
Green
Black

18
1 2 3 4 5 6 7 8 9-10 11 12 13 14 15 16 17 19 20 21
22-23
24
25
26
27
28

Be sure that oil groove faces the

correct direction when assembling

SM5525

1 - Wiper Ring 11 - Cylinder Rod 21 - Shim

2 - Backup Ring 12 - Cylinder Tube 22 - Set Screw
3 - U-Ring 13 - Cushion Bearing (front) 23 - Steel Ball
4 - Buffer Ring 14 - Cushion Seal (front) 24 - Nut
5 - Bushing 15 - Piston 25 - Snap Ring
6 - Snap Ring 16 - Backup Ring 26 - Cushion Seal (rear)
7 - Cylinder Head 17 - Seal Ring 27 - Cushion Bearing (rear)
8 - Socket Bolt 18 - O-Ring 28 - Stopper
9 - Backup Ring 19 - Slide Ring
10 - O-Ring 20 - Slide Ring
EX255-EX285
CYLINDERS
Assemble Arm Cylinder
1. Install bushing (5) to cylinder head (7) using a
press.
Special tools for bushing installation (5):
EX255: Ø 100 mm (75301686)
EX285: Ø 100 mm (75301651)
IMPORTANT - Be sure that the rings are installed
correctly.
2. Install U-ring (3), backup ring (2), buffer ring (4), and
snap ring (6) to cylinder head (7).
3. Install wiper ring (1) to cylinder head (7) using a
plastic hammer.
Special tools for wiper ring installation:
EX255-EX285: (75301676)
4. Install O-rings (10) and backup ring (9) to cylinder
head (7).
5. Install O -ring (18) buckup ring (16) (2 used), seal
ring (17), slide ring (19) (2 used), (20) (2 used), to
piston (15).
Special tool for seals assembly:
EX255: (75301659)
EX285: (75301170)
15
SM1367
6. Install cylinder head (7) to cylinder rod (11).
Special tools for cylinder head installation:
EX255: (75301690)
EX285: (75301692)
IMPORTANT - Be sure that the cushion seal slit faces
toward the piston and that the cushion bearing oil
groove faces the correct direction.
7. Install cushion seal (14) to cylinder rod (11). Install
cushion bearing (13) and piston (15) to cylinder rod
(11).
W4-2-23
8. Install shim (21) to cylinder rod (11). Tighten nut
(24) using special tool (75298623).
75298623
SM1365
Be sure to align the machine mark on the rod with
that on the nut.
Nut Turning Special Tools (24):
EX255: 100 mm (75297716)
: 10 200 N m (1040 kgf m, 7523 lbf ft)
EX285: 115 mm (75297549)
: 13 500 N m (1375 kgf m, 9957 lbf ft)
9. Align the holes on cylinder rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
screw (22) into the hole.
Mushroom the head of set screw (22) at two places
using a punch and hammer.
: 6 mm
: 56.9±10.7 N m (5.8±1.09 kgf m,
42±7,9 lbf ft)
IMPORTANT - Be sure that the cushion seal slit faces
toward the piston and that the cushion bearing oil
groove faces the correct direction.
10. Install snap ring (25) and cushion seal (26) to
cylinder rod (11). Install cushion bearing (27) and
stopper (28) to cylinder rod (11).
IMPORTANT - Be sure to keep cylinder rod (11)
aligned with the center of cylinder tube (12) when
inserting, in order to avoid damaging the rings.
11. Secure cylinder tube (12) horizontally using a vise.
Insert cylinder rod (11) into cylinder tube (12).
12. Install cylinder head (7) to cylinder tube (12).
Tighten socket bolts (8).
EX255:
: 14 mm
: 367 N m (37.4 kgf m, 271 lbf ft)
EX285:
: 17 mm
: 520 N m (53 kgf m, 384 lbf ft)
W4-2-24 EX255-EX285

CYLINDERS

Positioning Cylinder
(triple articulation version)

Slit
Green
Black
1 2 3 4 5 6 7 8 9-10 18
11 12 15 16 17 19 20 21

22-23

24

SM1368

1 - Wiper Ring 7 - Cylinder Head 15 - Piston 21 - Shim

2 - Backup Ring 8 - Socket Bolt 16 - Backup Ring 22 - Set Screw
3 - U-Ring 9 - Backup Ring 17 - Seal Ring 23 - Steel Ball
4 - Buffer Ring 10 - O-Ring 18 - O-Ring 24 - Nut
5 - Bushing 11 - Cylinder Rod 19 - Slide Ring
6 - Snap Ring 12 - Cylinder Tube 20 - Slide Ring
EX255-EX285
CYLINDERS
Assemble Positioning Cylinder
(triple articulation version)
1. Install bushing (5) to cylinder head (7) using a
press.
Special tools for bushing installation (5):
EX255-EX285: Ø 90 mm (75301646)
IMPORTANT- Be sure that the rings are installed
correctly.
2. Install U-ring (3), backup ring (2), buffer ring (4), and
snap ring (6) to cylinder head (7).
3. Install wiper ring (1) to cylinder head (7) using a
plastic hammer.
Special tools for wiper ring installation:
EX255-EX285: (75301665)
4. Install O-rings (10) and backup ring (9) to cylinder
head (7).
5. Install O -ring (18) buckup ring (16) (2 used), seal
ring (17), slide ring (19) (2 used), (20) (2 used) to
piston (15).
Special tool for seals assembly:
EX255-EX285: (75301170)
15
SM1367
6. Install cylinder head (7) to cylinder rod (11).
Special tools for cylinder head installation:
EX255-EX285: (75301536)
7. Install piston (15) to cylinder rod (11).
W4-2-25
8. Install shim (21) to cylinder rod (11). Tighten nut
(24) using special tool (75298623).
75298623
SM1365
Be sure to align the machine mark on the rod with that
on the nut.
Nut Turning Special Tools (24):
EX255-EX285: 110 mm (75298684)
: 8 460 N m (863 kgf m, 6240 lbf ft)
9. Align the holes on cylinder rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
screw (22) into the hole.
Mushroom the head of set screw (22) at two places
using a punch and hammer.
: 6 mm
: 56.9 ± 10.7 N m (5.8 ± 10.9 kgf m,
42±7,9 lbf ft)
IMPORTANT - Be sure to keep cylinder rod (11)
aligned with the center of cylinder tube (12) when
inserting, in order to avoid damaging the rings.
10.Secure cylinder tube (12) horizontally using a vise.
Insert cylinder rod (11) into cylinder tube (12).
11.Install cylinder head (7) to cylinder tube (12).
Tighten socket bolts (8).
: 17 mm
: 520 N m (53 kgf m, 384 lbf ft)
W4-2-26 EX255-EX285

CYLINDERS

MAINTENANCE STANDARD

Rod

EX255 Unit: mm (in)

Cylinders STANDARD (A) Remedy
Boom 90 ± 0.03
Arm 100 ± 0.03 Replace or
plate with
Bucket 85 ± 0.03
chromium
Positioning (*) 90 ± 0.03

(*) Triple articulation version

EX285 Unit: mm (in)

Cylinders STANDARD (A) Remedy
Boom 95 ± 0.03
Arm 100 ± 0.03 Replace or
Bucket 90 ± 0.03 plate with
chromium
Positioning (*) 90 ± 0.03

(*) Triple articulation version

EX255-EX285
EX255 W4-2-27

CYLINDERS

SPECIAL TOOLS (EX255)

Piston nut socket wrench:

75294752 for boom cylinders and bucket cylinder (95 mm)

75297716 for arm cylinder (100 mm)
75298684 for positioning cylinder (110 mm) (triple articulation version)

Use nut loosening/tightening workbench: 75298623

SM1366

Tools kit seals installation:

75301679 for boom cylinders and bucket cylinder

75301659 for arm cylinder
75301170 for positioning cylinder (triple articulation version)

SM1369

Wiper installation tool:

75301665 for boom cylinders

75301534 for bucket cylinder
75601676 for arm cylinder
75301665 for positioning cylinder (triple articulation version) SM1370

Bushing installation tool:

75301684 for boom cylinders (Ø 90 mm)

75301685 for bucket cylinder (Ø 85 mm)
75601686 for arm cylinder (Ø 100 mm)
75301646 for positioning cylinder (Ø 90 mm) (triple articulation version)
SM1371

Head installation tool:

75301688 for boom cylinders

75301689 for bucket cylinder
75301690 for arm cylinder
75301536 for positioning cylinder (triple articulation version) SM1372
W4-2-28 EX255-EX285
EX285

CYLINDERS

SPECIAL TOOLS (EX285)

Piston nut socket wrench:

75297716 for boom cylinders and bucket cylinder (100 mm)

75297549 for arm cylinder (115 mm)
75298684 for positioning cylinder (110 mm) (triple articulation version)

SM1366
Use nut loosening/tightening workbench: 75298623

Tools kit seals installation:

75301659 for boom cylinders and bucket cylinder

75301170 for arm cylinder
75301170 for positioning cylinder
(triple articulation version)

SM1369

Wiper installation tool:

75301533 for boom cylinders

75301665 for bucket cylinder
75301676 for arm cylinder
75301665 for positioning cylinder (triple articulation version)
SM1370

Bushing installation tool:

75301654 for boom cylinders (Ø 95 mm)

75301646 for bucket cylinder (Ø 90 mm)
75301651 for arm cylinder (Ø 100 mm)
75301646 for positioning cylinder (Ø 90 mm) (triple articulation version)
SM1371

Wiper installation tool:

75301537 for boom cylinders

75301693 for bucket cylinder
75301692 for arm cylinder
75301536 for positioning cylinder (triple articulation version) SM1372
SECTION 5
ENGINE AND ACCESSORY
CONTENTS
Group 1 - General Information
General Repair instructions ................... W5-1-1
Notes on the Format of this Manual ....... W5-1-1
External View ....................................... W5-1-5
Main Data and Specifications ................ W5-1-6
Angular Nut and Bolt Tightening
Method ............................................. W5-1-7
Torque Specifications ............................ W5-1-9
Standard Bolt Torque Specifications ..... W5-1-20
Special Tools List ............................... W5-1-22
Identifications .................................... W5-1-24
Group 2 - Maintenance
Lubricating System ............................... W5-2-1
Fuel System ........................................ W5-2-2
Cooling System .................................... W5-2-6
Valve Clearance Adjustment .................. W5-2-7
Injection Timing .................................... W5-2-8
Compression Pressure Measurement ... W5-2-12
Turbocharger Inspection ...................... W5-2-13
Engine Repair Kit ............................... W5-2-14
Recommended Lubricants ................... W5-2-15
Engine Oil Viscosity Chart .................. W5-2-15
Group 3 - Engine Disassembly
External Parts ...................................... W5-3-1
Major Components ............................... W5-3-5
Rocker Arm and Rocker Arm Shaft ...... W5-3-10
Cylinder Head .................................... W5-3-11
Piston and Connecting Rod ................. W5-3-12
EX255-EX285
Group 4 - Engine Inspection and
Repair
Cylinder Head ...................................... W5-4-1
Valve Guide ......................................... W5-4-2
Valve .................................................. W5-4-3
Valve seat insert .................................. W5-4-4
Valve Spring ........................................ W5-4-6
Tappet ................................................. W5-4-7
Rocket Arm Shaft and Rocker Arm ........ W5-4-8
Push Rod ............................................ W5-4-9
Idler Gear and Idler Gear Shaft .............. W5-4-9
Camshaft .......................................... W5-4-10
Cylinder Body and Liner ...................... W5-4-11
Piston and Piston Ring ....................... W5-4-15
Piston Pin ......................................... W5-4-16
Connecting Rod ................................. W5-4-17
Crankshaft ......................................... W5-4-19
Flywheel and Flywheel Housing ........... W5-4-25
Timing Gear Case Cover ..................... W5-4-25
Group 5 - Engine Reassembly
Piston and Connecting Rod ................... W5-5-1
Cylinder Head ...................................... W5-5-3
Rocket Arm and Rocker Arm Shaft ........ W5-5-6
Major Components ............................... W5-5-7
External Parts .................................... W5-5-16
Engine Tuning Operation ..................... W5-5-22
Group 6 - Lubricating System
General Description .............................. W5-6-1
Oil Pump ............................................. W5-6-2
Oil Cooler ............................................ W5-6-4
SECTION 5
Group 7 - Cooling System
General Description .............................. W5-7-1
Thermostat .......................................... W5-7-2
Group 8 - Fuel System
General Description .............................. W5-8-1
Injection Nozzle ................................... W5-8-2
Inuection Pump Calibration Data ............ W5-8-6
Group 9 - Turbocharger
General Description .............................. W5-9-1
Turbocharger Identification .................... W5-9-2
Inspection and Repair ........................... W5-9-3
Group 10 - Starting and Charging
Starter motor ..................................... W5-10-1
Alternator .......................................... W5-10-4
EX255-EX285
Group 11 - Troubleshooting
Hard Starting ..................................... W5-11-1
1) Starter Inoperative .......................... W5-11-1
2) Starter Operates but
Engine Does not Turn Over .............. W5-11-2
3) Engine Turns Over but Does not
Start (Fuel is Being
Delivered to the Injection Pump) ...... W5-11-3
4) Engine Turns Over but Does
not Start (Fuel is not Being Delivered
to the Injection Pump) ..................... W5-11-4
Unstable Low Idling ............................ W5-11-5
Insufficient Power ............................... W5-11-7
Overheating ..................................... W5-11-10
White Exhaust Smoke ...................... W5-11-12
Dark Exhaust Smoke ........................ W5-11-13
Oil Pressure Does not Rise ............... W5-11-14
Excessive Fuel Consumption ............ W5-11-16
Excessive Oil Consumption .............. W5-11-18
Abnormal Engine Noise ..................... W5-11-19
1) Engine Knocking .......................... W5-11-19
2) Gas Leakage Noise ...................... W5-11-20
3) Continuous Noise ......................... W5-11-21
4) Slapping Noise ............................. W5-11-22
Group 12 - Repair Standards
General Rules .................................... W5-12-1
EX255-EX285 W5-1-1

GENERAL INFORMATION

GENERAL REPAIR INSTRUCTIONS

1. Before performing any service operation with the engine mounted, disconnect the grounding cable from the
battery. This will reduce the chance of cable damage and burning due to short circuiting.

2. Always use the proper tool or tools ISUZU for the job at hand. Where specified, use the specially designed
tool or tools.

3. Use genuine parts referring FIAT KOBELCO PARTS CATALOG.

4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you remove
them. Replace them with new ones.

5. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation. It is
especially important to keep fastening parts separate. These parts vary in hardness and design, depending
on their installation position.

6. All parts should be carefully cleaned before inspection or reassembly. Oil ports and other openings should
be cleaned with compressed air to make sure that they are completely free of obstructions.

7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly.

8. If necessary, use a sealer on gaskets to prevent leakage.

9. Nut and bolt torque specifications should be carefully followed.

10. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine or
disconnecting pipes and hoses. To not do so is extremely dangerous.

11. Always check and recheck you work. No service operation is complete until you have done this.

12. Information contained in the "Main Data and Specifications" of the Workshop Manual and the Operation and
Maintenance Instruction Manual may differ. In this case, the information contained in the Operation and
Maintenance Instruction Manual should be considered applicable.

NOTES ON THE FORMAT OF THIS MANUAL

This Workshop Manual is applicable to the 6BG1 and 6BG1T family of industrial diesel engines. Unless otherwise
specified, these engines have common parts and components as well as data and specifications. Illustrations used
in this Workshop Manual are based on the AA-6BG1 and BB-6BG1T engines. The BB-6BG1T engine is
turbocharged with intercooler.

1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual.

2. Common technical data such as general maintenance items, service specifications and tightening torques
are included in the “General Information” section.

3. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and reassembly.
The section ENGINE ASSEMBLY is an exception. This part is divided into three sections to facilitates quick
indexing.

4. When the same servicing operation is applicable to several different units, the manual will direct you to the
appropriate page.

5. For the sake of brevity, self-explanatory removal and installation procedures are omitted. More complex
procedures are covered in detail.
W5-1-2
6. Each service operation section in this Workshop Manual begins with an exploded view of the applicable area.
A brief explanation of the notation used follows.
Disassembly Steps - 2
1. Water by-pass hose
2. Thermostat housing
3. Water pump
▲ 4. Injection nozzle holder
5. Glow plug and glow plug connector
6. Cylinder head cover
▲ 7. Rocker arm shaft and rocker arm
8. Push rod
▲ 9. Cylinder head
10. Cylinder head gasket
EX255-EX285
GENERAL INFORMATION
Parts marked with an asterisk (*) are
included in the repair kit.
Parts within a square frame are to be
removed and installed as a single unit.
All parts within an irregularly shaped
frame form a single assembly. They
are considered a "major component".
Individual parts within the irregularly
shaped frame are considered "minor
components".
The number tells you the service op-
eration sequence.
Removal of unnumbered parts is un-
necessary unless replacement is re-
quired.
The "*Repair Kit" indicates that a repair
kit is available.
▲ 11. Crankshaft damper pulley
with dust seal The parts listed under "Reassembly
12. Timing gear case cover
(Option) Steps" or "Installation Steps" are in the
13. Timing gear cover
14. Timing gear oil pipe service operation sequence.
15. Idler gear ‘B’ and shaft
16. Idler gear “A”
17. Idler gear shaft
The removal or installation of parts
Inverted Engine marked with a triangle (▲) is an impor-
tant operation. Detailed information is
SM7400 given in the text.
EX255-EX285 W5-1-3

GENERAL INFORMATION

7. Below is a sample of the text of the Workshop Manual.

This is the item shown in the

illustration. It is marked with a
Valve Guide Installation triangle (▲) on the Major Com-
1. Lubricate the valve guide outer face with engine
oil. ponents page.
2. Attach the installer to the valve guide.
3. Use a hammer to drive the valve guide into
position from the cylinder head upper face. Valve
Guide Installer: 1-85220-001-0 Special tools are identified by the
4. Measure the height of the valve guideuide upper tool name and/or number.
end from the upper face of the cylinder head.

Valve Guide Upper End

The illustration shows how the
14.1 (0.56)
Height (H) special tool is to be used.
Note:
If the valve guide has en removed, both the Iva and
the valve guide must be placed with new on as a set. Letters and numbers contained
Be absolutely sure to discard the used valves and
valve guides. in a circle refer to the illustration.

Symbols indicate the type of

SM7401 service operation or step to be
performed. A detailed explana-
tion of these symbols follows.

Service data and specifications

are given in this table.

8. The following symbols appear throughout this Workshop Manual. They tell you the type of service operation
or step to perform.

Removal Adjustment

Installation Cleaning

Disassembly Important Operation Requiring Extra Care

Reassembly Specified Torque (Tighten)

Special Tool Use Required or Recom-

Alignment (Marks) mended (Isuzu Tool or Tools)

Directional Indication
Commercially Available Tool Use Required
or Recommended

Inspection
Lubrication (Oil)

Measurement
Lubrication (Grease)

Sealant Application
W5-1-4 EX255-EX285

GENERAL INFORMATION

9. Measurement criteria are defined by the terms “Standard” and “Limit”.

A measurement falling within the “Standard” range indicates that the applicable part or parts are serviceable.
“Limit” should be thought of as an absolute value.
A measurement which is outside the “Limit” indicates that the applicable part or parts must be either repaired
or replaced.

10. Components and parts are listed in the singular from throughout the Manual.

11. Directions used in this Manual are as follows:

Front
The cooling fan side of the engine viewed from the flywheel.
Right
The injection pump side of the engine.
Left
The exhaust manifold side of the engine.
Rear
The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine.
The front most cylinder is No. 1 and rear most cylinder is No. 6.
The engine’s direction of rotation is counterclockwise viewed from the flywheel.

Right

Inj. pump

Front Rear

Left

SM7402

12. Maintenance procedure call for use of Special or Commercial Tools, where necessary.
The Special Tools required or recommended are identified by an ISUZU Part Number.
Any Special Tools are available in Europe making a purchase order to the following:

IED MAESA
BOOMSESTENWEG 42B
2630 AARTSELAAR
BELGIUM
 EX255-EX285 W5-1-5

GENERAL INFORMATION

EXTERNAL VIEW
Turbocharger Turbocharger
Oil filler cap
Dipstick
Nozzle holder
Air breather

Injection
Flywheel housing pump

Main
oil filter
Alternator Partial
oil filter
Crank pulley
Starter motor
Flywheel
Oil filler cap
Fuel filter Fan pulley
Nozzle holder Cooling fan
Fuel filter

Water Water pump

drain plug

Alternator
pulley
Injection pump

Oil pan
Flywheel Oil pan
housing Main oil filter
Partial oil filter Crank pulley
Partial oil filter
Turbocharger Exhaust manifold
Oil drain plug
Alternator
Flywheel housing

Cylinder
head cover

Nozzle
holder
NOTE: Engine details may vary depending on
the specifications.

Glow plug Inlet manifold SM7403

Air duct Oil filler cap

W5-1-6 EX255-EX285

GENERAL INFORMATION

MAIN DATA AND SPECIFICATIONS

ENGINE MODEL
CC-6BG1T
ITEM

Engine type Water cooled, four cycle, vertical in-line overhead valve
Combustion chamber type Direct injection
Cylinder liner type Dry
No. of cylinders - bore x stroke mm (in) 6 - 105.0 x 125.0 (4.13 x 4.92)
Total piston displacement cm3 (cid) 6,494 (396)
Compression ratio 18.0 to 1
* Engine dimensions mm 1204 x 762 x 961
Length x width x height (in) (47.4 x 30.0 x 37.8)
* Engine weight (Dry) kg (Ib) 484 (1067)
Fuel injection order 1-5-3-6-2-4
Specified fuel Diesel fuel (ASTM D975 No. 2D)
Injection pump In-line plunger, Bosch AD type
* Governor Mechanical, RSV type
Injection nozzle Multi hole
Injection starting pressure MPa (kgf/cm2/psi) 18.1 (185/2,630)
Fuel filter type Cartridge (spin-on)
Water sedimentor Sedimenter/water level indicating type
Compression pressure MPa (kgf/cm2/psi) 3.0 (31/441) at 200 min-1, at sea level
(At warm)
Valve clearances (At cold) Intake mm (in) 0.40 (0.016)
Exhaust mm (in) 0.40 (0.016)
Lubrication method Pressurized circulation
Oil pump Gear type
Main oil filter type Cartridge (spin-on)
* Lubricating oil volume L (US gal) 21.5 (5.68)
Oil cooler Water cooled integral type
Cooling method Pressurized forced circulation
Coolant volume (engine only) L (US gal) 12 (3.2)
Water pump Belt driven impeller type
Thermostat type Wax pellet type
* Generator V-A 24-40
* Starter V-kW 24-4.5
* Turbocharger manufacturer IHI
* Turbocharger model RHG6

NOTE: 1. These specifications are based on the standard engine.

2. Specifications for items marked with an asterisk (*) will vary according to the type of equipment on
which the engine is installed. If you are unable to locate the data applicable to these specifications,
please contact Isuzu Motors LTD through your FIAT KOBELCO Dealer.
EX255-EX285 W5-1-7

GENERAL INFORMATION

ANGULAR NUT AND BOLT TIGHTENING

METHOD

1. Carefully wash the nuts and bolts to re-

move all oil and grease.

2. Apply a coat of molybdenum disulfide

grease to the threads and setting faces of
the nuts and bolts.
m
nu
b d e ide
y lf
o l u se
M d i s rea
g

SM7404

3. Tighten the nuts and bolts to the specified

torque (snug torque) with a torque
wrench.

NUT
OR
BOLT

Snug torque

SM7405

4. Draw a line (A-B) across the center of each

bolt.
Center line

SM7406
W5-1-8 EX255-EX285

GENERAL INFORMATION

5. Draw another line (C-D) on the face of each

of the parts to be clamped. This line should
be an extension of the line (A-B).

Line

SM7407

6. Draw another line (F-G) on the face of each

of the parts to be clamped. This line will be
in the direction of the specified angle (Q)
across the center (E) of the nut or bolt.

Specified angle (Q)

Coinciding line

SM7408

7. Use a socket wrench to tighten each nut or

bolt to the point where the line (A-B) is
aligned with the line (F-G).
Tighten

SM7409

Example: Specified Angle and Tightening Rotation

A 30° 1/12 of a turn

B 60° 1/6 of a turn
C 90° 1/4 of a turn
D 180° 1 /2 of a torn
E 360° One full turn

SM7410
EX255-EX285 W5-1-9

GENERAL INFORMATION

TORQUE SPECIFICATIONS

Cylinder Head and Cover

N•m (kgf•m/lb.ft)

7.8–9.8
(0.8–1.0/5.8–7.2)

42–62
→ 88
69→ (4.3–6.3/31–46)
→90°–120°
→(9.0/65)
(7.0/5.1)→

Apply MoS2 grease

20–25
(2.0–2.5/14–18)

Glow plug

42–62
(4.3–6.3/31–46)

SM7411

MoS2..........Molybdenum disulfide paste.

W5-1-10 EX255-EX285

GENERAL INFORMATION

Cylinder Body
N•m (kgf•m/lb.ft)

42–62
(4.3–6.3/31–46)

21–30
(2.1–3.1/15–22)

21–30
(2.1–3.1/15–22)

21–30
(2.1–3.1/15–22)

226–245
(23–25/166–181)

Apply engine oil

16–25
(1.6–2.6/12–19)

SM7412
EX255-EX285 W5-1-11

GENERAL INFORMATION

Oil Pan and Dipstick

N•m (kgf•m/lb.ft)

25–30
(2.6–3.1/19–22)

21–30
(2.1–3.1/15–22)

69–88
(7–9/51–65)

SM7413
W5-1-12 EX255-EX285

GENERAL INFORMATION

Camshaft and Rocker Arm

N•m (kgf•m/lb.ft)

25–35 (2.6–3.6/19–26)

25–35 (2.6–3.6/19–26)

21–30
(2.1–3.1/15–22)

21–30
(2.1–3.1/15–22)

142–172
(14.5–17.5/105–127)

Lubricate with engine oil

44–64 (4.5–6.5/33–47)

SM7414
EX255-EX285 W5-1-13

GENERAL INFORMATION

Crankshaft, Piston, and Flywheel

N•m (kgf•m/lb.ft)

Apply MoS2 grease

197–240
(20.1–24.5/145–177)

Apply MoS2 grease Apply engine oil

SM7415
W5-1-14 EX255-EX285

GENERAL INFORMATION

Thermostat and Thermostat Housing

N•m (kgf•m/lb.ft)

21–30
(2.1–3.1/15–22)

42–62
(4.3–6.3/31–46)

42–62
(4.3–6.3/31–46)

SM7416
EX255-EX285 W5-1-15

GENERAL INFORMATION

Thermostat and Thermostat Housing

N•m (kgf•m/lb.ft)

21–30
(2.1–3.1/15–22)

42–62 (4.3–6.3/31–46)

21–30 (2.1–3.1/15–22)

25–31 (2.6–3.2/19–23)

SM7417
W5-1-16 EX255-EX285

GENERAL INFORMATION

Timing Gear Case and Flywheel Housing

N•m (kgf•m/lb.ft)

21–30
(2.1–3.1/15–22)

147-167
(15-17/108-123)

Outer side
21–30 (2.1–3.1/15–22)

147-167
(15-17/108-123)

21–30
(2.1–3.1/15–22)

Inner side

SM7418
EX255-EX285 W5-1-17

GENERAL INFORMATION

Oil Cooler, Oil Filter, and Oil Pump

N•m (kgf•m/lb.ft)

Refer to the section MAINTENANCE

42–62 (4.3–6.3/31–46)

42–62
(4.3–6.3/31–46)

21–30
(2.1–3.1/15–22)

14–24 (1.4–2.4/10–17)

SM7419
W5-1-18 EX255-EX285

GENERAL INFORMATION

Fuel System
N•m (kgf•m/lb.ft)

16–18
(1.6–1.8/12–13)

33–49
(3.4–5.0/25–36)

17–21
33–49
(1.7–2.1/12–15) 42–62 (3.4–5.0/25–36)
(4.3–6.3/31–46)

16–18
(1.6–1.8/12–13)

16–18
(1.6–1.8/12–13)

28–32
(2.9–3.3/21–24) 16–18
(1.6–1.8/12–13)

21–30
(2.1–3.1/15–22)

3.9–7.8
(0.4–0.8/2.9–5.8)

SM7420
EX255-EX285 W5-1-19

GENERAL INFORMATION

Turbocharger
N•m (kgf•m/lb.ft)

16–25
(1.6–2.6/12–19)

42–62 (4.3–6.3/31–46)

28–46
(2.9–4.7/21–34)

16–25
(1.6–2.6/12–19)

SM7421
W5-1-20 EX255-EX285

GENERAL INFORMATION

STANDARD TORQUE SPECIFICATION

The tightening torque values given in the tables below are applicable to the bolts unless otherwise specified.

Standard Bolt N•m (kgf•m/Ib.ft)

Bolt
Identifi-
cation
Bolt
Diameter
x pitch (mm)

M 6 x 1.0 3.9-7.8 (0.4-0.8/2.9-5.8) 4.9-9.8 (0.5-1.0/3.6-7.2) ——————-

M 8 x 1.25 7.8-17.7 (0.8-1.8/5.8-13.0) 11.8-22.6 (1.2-2.3/8.7-16.6) 16.7-30.4 (1.7-3.1/12.3-22.4)

M10 x 1.25 20.6-34.3 (2.1-3.5/5.2-25.3) 27.5-46.1 (2.8-4.7/20.3-33.4) 37.3-62.8 (3.8-6.4/27.5-46.3)

* M10 x 1.5 19.6-33.4 (2.0-3.4/14.5-24.6) 27.5-45.1 (2.8-4.6/20.3-33.3) 36.3-59.8 (3.7-6.1/26.8-44.1)

M12 x 1.25 49.1-73.6 (5.0-7.5/36.2-54.2) 60.8-91.2 (6.2-9.3/44.8-67.3) 75.5-114.0 (7.7-11.6/55.7-83.9)

* M12 x 1.75 45.1-68.7 (4.6-7.0/33.3-50.6) 56.9-84.4 (5.8-8.6/42.0-62.2) 71.6-107.0 (7.3-10.9/52.8-78.8)

M14 x 1.5 76.5-115.0 (7.811.7/56.4-84.6) 93.2-139.0 (9.5-14.2/68.7-103.0) 114.0-171.0 (11.6-17.4/83.9-126.0)

* M14 x 2.0 71.6-107.0 (7.3-10.9/52.8-78.8) 88.3-131.0 (9.0-13.4/65.1-96.9) 107.0-160.0 (10.9-16.3/78.8-118.0)

M16 x 1.5 104.0-157.0 (10.6-16.0/76.7-115.7) 135.0-204.0 (13.8-20.8/99.8-150.0) 160.0-240.0 (16.3-24.5/118.0-177.0)

* M16 x 2.0 100.0-149.0 (10.2-15.2/73.8-110.0) 129.0-194.0 (13.2-19.8/95.5-143.0) 153.0-230.0 (15.6-23.4/113.0-169.0)

M18 x 1.5 151.0-226.0 (15.4-23.0/111.0-166.0) 195.0-293.0 (19.9-29.9/144.0-216.0) 230.0-345.0 (23.4-35.2/169.0-255.0)

* M18 x 2.5 151.0-226.0 (15.4-23.0/111.0-166.0) 196.0-294.0 (20.0-30.0/145.0-217.0) 231.0-346.0 (23.6-35.3/171.0-255.0)

M20 x 1.5 206.0-310.0 (21.0-31.6/152.0-229.0) 270.0-405.0 (27.5-41.3/199.0-299.0) 317.0-476.0 (32.3-48.5/234.0-351.0)

* M20 x 2.5 190.0-286.0 (19.4-29.2/140.0-211.0) 249.0-375.0 (25.4-38.2/184.0-276.0) 293.0-440.0 (29.9-44.9/216.0-325.0)

M22 x 1.5 251.0-414.0 (25.6-42.2/185.0-305.0) 363.0-544.0 (37.0-55.5/268.0-401.0) 425.0-637.0 (43.3-64.9/313.0-469.0)

* M22 x 2.5 218.0-328.0 (22.2-33.4/161.0-242.0) 338.0-507.0 (34.5-51.7/250.0-374.0) 394.0-592.0 (40.2-60.4/291.0-437.0)

M24 x 2.0 359.0-540.0 (36.6-55.0/265.0-398.0) 431.0-711.0 (43.9-72.5/318.0-524.0) 554.0-831.0 (56.5-84.7/409.0-613.0)

* M24 x 3.0 338.0-507.0 (34.5-51.7/250.0-374.0) 406.0-608.0 (41.4-62.0/299.0-448.0) 521.0-782.0 (53.1-79.7/384.0-576.0)

An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such
as casting.
EX255-EX285 W5-1-21

GENERAL INFORMATION

Flanged head bolt N•m (kgf•m/Ib.ft)

Bolt
Identifi-
cation
Bolt
Diameter
x pitch (mm)

M 6 x 1.0 4.6-8.5 (0.5-0.9/3.6-6.5) 6.6-12.2 (0.6-1.2/4.3-8.7) -------------------

M 8 x 1.25 10.5-19.6 (1.1-2.0/8.0-14.5) 15.3-28.4 (1.6-2.9/11.6-21.0) 18.1-33.6 (2.1-3.4/15.2-25.0)

M10 x 1.25 23.1-38.5 (2.4-3.9/17.4-28.2) 35.4-58.9 (3.6-6.1/26.0-44.1) 42.3-70.5 (4.3-7.2/31.1-52.1)

* M10 x 1.5 22.3-37.2 (2.3-3.8/16.6-27.5) 34.5-57.5 (3.5-5.8/25.3-42.0) 40.1-66.9 (4.1-6.8/29.7-49.2)

M12 x 1.25 54.9-82.3 (5.6-8.4/40.1-60.8) 77.7-117.0 (7.9-11.9/57.1-86.1) 85.0-128.0 (8.7-13.0/62.9-94.0)

* M12 x 1.75 51.0-76.5 (5.2-7.8/37.6-56.4) 71.4-107.0 (7.3-10.9/52.8-78.8) 79.5-119.0 (8.1-12.2/58.6-88.2)

M14 x 1.5 83.0-125.0 (8.5-12.7/61.5-91.9) 115.0-172.0 (11.7-17.6/84.6-127.0) 123.0-185.0 (12.6-18.9/91.1-137.0)

* M14 x 2.0 77.2-116.0 (7.9-11.8/57.1-85.3) 108.0-162.0 (11.1-16.6/80.3-120.0) 116.0-173.0 (11.8-17.7/85.3-128.0)

M16 x 1.5 116.0-173.0 (11.8-17.7/85.3-128) 171.0-257.0 (17.4-26.2/126.0-190.0) 177.0-265.0 (18.0-27.1/130.0-196.0)

* M16 x 2.0 109.0-164.0 (11.2-16.7/81.0-121.0) 163.0-244.0 (16.6-24.9/120.0-180.0) 169.0-253.0 (17.2-25.8/124.0-187.0)

A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.
W5-1-22 EX255-EX285

GENERAL INFORMATION

SPECIAL TOOL LIST

ITEM NO. ILLUSTRATION PART NO. PARTS NAME PAGE

1. 5-85317-001-0 Compression gauge adaptor W5-2-12

2. 1-85111-003-0 Cylinder head bolt wrench W5-3-6

3. 9-8521-0122-0 Crankshaft taper bushing remover W5-3-7

4. 5-8840-2360-0 Rear oil seal remover W5-3-7

5. 1-85235-006-0 Valve spring compressor W5-3-11

W5-5-4

6. 1-85232-001-0 Valve guide remover and W5-4-2

9-85220-035-0 installer

7. 9-8523-1818-0 Camshaft bearing remover and W5-4-10

installer

8. 9-8523-1169-0 Cylinder liner remover W5-4-11

9. 5-8523-1004-0 Cylinder liner remover ankle W5-4-11

10. 5-8522-1018-0 Cylinder liner installer W5-4-13

EX255-EX285 W5-1-23

GENERAL INFORMATION

ITEM NO. ILLUSTRATION PART NO. PARTS NAME PAGE

11. 9-8523-1369-0 Connecting rod bushing installer W5-4-18

12. 9-8521-0141-0 Crankshaft gear remover W5-4-24

13. 9-8522-0033-0 Crankshaft gear installer W5-4-24

14. 9-8522-0034-0 Crankshaft front oil seal installer W5-4-25

15. 1-85221-005-0 Valve stem oil seal installer W5-5-4

16. 9-8522-1251-0 Piston ring compressor W5-5-10

17. 5-8840-9025-0 Rear oil seal installer W5-5-11

W5-1-24 EX255-EX285

GENERAL INFORMATION

IDENTIFICATIONS

Engine Serial Number

The engine number is stamped on the front left hand
side of the cylinder body.

Engine serial number

SM7422

Injection Pump Number

Injection volume should be adjusted after referring to
the adjustment data applicable to the injection pump
installed.
The injection pump identification number (A) is
stamped on the injection pump identification plate.

NOTE: Always check the identification number be-

fore beginning a service operation. Pump No.
Applicable service data will vary according to the NP-PE
Identification number. Use of the wrong service data (LICENCE BOSCH)
will result in reduced engine performance and engine Identification number
damage.

SM7423
EX255-EX285 W5-2-1

MAINTENANCE

LUBRICATING SYSTEM
Main Oil Filter Replacement
Cartridge (Spin-On) Type

REMOVAL
Removal and Installer: Filter Wrench
1. Loosen the used oil filter by turning it
counterclockwise with the filter wrench.
Main oil filter
2. Discard the used oil filter.

Partial filter
INSTALLATION
1. Wipe the oil filter mounting face with a SM7424
clean rag. This will allow the new oil filter to
seat properly.
2. Lightly oil the O-ring.
3. Turn in the new oil filter until the sealing
face is fitted against the O-ring.
4. Use the filter wrench to turn in the oil filter
an additional 3/4 of a turn or one turn.
5. Check the engine oil level and replenish to
the specified level if required.
6. Start the engine and check for oil leakage
from the oil filter.
W5-2-2 EX255-EX285

MAINTENANCE

FUEL SYSTEM
Fuel Filter Replacement
Cartridge (Spin-On) Type

REMOVAL
1. Loosen the fuel filter by turning it
counterclockwise with the filter wrench or
your hand. Discard the used filter.

2. Wipe the fuel filter fitting face clean with a

rag.
This will allow the new fuel filter to seat
properly. SM7425

INSTALLATION
1. Apply a light coat of engine oil to the O-ring.
2. Supply fuel to the new fuel filter. This will
facilitate air bleeding.
3. Turn in the new fuel filter until the filter
O-ring is fitted against the sealing face.
4. Use the filter wrench to turn in the fuel filter
an additional 2/3 of a turn.

Overflow Valve
Check the overflow valve for clogging.
Check the ball side for suction leakage.
kPa (kgf/cm2/psi)

Overflow Valve Opening

Pressure (Reference) 147 (1.5/21)

SM7426
EX255-EX285 W5-2-3

MAINTENANCE

Injection Nozzle
INSPECTION PROCEDURE
1. Clamp the injection nozzle holder in a vise.
2. Use a wrench to remove the injection
nozzle holder cap.
3. Remove the injection nozzle holder from
the vise.

SM7427

ADJUSTING PROCEDURE
Injection Starting Pressure Check
1. Attach the injection nozzle holder to the
injection nozzle tester.
2. Loosen the adjusting screw (1).
3. Check the injection nozzle starting pres-
sure and the spray condition by operating
the injection nozzle tester.
4. Adjust the injection nozzle starting pres- SM7428
sure. Turn the adjusting screw clockwise
while operating the injection nozzle tester
handle.

SM7429
MPa (kgf/cm2/psi)
Injection Starting
18.1 (185/2630)
Pressure

WARNING
TEST FLUID FROM THE NOZZLE
TESTER WILL SPRAY OUT UNDER
GREAT PRESSURE. IT CAN EASILY
PUNCTURE A PERSON’S SKIN. KEEP
YOUR HANDS AWAY FROM THE NOZ-
ZLE TESTER AT ALL TIMES. SM7430
W5-2-4 EX255-EX285

MAINTENANCE

Spray Condition Check (During Injection Noz-

zle Tester Operation)
1. Tighten the cap nut.
2. Check the injection nozzle starting pres-
sure.
3. Check the injection nozzle spray condi-
tion. Operate the injection nozzle tester
hand lever 4 to 6 times a second while
looking for abnormal injection nozzle
spray conditions. Refer to the illustration
for different spray conditions
(1) Good
(2) Bad (Restrictions in orifice)
SM7431
(3) Bad (Dripping)

Feed Pump Strainer

1. Remove the joint bolt.
2. Use a screwdriver to remove the strainer.
3. Wash the strainer in clean diesel fuel.

SM7432

Strainer

SM7433
EX255-EX285 W5-2-5

MAINTENANCE

Water Separator (Water Sedimentor)

Check the water separator float (1) level.
If the float (1) has reached level (2), loosen the
drain plug (3) (at the bottom side of the water
separator) to drain the water.

N•m (kgf•m/ft.lb)
Drain Plug Torque 9-15 (0.9-1.5/7-11)

SM7434

Air Bleeding
1. Loosen the feed pump cap (1) on the
injection pump.
2. Loosen the fuel filter fuel return eye bolt
(2).
3. Operate the feed pump until there are no
more bubbles visible in the fuel being
discharged from the fuel filter fuel return
eye bolt.
4. Retighten the fuel filter fuel return eye bolt.
5. Operate the feed pump several times and
check for fuel leakage around the injection
pump and the fuel filter. SM7435

SM7436
W5-2-6 EX255-EX285

MAINTENANCE

COOLING SYSTEM
Cooling Fan Drive Belt Depress here
98N (10kgf/22lb)
ADJUSTMENT
1. Check the cooling fan drive belt for crack-
ing and other damage.
2. Check the drive belt tension by exerting a
Deflection
force of 98N (10kgf/22lb) midway be-
tween the fan pulley (2) and the alternator
(3).
3. Adjust the belt tension by loosening the
alternator mounting bolt and the alternator
adjusting bolt and pivoting the alternator. SM7437
Be sure to retighten the bolts after adjust-
ing the belt tension.

mm (in)
Cooling Fan Drive 7.0-10.0
Belt Deflection (0.28-0.39)

Thermostat
INSPECTION
Visually inspect the thermostat.
Replace the thermostat if excessive wear or Thremometer
damage is discovered during inspection.
Measure the valve lift. Agitating rod

mm (in)
Amount of Valve Lift
at 95 °C (203 °F) 10.0 (0.39)
Wood piece

°C(°F)
Valve Opening
80-84 (176-183) SM7438
Temperature
EX255-EX285 W5-2-7

MAINTENANCE

VALVE CLEARANCE ADJUSTMENT

NOTE: The cylinder head bolts were previ-

ously tightened with the “Angular Tightening
Method”. Therefore, it is not necessary to
retighten the cylinder head bolts before adjust-
ing the valve clearance.

1. Bring the piston in either the No. 1 cylinder

SM7439
or the No. 6 cylinder to Top Dead Center on
the compression stroke by turning the
crankshaft until the TDC notched line on
the crankshaft pulley is aligned with the
timing pointer.
2. Check to see if there is play in the No. 1
intake and exhaust valve rocker arms.
If the No. 1 cylinder intake and exhaust
valve rocker arms have play, the No. 1
piston is at TDC on the compression
stroke.
If the No. 1 cylinder intake and exhaust
SM7440
valve rocker arms are depressed, the No.
6 piston is at TDC on the compression
stroke.

Adjust the No. 1 or the No. 6 cylinder valve

clearances while their respective cylinders
are at TDC on the compression stroke.
mm (in)
Intake and Exhaust
Valve Clearance (cold) 0.40 (0.016)

3. Loosen each valve clearance adjusting SM7439

screw as shown in the illustration.
4. Insert a 0.40 mm (0.016 in) feeler gauge
between the rocker arm and the valve
stem end. Front
5. Turn the valve clearance adjusting screw
until a slight drag can be felt on the feeler
gauge.
6. Tighten the lock nut securely.
7. Rotate the crankshaft 360°.
Realign the crankshaft pulley TDC
When No. 1 cylinder at TDC
notched line with the timing pointer. in compression stroke SM7441

8. Adjust the clearances for the remaining

valves as shown in the illustration.

N•m (kgf•m/ft.lb)
Front
Rocker Arm Screw
Lock Nut Torque 21-30 (2.1-3.1/15-22)

When No. 6 cylinder at TDC

in compression stroke SM7442
W5-2-8 EX255-EX285

MAINTENANCE

INJECTION TIMING

NOTE: Take care to avoid entry of dust or

foreign particles into the pump interior when
the timing adjustment is made.

The flange mounted injection pump is installed

behind the timing gear case.

SM7440
Checking Procedure
1. Align the crankshaft pulley TDC mark with
the pointer.
Remove the inspection hole cover at the
front of the injection pump on the timing
gear case cover.
Check the alignment between the pointer
(4) on the injection pump gear nut lock plate
and the projection area mark (3) on the
injection pump gear case.
If it is in misalignment, recheck with turn-
ing the crankshaft pulley one more turn to
SM7443
repeat the aforegoing procedure to mark
sure that it is in alignment.
Check the alignment of the notched lines
(1) and (2) .
(These notched lines were aligned at the
factory to set the injection pump body and
the mounting flange.)
Next, inspect the crankangle position of
the injection starting.
2. Reversely turn the crankshaft pulley
counterclockwise about 30° crankangle.
3. Disconnect the injection pipe from the No. SM7444
1 plunger.
This will allow you to visually check the full
injection starting flow at No. 1 plunger.

4. Remove the delivery valve holder (1) , the

valve seat (2) , valve spring (3) the delivery SM7445
valve (4) from the No. 1 plunger.
5. Reinstall the delivery holder (1) and tighten
it to the specified torque.
Do not reinstall the delivery valve spring,
the valve seat and the delivery valve.
These parts will be reinstalled later.

SM7446
EX255-EX285 W5-2-9

MAINTENANCE

6. Hold the fuel control lever at the fully open

position.

SM7447

7. Slowly turn the crankshaft pulley clock-

wise, at the same time, continue to feed
the fuel with pumping the priming
pump.
When the fuel stop to flow out from the No.
1 delivery valve holder, stop the pump
instantaneously.
This crankangle position is the injection
starting of the engine.

SM7448

8. Observe and make sure that mark (injec-

tion starting angle line α°) on the crank-
shaft pulley is aligning with the pointer.
The timing line shows the injection starting
angle of the engine.
Blow out the remaining fuel from the deliv-
ery valve holder.
Make sure that there is no fuel being
delivered from the priming pump.

NOTE: This engine has eight timing notch lines

punched on the crankshaft damper pulley.
These notched lines must be aligned for cor-
rect engine timing.
Refer to the illustration.

Degree Damper
pulley
Injection Timing B.T.D.C. 8

SM7449
W5-2-10 EX255-EX285

MAINTENANCE

NOTE: Injection pump injection timing will vary

among identical engines, contact your FIAT
KOBELCO Dealer.

9. Remove the delivery valve holder from the

No. 1 plunger.
10. Reinstall the delivery valve internal parts
(seat, spring, and valve) to the delivery
valve holder.
11. Reinstall the delivery valve holder assem-
bly to the No. 1 plunger and tighten it to the
specified torque. Holder

N•m (kgf•m/ft.lb)
Delivery Valve Holder Seat
Torque 39-44 (4-4.5/29-33)
Spring

12. Install the No. 1 cylinder injection pipe and

tighten it to the specified torque. Derivery Valve

N•m (kgf•m/ft.lb)
SM7450

Injection Pipe Nut 28-32 (2.9-3.3/21-24)

Torque

NOTE: DO NOT OVERTIGHTEN THE INJEC-

TION PUMP BODY.
THE INJECTION PUMP BODY IS MADE OF
ALUMINUM. OVERTIGHTENING WILL DIS-
TORT THE INJECTION PUMP BODY SHAPE
AND ADVERSELY AFFECT CONTROL
RACK OPERATION.
EX255-EX285 W5-2-11

MAINTENANCE

Adjusting Procedure
1. Align the pointer and the specified timing
mark on the crank pulley.
2. Perform the operations described on page
W5-2-8 and W5-2-9, steps 3, 4, 5, 6.
3. Loosen the four injection pump fixing nut.
4. To advance the timing
Pivot the injection pump at the pump
Loosen
driveshaft toward out. (Back side nuts also)
To retard the timing.
Pivot the injection pump at the pump
driveshaft toward in (toward the cylinder
block). SM7451
Reference; the 1 mm misalignment be-
tween the two setting mark lines corre-
sponds to about 2° in crankangle.
5. Do a fine injection pump position adjust-
ment, while continue the pumping opera-
tion to feed the fuel, and stop to pivot the
injection pump when the fuel stop to flow
out from the No. 1 delivery valve holder.
6. Tighten the four injection pump fixing nuts.
7. Once remove the No. 1 delivery valve
holder, and reinstall the delivery valve,
spring and the valve holder with the speci-
fied torque.
8. Install the No. 1 injection pipe and tighten
it to the specified torque.
W5-2-12 EX255-EX285

MAINTENANCE

COMPRESSION PRESSURE MEAS-

UREMENT

1. Operate the engine to warm-up until the

coolant temperature reaches to 75 °C
(167 °F).
2. Remove all of the glow plugs and the
injection pipes.
3. Attach a compression gauge to the No. 1
cylinder glow plug installation threads.
Compression gauge adaptor
NOTE: Compression pressure may be meas-
SM7458
ured starting at any cylinder and in no particular
cylinder order. However, it is very important
that the compression pressure be measured in
each cylinder.
Therefore, start at the No.1 cylinder and work
back. In this way, you will be sure to measure
the compression pressure in each cylinder.

Compression Gauge:

Compression Gauge Adapter: 5-85317-001-0

(JKM-1015)

4. Crank the engine with the starter motor and

take the compression gauge reading.

MPa (kgf/cm2/psi) at 200 min-1 at sea level

Standard Limit
3.0 (31/440) 2.5 (26/370)

5. Repeat the procedure (Steps 2 and 3) for

the remaining cylinders.
Compression pressure should be approxi-
mately the same for each cylinder. A vari-
ation exceeding 200 kPa (2 kgf/cm2/28 psi)
SM7459
is unacceptable.
If the measured value exceeds the speci-
fied limit, the related parts must be
checked.
EX255-EX285 W5-2-13

MAINTENANCE

TURBOCHARGER INSPECTION

1. Check the air intake duct connections for

air leakage.

SM7460

2. Check the air duct connections for air

leakage.

SM7461

3. Check the exhaust duct connections for

smoke leakage.
4. Check the turbocharger mounting nuts for
looseness.

SM7462

5. Check the oil feed pipe for oil leakage.

SM7463

6. Check the oil return pipe joints for oil

leakage.

SM7464
W5-2-14 EX255-EX285

MAINTENANCE

ENGINE REPAIR KIT

VIEW (A)

SM7465

1. Cylinder head gasket 19. Oil pipe joint gasket

2. Cylinder head cover gasket 20. Joint bolt gasket
3. Cylinder head cover nut gasket 21. Oil pipe gasket
4. Chamber cover fixing bolt gasket 22. Injection pump oil pipe gasket
5. Oil pump hole cover gasket 23. Injection pump oil pipe gasket
6. Oil relief valve gasket 24. Water pump gasket
7. Water drain valve gasket 25. Thermostat housing gasket
8. Gear case to cylinder block gasket 26. Intake manifold gasket
9. Crank pulley to gear case oil seal 27. Inlet pipe manifold gasket
10. Gear case cover gasket 28. Exhaust manifold gasket
11. Crankshaft rear end oil seal 29. Exhaust manifold to turbocharger gasket
12. Valve guide oil seal 30. Oil feed pipe gasket
13. Drain plug gasket 31. Oil drain pipe gasket
14. Oil pan gasket 32. Oil drain pipe gasket
15. Oil pipe gasket 33. Overflow fuel pipe gasket
16. Oil filter gasket 34. Injection nozzle gasket
17. Oil filter fixing bolt gasket 35. Injection nozzle leak off pipe gasket
18. Oil cooler gasket 36. Thermostat gasket
EX255-EX285 W5-2-15

MAINTENANCE

RECOMMENDED LUBRICANTS

ENGINE TYPE TYPE OF LUBRICANT (API)

Diesel engine oil

With turbocharger
CD grade

ENGINE OIL VISCOSITY CHART

ENGINE OIL VISCOSITY GRADE-AMBIENT TEMPERATURE

[Single grade]

Ambient
temperature (5ºF) (59ºF) (77ºF) (86ºF)

[Multi-grade]

SM7033
W5-2-16 EX255-EX285

MAINTENANCE

NOTE
EX255-EX285 W5-3-1

ENGINE DISASSEMBLY

EXTERNAL PARTS

SM7466

Right-hand Side Disassembly Steps

1. Cooling fan 9. Injection nozzle
2. Not installed 10. Oil pipe; injection pump to cylinder body
3. Not installed 11. Not installed
4. Intake pipe 12. Oil pipe; filter to oil cooler
5. Fuel return pipe ▲ 13. Injection pump with injection pump gear
6. Fuel pipe; fuel filter to injection pump 14. Fuel filter
7. Fuel pipe; feed pump to filter 15. Oil filters
8. Injection pipe and leak off pipe 16. Glow plug
W5-3-2 EX255-EX285

ENGINE DISASSEMBLY

Important Operations
13. Injection Pump with Injection Pump
Gear
Use the shipping plugs (or something simi-
lar) to seal the injection pump delivery
valve ports. This will prevent the entry of
foreign material.
1) Remove the injection pump flange
bolts.
2) Pull the injection pump with the injection
pump drive gear free.
Refer to the illustration.
SM7467
EX255-EX285 W5-3-3

ENGINE DISASSEMBLY

SM7469

Left-hand Side Disassembly Steps

1. Dipstick and guide tube 7. Starter
2. Air breather 8. Fan belt
3. Oil feed pipe 9. Alternator
4. Oil drain pipe 10. Fan pulley
▲ 5. Turbocharger 11. Cylinder head cover
6. Gasket
W5-3-4 EX255-EX285

ENGINE DISASSEMBLY

Important Operations

5. Turbocharger
Plug oil ports in turbocharger body imme-
diately after removal of the turbocharger.

SM7470
EX255-EX285 W5-3-5

ENGINE DISASSEMBLY

MAJOR COMPONENTS

* : Repair kit
SM7471

Disassembly Steps - I 8. Tappet chamber cover

▲ 1. Rubber hose; water by-pass ▲ 9. Oil pump driving pinion
2. Rocker arm shaft assembly ▲ 10. Starting handle nut
▲ 3. Push rod 11. Taper bushing
4. Cylinder head bolt 12. Crankshaft pulley and dust thrower
5. Cylinder head assembly 13. Timing gear cover
6. Cylinder head gasket ▲ 14. Oil thrower
7. Water pump assembly ▲ 15. Flywheel
16. Rear oil seal
W5-3-6 EX255-EX285

ENGINE DISASSEMBLY

Important Operations

2. Rocker Arm Shaft

Loosen the rocker arm shaft fixing bolts a
little at a time in numerical sequence as
specified.

SM7472

4. Cylinder Head Bolts

Loosen the cylinder head bolts a little at a
time in the numerical order shown in the
illustration.
Cylinder head bolt wrench: 1-85111-003-0

Front

SM7473

10. Crankshaft Pulley Nut

Wrench: 54 mm (2.13 in)
Use an appropriate wrench to remove the Crankshaft pulley
crankshaft pulley nut.

Wrench

SM7474
EX255-EX285 W5-3-7

ENGINE DISASSEMBLY

11. Taper Bushing

Remover: 9-8521-0122-0 Use the taper
bushing remover to remove the crankshaft
Taper bushing
end taper bushing.

Crankshaft

Pulley
Taper bushing
remover
SM7475

15. Flywheel
Loosen the flywheel bolt a little at a time in
the numerical order as specified.

SM7476

16. Crankshaft Rear Oil Seal (Axial Type)

With the oil seal pushed in deep, install the
special tool as shown in the illustration and
remove the oil seal.
Oil Seal Remover: 5-8840-2360-0

SM7477
W5-3-8 EX255-EX285

ENGINE DISASSEMBLY

* : Repair kit
SM7471

Disassembly Steps - II
1. Oil cooler 9. Timing gear case
2. Oil pan 10. Idler gear shaft
3. Oil pump and coupling ▲ 11. Crankshaft bearing cap
4. Flywheel housing 12. Crankshaft bearing (lower half)
5. Piston and connecting rod 13. Thrust bearing
▲ 6. Idler gear 14. Crankshaft
▲ 7. Camshaft 15. Crankshaft bearing (upper half)
8. Tappet 16. Oiling jet
EX255-EX285 W5-3-9

ENGINE DISASSEMBLY

Important Operations

6. Idler Gear
Measure the following points before disas-
sembly.

mm (in)
Standard Limit
Idler Gear End 0.128-0.185 0.2
Play (0.005-0.0070) (0.008)
Feeler gauge
mm (in)
SM7479
Standard Limit
Timing Gears 0.10-0.17 0.3
Backlash (0.004-0.007) (0.012)

Includes the crankshaft gear, the cam-

shaft gear, and the idler gear.

Dial indicator

SM7480

7. Camshaft
Measure the following points before disas-
Crankshaft gear
sembly.

mm (in)
Standard Limit
Thrust plate
Cam Gear End 0.050-0.114 0.2
Play (0.002-0.005) (0.008) Feeler gauge Camshaft

SM7481

11. Crankshaft Bearing Cap

Measure the crankshaft end play at the Feeler gauge
thrust bearing (center main bearing) be-
fore disassembly.

mm (in)
Standard Limit
Crankshaft End 0.15-0.33 0.4
Play (0.006-0.013) (0.016)

Crankshaft

SM7482
W5-3-10 EX255-EX285

ENGINE DISASSEMBLY

ROCKER ARM AND ROCKER ARM SHAFT

SM7483

Disassembly Steps
1. Bracket 3. Spring
2. Rocker arm 4. Rocker arm shaft
EX255-EX285 W5-3-11

ENGINE DISASSEMBLY

CYLINDER HEAD

* : Repair kit
SM7484

Disassembly Steps
1. Exhaust manifold and gasket 7. Spring seat (upper)
2. Intake manifold and gasket 8. Valve spring
3. Water outlet pipe 9. Spring seat (lower)
4. Thermostat 10. Valve
5. Thermostat housing and gasket 11. Valve stem oil seal
▲ 6. Split collar

Important Operation

6. Split collar
Use the valve spring compressor to re-
move the split collar.
Valve Spring Compressor: 1-85235-006-0

Valve spring compressor

SM7485
W5-3-12 EX255-EX285

ENGINE DISASSEMBLY

PISTON AND CONNECTING ROD

SM7486

Disassembly Steps
▲ 1. Piston rings 4. Piston
▲ 2. Snap ring 5. Connecting rod bearing
▲ 3. Piston pin and connecting rod
EX255-EX285 W5-3-13

ENGINE DISASSEMBLY

Important Operation

NOTE: Remove any carbon deposits from the

upper part of the cylinder bore. This will prevent
damage to the piston and the piston rings when
they are removed from the cylinder bore.
Carbon deposits

SM7487

1. Piston Rings
Use a piston ring remover to remove the
Piston ring remover
piston rings. Do not attempt to use some
other tool. Piston ring stretching will result
in reduced piston ring tension.
Piston ring remover:

SM7488

2, 3.Snap Ring and Piston Pin

(1) Use a pair of snap ring pliers to remove
the snap ring.

SM7489

(2) Tap the piston pin out with a hammer

and brass bar.
Piston pin

SM7490
W5-3-14 EX255-EX285

ENGINE DISASSEMBLY

NOTE
EX255-EX285 W5-4-1

ENGINE INSPECTION AND REPAIR

NOTE: Make the necessary adjustments, re-

pairs, and part replacements if excessive wear
or damage is discovered during inspection.

CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to
measure the four sides and the two diago-
nals of the cylinder head lower face.
2. Regrind the cylinder head lower face if the
measured values are greater than the
specified limit but less than the maximum
grinding allowance.
SM7491

If the measured values exceed the maximum

grinding allowance, the cylinder head must be
replaced.

Cylinder Head Lower Face Warpage mm (in)

Standard Limit Maximum Grinding
Allowance
0.075 0.2 0.3
(0.003) or less (0.0079) (0.012)
SM7492

Cylinder Head Height (Reference) mm (in)

Standard Limit
89.95 (3.541)-90.05 (3.545) 89.65 (3.530)

NOTE: If the cylinder head lower face is

reground, valve depression must be checked.

SM7493

Water Jacket Water Pressure Test

Use the hydraulic gauge to check the water
jacket water pressure.
Apply water pressure to the water jacket at
490 kPa (5 kgf/cm2/71.1 psi) for three minutes.
Check the entire cylinder head for water leak-
age.

SM7494
W5-4-2 EX255-EX285

ENGINE INSPECTION AND REPAIR

VALVE GUIDE
Valve Stem and Valve Guide Clearance
MEASURING METHOD - I
1. With the valve stem inserted in the valve
guide, set the dial indicator needle to “0”.
2. Move the valve head from side to side.
Note the total dial indicator reading (TIR).
This value is the clearance between the
valve stem and the valve guide.
If the measured values exceed the speci-
fied limit, the valve and the valve guide
must be replaced as a set.
SM7495

Valve Stem Clearance mm (in)

Standard Limit
Intake Side TIR 0.039-0.071 0.20
(0.0015-0.0028) (0.008)
Exhaust Side TIR 0.064-0.096 0.25
(0.0025-0.0038) (0.0098)

MEASURING METHOD - II
1. Measure the valve stem outside diameter.
2. Use a caliper calibrator or a telescoping
gauge to measure the valve guide inside
diameter.
The difference between the valve stem SM7496

outside diameter and the valve guide in-

side diameter is equal to the valve stem
clearance.

Valve Guide Replacement

REMOVAL
Use a hammer and the valve guide remover to
drive out the valve guide from the cylinder head
lower face.
Valve Guide Remover: 9-85220-035-0

INSTALLATION
1. Apply clean engine oil the outer periphery
of the valve guide.
SM7497
2. Attach the installer to the valve guide.
3. Use a hammer to drive in the valve guide
from the upper face of the head until the
installer’s lower edge meets the head sur-
face.
Valve guide installer: 1-85232-001-0
4. After installation, measure the distance
(height) from the cylinder head’s upper
surface to the upper edge of the valve
guide.

Height to valve guide upper edge mm (in)

14.1 (0.555)
SM7498
EX255-EX285 W5-4-3

ENGINE INSPECTION AND REPAIR

VALVE
Valve Depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with
steel rule to measure the valve depression
from the cylinder head lower surface. If the
measured value exceeds the specified
limit, the valve seat insert and/or valve
must be replaced. If the valve is replaced,
the valve guide must be also replaced.

mm (in)
Standard Limit SM7499

Intake and Exhaust

1.0 (0.039) 2.5 (0.098)
Valve Depression

Valve Contact Width

1. Inspect the valve contact faces for rough-
ness and unevenness. Make smooth the
valve contact surfaces.
2. Measure the valve contact width. If the
measured value exceeds the specified
limit, the valve seat insert must be re-
placed.

mm (in)
Standard Limit
Valve Contact SM7500

Width 1.5 (0.059) 2.0 (0.079)

W5-4-4 EX255-EX285

ENGINE INSPECTION AND REPAIR

VALVE SEAT INSERT

Removal
1. Arc weld the entire inside circumference
(1) of the valve seat insert (2).
2. Allow the valve seat insert to cool for a few
minutes. This will invite contraction and
make removal of the valve seat insert
easier.
3. Use a screwdriver (3) to pry the valve seat
insert free.
Take care not to damage the cylinder head
(4).
4. Carefully remove carbon and other foreign SM7501

material from the cylinder head insert bore.

Installation
1. Carefully place the attachment (1) (having
the smaller outside diameter than the valve
seat insert) on the valve seat insert (2).

NOTE: The smooth side of the attachment

must contact the valve seat insert.

2. Use a bench press (3) to slowly apply

pressure to the attachment and press the
valve seat insert into place. Amount of
pressure needed is more than 25 kN (2,500
kgf/5,512 lb). SM7502

NOTE: Do not apply an excessive amount of

pressure with the bench press. Damage to the
valve seat insert will result.

Correction
1. Remove the carbon deposits from the
valve seat insert surface.
2. Use valve cutters (15°, 30°, or 75° blades)
to remove scratches and other rough ar-
eas.
This will bring the contact width back to the
standard value of 90° (A).
Remove only the scratches and rough
areas. Do not cut away too much. Take
care not to cut away unblemished areas of
the valve seat surfaces.

SM7503
EX255-EX285 W5-4-5

ENGINE INSPECTION AND REPAIR

Angle Location Standard

Intake Valve Seat Angle (B) 45°
Exhaust Valve Seat Angle (B) 45°

NOTE: Use an adjustable valve cutter pilot.

Do not allow the cutter pilot to wobble inside the
valve guide.

3. Apply abrasive compound to the valve SM7504

seat insert surface.

4. Insert the valve into the valve guide.
5. Hand lap the valve and the valve seat with
a lapping cup. This will provide optimum
valve and valve seat contact for effective
gas sealing.
6. Check that the valve contact width is
correct.
7. Check that the valve seat insert surface is
in contact with the entire circumference of
SM7505
the valve.

SM7506
W5-4-6 EX255-EX285

ENGINE INSPECTION AND REPAIR

VALVE SPRING
Valve Spring Free Length
Use a vernier caliper to measure the valve
spring free length.
If the measured value is less than the specified
limit, the valve spring must be replaced.

mm (in)
Color Standard Limit SM7507
Exhaust and
Intake Valve 60.6 58.0
blue
Spring Free (2.39) (2.28)
Length

Painted portion
SM7508

Valve Spring Inclination

Use a surface plate and a square to measure
the valve spring inclination.
If the measured value exceeds the specified
limit, the valve spring must be replaced.

mm (in)
Standard Limit
Valve Spring less than 2.7
SM7509
Inclination 1.9 (0.075) (0.106)

Valve Spring Tension

Use a spring tester to measure the valve spring
tension.
If the measured value is less than the specified
limit, the valve spring must be replaced.

N (kg/Ib)
Set Length Standard Limit
44.5 mm 142 127
SM7510
(1.75 in) (14.5/30.9) (13.0/28.7)
EX255-EX285 W5-4-7

ENGINE INSPECTION AND REPAIR

TAPPET
Inspect the tappets for excessive wear, dam-
age and any abnormalities.

Pitted Crack Normal contact

Irregular contact SM7511

Use a micrometer to measure the tappet diam-

eter.

mm (in)
Standard Limit
Tappet 27.97-27.98 27.92
Diameter (1.1020-1.1024) (1.1000)

SM7512

Use a dial indicator to measure the clearance

between the tappet and cylinder body tappet
travelling bore.

mm (in)
Standard Limit
Tappet and Tappet
Travelling Bore 0.020-0.054 0.1
Clearance (0.001-0.002) (0.004)
SM7513
W5-4-8 EX255-EX285

ENGINE INSPECTION AND REPAIR

ROCKER ARM SHAFT AND ROCKER

ARM
Inspect all disassembled parts for wear, dam-
age and any abnormalities.

SM7516

Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm
outside diameter.
If the measured value is less than the specified
limit, the shaft must be replaced.

mm (in)
Standard Limit
Rocker Arm Shaft 18.98-19.00 18.85
Diameter (0.747-0.748) (0.742)

SM7517

Rocker Arm Shaft and Rocker Arm Clear-

ance
1. Use a vernier caliper to measure the rocker
arm bushing inside diameter.

mm (in)
Standard Limit
Rocker Arm
19.01-19.03 19.05
Bushing
(0.749-0.750) (0.751)
Inside Diameter

2. Measure the rocker arm shaft outside di-

ameter. Replace either the rocker arm or SM7518
the rocker arm shaft if the clearance ex-
ceeds the specified limit.

mm (in)
Standard Limit
Rocker Arm
Bushing and 0.01-0.05 0.2
Rocker Arm (0.0004-0.0020) (0.0079)
Shaft Clearance

3. Check that the rocker arm oil port is free of

obstructions. If necessary, use com-
pressed air to clean the rocker arm oil port.
SM7519
EX255-EX285 W5-4-9

ENGINE INSPECTION AND REPAIR

Rocker Arm Correction

Inspect the rocker arm valve stem contact
surfaces for ridge (1) and scoring (2).
If the surfaces have light ridge or scoring, they
may be honed with an oil stone. If the ridge or
scoring is severe, the rocker arm must be
replaced.

SM7515

PUSH ROD
Use a filler gauge to measure the valve push
rod run out. Roll the push rod along a smooth
flat surface (illustration).
mm (in)
Limit
Push Rod Run-Out 0.3 (0.012)

SM7514

IDLER GEAR AND IDLER GEAR

SHAFT
1. Use a micrometer to measure the idler gear
shaft outside diameter. If measured diam-
eter exceeds specified limit, replace the
idler gear shaft.

mm (in)
Standard Limit
Idler Gear Shaft 44.945-44.975 44.9
Outside Diameter (1.769-1.771) (1.768)
SM7520

2. Use a dial indicator to measure the idler

gear inside diameter.

mm (in)
Standard Limit
Idler Gear
and Idler 0.025-0.085 0.2
Gear Shaft (0.001-0.003) (0.008)
Clearance

SM7521
W5-4-10 EX255-EX285

ENGINE INSPECTION AND REPAIR

CAMSHAFT
1. Use the camshaft bearing remover and
installer to remove camshaft bearing from
the cylinder body.
Camshaft Bearing Remover and Installer:
9-8523-1818-0
2. Measure the clearance between the cam
journal and the camshaft bearing.

mm (in) Remover and installer

SM7522
Standard Limit
Cam Journal
and Cam 0.03-0.09 0.15
Bearing Clearance (0.001-0.004) (0.006)

Cam bearing

SM7523

3. Align the camshaft bearing oil holes with

the mating oil ports (machined on the
cylinder body camshaft bearing fitting
bore).

Align oil ports

SM7524

4. Use a micrometer to measure the cam lobe

height. If the cam lobe height is less than
the specified limit, the camshaft must be
replaced.

mm (in)
Standard Limit
Cam Lobe
Height (C-D) 7.71 (0.304) 7.21 (0.284)
Cam Journal 55.94-55.97
Diameter (2.202-2.204) 55.6 (2.189)
SM7525

5. Place the camshaft on a measuring stand.

Use a dial indicator to measure the cam-
shaft runout. Note the total indicator read-
ing (TIR). If the measured run-out exceeds
the specified limit, the camshaft must be
replaced.

mm (in)
Limit
Camshaft Run-Out TIR 0.12 (0.005) SM7526
EX255-EX285 W5-4-11

ENGINE INSPECTION AND REPAIR

CYLINDER BODY AND LINER

Cylinder Liner Bore Measurement
Use a cylinder indicator to measure the cylin-
der liner bore at measuring position (1) in line
with the crankshaft (2) and across the crank-
shaft (3).
Measuring Point (1) mm (in): 20.0 (0.79) (Maxi-
mum Wear Portion)

If the measured value exceeds the specified

limit, the cylinder liner must be replaced.

mm (in)
SM7527
Standard Limit
Cylinder Liner
Bore 105.021-105.060 105.20
Total Indicator (4.1347-4.1362) (4.1417)
Reading

NOTE: The inside of the dry type cylinder liner

is chrome plated. It cannot be rebored or
honed.
If the inside of the cylinder liner is scored or
scorched, the cylinder liner must be replaced.

Cylinder Liner Projection Inspection

1. Hold a straight edge (1) along the top edge
of the cylinder liner to be measured. SM7528
2. Use a feeler gauge (2) to measure each
cylinder liner projection.

mm (in)
Standard
Cylinder Liner
Projection 0.03-0.10 (0.001-0.004)

The difference in the cylinder liner projection

height between any two adjacent cylinders
must not exceed 0.03 mm (0.001 in).

Cylinder Liner Replacement

REMOVAL
SM7529
1. Set the cylinder liner remover to the cylin-
der liner.
2. Check that the remover shaft ankle is
firmly gripping the cylinder liner bottom
edge.
3. Slowly turn the remover shaft handle Remover
counterclockwise to pull the cylinder liner
free.
Cylinder Liner Remover: 9-8523-1169-0
Cylinder Liner Remover Ankle:
5-8523-1004-0

NOTE: Take care not to damage the cylinder

body upper face during the cylinder liner re-
moval procedure. SM7530
W5-4-12 EX255-EX285

ENGINE INSPECTION AND REPAIR

CYLINDER LINER GRADE SELECTION

The term “grade” refers to the cylinder body
inside diameter and the cylinder liner outside
diameter combination.
Measure the cylinder body inside diameter and
select the appropriate cylinder liner grade.
Loose fitting cylinder liners (the liner is too
small for the cylinder bore) will adversely affect
engine cooling efficiency and may lead to
serious engine damage.
Cylinder liners which are too large for the
cylinder bore will be difficult to install.

Cylinder Body Inside Diameter Measurement SM7531

1. Take measurements at measuring point

(1) across the positions W-W, X-X, Y-Y,
and Z-Z.
Measuring Point (1): 115 mm (4.531 in)
2. Calculate the average value of the four
measurements to determine the correct
cylinder liner grade.

Cylinder Bore and Cylinder Liner Outside Di- SM7532

ameter Combinations
(Reference)
mm (in)
Grade Cylinder Bore Cylinder Liner
Outside Diameter
107.001-107.010 107.011-107.020
1 (4.2126-4.2130) (4.2130-4.2134)
107.011-107.020 107 .021-107.030
2
(4.2130-4.2134) (4.2134-4.2138)
107.021-107.030 107 .031-107.040
3
(4.2134-4.2138 ) (4.2138-4.2142 )

SM7533

Cylinder Liner Outside Diameter Measurement

1. Take measurements at measuring point
(1), (2), and (3).
Measuring Points mm (in):
(1) 20.0 (0.788)
(2) 105.0 (4.137)
(3) 195.0 (7.683)
2. Calculate the average value of the 6 meas-
urements to determine the correct cylinder
liner grade.
mm (in)
Cylinder Liner Fitting 0.001-0.019
Clearance Standard (0.00004-0.0007) SM7534
EX255-EX285 W5-4-13

ENGINE INSPECTION AND REPAIR

INSTALLATION
1. Carefully wipe away any foreign material
from the cylinder liner inside and outside
surfaces and the cylinder bore.
2. Use new kerosene or diesel oil to thor-
oughly clean the cylinder liner and bore
surfaces.
3. Use a clean rag to remove all traces of
kerosene or diesel oil from the cylinder liner
and bore surfaces.

4. Insert the cylinder liner (1) into the cylinder

body (2) from the top of the cylinder body.
5. Set the cylinder liner installer (3) to the top
of the cylinder liner.
Cylinder Liner Installer: 5-8522-1018-0
6. Position the cylinder body so that the
installer center (3) is directly beneath the
bench press shaft center (4).
7. Check that the cylinder liner is set perpen-
dicular to the cylinder.
Check that the cylinder liner does not
wobble.
8. Use the bench press to apply an initial SM7531

seating force of 5 kN (500 kgf/1,102 lb) to

the cylinder liner.
9. Use the bench press to apply a final seat-
ing force of 25 kN (2,500 kgf/5,512 lb) to
fully seat the cylinder liner.
10. After installing the cylinder liner, measure
the cylinder liner projection.
Refer to “Cylinder Liner Projection Inspec-
tion”.

PISTON GRADE SELECTION SM7532

The term “piston grade” refers to the piston
diameter and cylinder liner bore combination.
Selection of the proper piston grade will ensure
efficient engine operation, free from cylinder
liner and piston problems.
W5-4-14 EX255-EX285

ENGINE INSPECTION AND REPAIR

Cylinder Liner Bore Measurement

1. Locate the two measuring points.
Cylinder Liner Measuring Point (1): 20 mm
(0.788 in)
Cylinder Liner Measuring Point (2): 105
mm (4.173 in)
2. Measure the cylinder liner bore at measur-
ing point (1) and (2) in four different direc-
tions (W-W, X-X, Y-Y, and Z-Z).
3. Calculate the average value of the eight
measurements.
mm (in)
Cylinder Liner Bore 105.021-105.060 SM7533
Total Indicator Reading (4.1347-4.1362)

Relation between liner bore and piston grade

mm (in)
Liner Bore Diameter Piston Grade
105.021-105.040
( 4.1347-4.1354) AX

105.041-105.060
(4.1355-4.1362) CX

NOTE: It is most important that the correct

piston grade be used. Failure to select the
correct piston grade will result in piston sei-
zure.
Always measure the cylinder bore and select
the appropriate piston grade.

Piston Outside Diameter

Measure the piston outside diameter at the
measuring piston shown in the illustration.

Piston Grade (For service parts) mm (in)

AX CX SM7533
104.959-104.974 104.975-104.990
(4.1322-4.1328) (4.1329-4.1335)

Cylinder Liner Bore and Piston Clearance

mm (in)
Cylinder Liner Bore and 0.051-0.085 Grade of
Piston Clearance (0.002-0.0033) cylinder inside Grade of Combination
diameter piston
Piston Selection
AX AX OK
Select the same grade number as the one for CX CX OK
the cylinder liner inside diameter. AX CX NG
CX AX NG
NOTE: Cylinder liner piston kit clearances are
preset. However, the cylinder liner installation
procedure may result in slight decreases in
cylinder liner bore clearances.
EX255-EX285 W5-4-15

ENGINE INSPECTION AND REPAIR

PISTON AND PISTON RING

Piston Ring and Piston Ring Groove Clear-
ance
Use a feeler gauge to measure the clearance
between the piston ring and the piston ring
groove. Do this at several points around the
piston. If the clearance between the piston ring
and the piston ring groove exceeds the speci-
fied limit, the piston ring must be replaced.

mm (in)
Standard Limit
SM7539
st
1 Compression
Ring – –

2nd Compression 0.070-0.110 0.15

Ring (0.0028-0.0043) (0.0059)
3rd Compression 0.050-0.090 0.15
Ring (0.0020-0.0035) (0.0059)
0.030-0.070 0.15
Oil Ring (0.12-0.28) (0.0059)

Piston Ring Gap

1. Insert the piston ring horizontally (in the
position it would assume if it were installed
to the piston) into the cylinder liner.
SM7540
2. Use an inverted piston to push the piston
ring into the cylinder liner until it reaches
either measuring point (1) or measuring
point (2). Cylinder liner diameter is the
smallest at these two points.
Do not allow the piston ring to slant to one
side or the other. It must be perfectly
horizontal.
Cylinder Liner Measuring Point (1):
10 mm (0.39 in)
Cylinder Liner Measuring Point (2):
130 mm (5.12 in)
3. Use a feeler gauge to measure the piston
ring gap. If the measured value exceeds
the specified limit, the piston ring must be
replaced.
SM7541

mm (in)
Standard Limit
st
1 Compression 0.35-0.50
Ring (0.014-0.020)
2nd Compression 0.60-0.75
Ring (0.0236-0.0295) 1.5
3rd Compression 0.60-0.75 (0.059)
Ring (0.0236-0.0295)
Oil Ring 0.30-0.50
(0.014-0.020)
W5-4-16 EX255-EX285

ENGINE INSPECTION AND REPAIR

PISTON PIN
Piston Pin Outside Diameter
Use a micrometer to measure the piston pin
outside diameter at several points. If the meas-
ured piston pin outside diameter exceeds the
specified limit, the piston pin must be replace.

mm (in)
Standard Limit
Piston Pin
35.000-35.005 34.95
Outside
(1.3780-1.3781) (1.3760)
Diameter
SM7542

Piston Pin and Piston Clearance

Use an inside dial indicator to measure the
piston pin hole.

mm (in)
Standard
Piston Pin Hole 35.015-35.023
Diameter (1.3785-1.3789)

SM7543

Determine the clearance between the piston

pin and the piston pin hole by calculating the
difference between the piston pin hole diam-
eter and the piston pin outside diameter.

mm (in)
Standard Limit
Piston Pin
and Piston 0.010-0.023 0.050
Pin Hole (0.00039-0.0009) (0.00197)
Clearance

SM7544

If an inside dial indicator is not available, use

the following procedure to check the piston pin
fit.
1. Use a piston heater to heat the piston to
approximately 60 °C (140 °F).
2. Push strongly against the piston pin with
your thumbs. The piston pin fitting should
feel tight.

SM7545
EX255-EX285 W5-4-17

ENGINE INSPECTION AND REPAIR

CONNECTING ROD
Connecting Rod Alignment
Use a connecting rod aligner to measure the
connecting rod’s twist distortion and
parralelism between the rod’s large and small
ends.
If the measured value exceeds the limit, re-
place the connecting rod.

Connecting Rod Alignment

(Per Length of 100 mm (3.94 in)) mm (in)
Standard Limit
SM7546
Twist, Parallelism 0.05 (0.002) 0.20
or less (0.0079)

Piston Pin and Connecting Rod Small End

Bushing Clearance
Use a caliper calibrator and a micrometer to
measure the piston pin and connecting rod
small end bushing clearance.
If the clearance between the piston pin and the
connecting rod small end bushing exceeds the
specified limit, replace either the piston pin or
the connecting rod bushing.

mm (in)
Standard Limit
Piston Pin and SM7547

Connecting
Rod Small End 0.012-0.025 0.05
Bushing (0.00047-0.00098) (0.00197)
Clearance

Connecting Rod Bushing Replacement

REMOVAL
1. Clamp the connecting rod in a vise.
2. Use a brass bar and a bench press or
hammer to remove the connecting rod
bushing.
W5-4-18 EX255-EX285

ENGINE INSPECTION AND REPAIR

INSTALLATION
Use the connecting rod bushing installer to
install the connecting rod bushing.
Connecting Rod Bushing Installer:
9-8523-1369-0 (J-29765)

NOTE: The connecting rod bushing oil port

must be aligned with the connecting rod oil
port.

3. Use a piston pin hole grinder (1) fitted with

a reamer (2) or an adjustable pilot reamer to
ream the piston pin hole. SM7548

mm (in)
Standard
Connecting Rod Bushing 35.017-35.025
Inside Diameter (1.3786-1.3789)

SM7549
Connecting Rod Bearing Inspection
1. Fit the connecting rod bearing lower half
into the connecting rod bearing cap.
2. Check the connecting rod bearing lower
half tension. If the tension is insufficient,
the bearing must be replaced.
3. Tighten the connecting rod and the bearing
cap to the specified torque.

N•m (kgf•m/ft.lb)
st
1 step 2nd step
Connecting Rod and
39
Bearing Cap Bolt 60°-90°
(4/29)
Tightening Torque SM7550

4. Use an inside dial indicator to measure the

connecting rod inside diameter.

mm (in)
Standard
Connecting Rod Bearing
64 (2.520)
Nominal Diameter

SM7551
EX255-EX285 W5-4-19

ENGINE INSPECTION AND REPAIR

CRANKSHAFT
Crankshaft and Bearing Inspection
1. Inspect the crankshaft journal surfaces
and the crank pin surfaces for excessive
wear and damage.
2. Inspect the oil seal fitting surfaces of the
crankshaft front and rear ends for exces-
sive wear and damage.
3. Replace or repair the crankshaft if any
excessive wear or damage is discovered.
4. Inspect the crankshaft oil ports for obstruc-
tions.
5. Use high pressure air to clean the oil ports
if necessary.

Crankshaft Journal and Crankpin Outside

Diameter
1. Use a micrometer to measure the crank-
shaft journal outside diameter across
points (1) - (1) and (2) - (2).
2. Use the micrometer to measure the crank-
shaft journal outside diameter at the two
points (3) and (4).
3. Repeat steps 1. and 2. to measure the
crankpin outside diameter.
mm (in)
Position at Standard
Center 79.905-79.925
Crankshaft Bearing Only (3.1459-3.1467) SM7552
Journal
Diameter Other 79.919-79.939
Bearings (3.1464-3.1472)

mm (in)
Standard
63.924-63.944
Crankpin Diameter (2.5167-2. 517 5)

4. Measure the crankshaft journal outside

diameter (and/or the crankpin outside di-
ameter) and the bearing inside diameters
to determine the bearing clearance.

Crankshaft Journal and Bearing Clearances

If the bearing clearance exceeds the specified
limit, the bearing must be replaced.
mm (in)
Position at Standard Limit
Crankshaft Center 0,039-0.098
Journal Bearing (0.0015-0.0039)
and Main Only 0.11
Bearing Other 0.025-0.084 (0.0043)
Clearance Bearings (0.0010-0.0033)

Crankpin and Bearing Clearance

mm (in)
Standard Limit
Crankpin and
Connecting Rod 0.03-0.073 0.10
Bearing Clearance (0.0012-0.0029) (0.0039)
W5-4-20 EX255-EX285

ENGINE INSPECTION AND REPAIR

Crankshaft Journal Bearing Inside Diam-

eter
1. Install the main bearing cap with bearings
to the cylinder body with the specified
torque and facing the arrow mark on the
bearing cap toward front. Place them in
order of punched cylinder numbers.
2. Use an inside dial indicator to measure the
main bearing diameters.

N•m (kgf•m/ft.lb)
Main Bearing Cap 226 - 245
Torque (23 - 25/160 - 181)
SM7553

mm (in)
Main Bearing Nominal 80
Diameter (3.149)

Crankshaft Run-Out
1. Mount the crankshaft on a set of V-blocks.
2. Set a dial indicator to the center of the
crankshaft journal.
3. Gently turn the crankshaft in the normal
direction of engine rotation.
Read the dial indicator (TIR) as you turn the
crankshaft.
If the measured value exceeds the speci-
fied limit, the crankshaft must be replaced.

mm (in)
Standard Limit
SM7554
Crankshaft 0.05 (0.002) 0.40 (0.016)
Run-Out or less

If the crankshaft generated a crack after repair,

replace the crankshaft.
Crankshaft can not be bench pressed, be-
cause it is finished with tufftride method.

Main Bearing and Connecting Rod Bearing

Tension
Check to see if the bearing has enough ten-
sion, so that good finger pressure is needed to
fit the bearing into position.

SM7550
EX255-EX285 W5-4-21

ENGINE INSPECTION AND REPAIR

Plastigage Clearance Measurements

This is another method to measure the crank
journal bearing clearance.

CRANKSHAFT JOURNAL BEARING CLEAR-

ANCE
1. Clean the cylinder body, the journal bearing
fitting portions, the bearing cap, and the
inside the outside surfaces of the bearing.
2. Install the new journal bearing to the cylin-
der body.
3. Carefully place the crankshaft on the bearing. SM7555

4. Rotate the crankshaft approximately 30° to

seat the bearing.
5. Place the Plastigage (arrow) over the
crankshaft journal across the full width of
the bearing.
Apply engine oil to the Plastigage to keep
it from falling.

6. Install the bearing cap with the bearing.

7. Tighten the bearing cap to the specified
torque.
Do not allow the crankshaft to turn during
bearing cap installation and tightening.
8. Remove the bearing cap.
9. Compare the width of the plastigage at-
tached to either the crankshaft or the bear- SM7556
ing against the scale printed on the
plastigage container.
If the measured value exceeds the limit,
perform the following additional steps.
1) Use a micrometer to measure the crank-
shaft outside diameter.
2) Use an inside dial indicator to measure
the bearing inside diameter.
3) Replace the crankshaft and/or the bear-
ing if the measured values) exceed the
limit.

SM7557
W5-4-22 EX255-EX285

ENGINE INSPECTION AND REPAIR

CRANKPIN BEARING CLEARANCE

1. Clean the crankshaft, the connecting rod,
the bearing cap, and the bearings.
2. Install the bearing to the connecting rod.
Do not allow the crankshaft to move when
installing the bearing cap.
3. Hold the connecting rod (with the bearing
installed) against the crankpin.
4. Attach the plastigage to the crankpin.
Apply engine oil to the plastigage to keep
it from falling.
5. Install the connecting rod bearing cap and
tighten it to the specified torque.
Do not allow the connecting rod to move
when installing and tightening the bearing
cap.
6. Remove the bearing cap.
7. Compare the width of the plastigage at-
tached to either the crankshaft or the bear-
ing against the scale printed on the
plastigage container.
If the measured value exceeds the limit,
perform the following additional steps.
1) Use a micrometer to measure the crank-
pin outside diameter.
2) Use an inside dial indicator to measure
the bearing inside diameter.
3) Replace the crankshaft and/or the bear-
ing if the measured values) exceed the
limit.
EX255-EX285 W5-4-23

ENGINE INSPECTION AND REPAIR

Crankshaft Regrinding

NOTE: Crankshaft can not be reground be-

cause it is finished with TUFFTRIDE method.
For the crankshaft on this engine no attempt
should be made to grind finish the faces of the
journals and crankpins as they are
TUFFTRIDED (Special hardening treatment).
Therefore, the undersize bearings are not pre-
pared.

Crankshaft Tufftriding
INSPECTION
1. Use an organic cleaner to thoroughly clean
Ammonium cuprous
the crankshaft. There must be no traces of Test liquid should
chloride
not be applied to
oil on the surfaces to be inspected. area around oil port
2. Prepare a 10% solution of ammonium
Face in contact with
cuprous chloride (dissolved in distilled crank pin or journal
water).
3. Use a spot glass rod to apply the solution
to the surface to be inspected.
Hold the surface to be inspected perfectly
horizontal to prevent the solution from
running. SM7558

NOTE: Do not allow the solution to come in

contact with the oil ports and their surrounding
area.

JUDGEMENT
1. Wait for thirty to forty seconds.
If there is no discoloration after thirty or
forty seconds, the crankshaft is usable.
If discoloration appears (the surface being
tested will become the color of copper), the
crankshaft must be replaced.
2. Clean the surface being tested with clean
water of steam immediately after complet-
ing the test.

NOTE: The ammonium cuprous chloride solu-

tion is highly corrosive. Because of this, it is
imperative that the surfaces being tested be
cleaned immediately after completing the test.
W5-4-24 EX255-EX285

ENGINE INSPECTION AND REPAIR

Crankshaft Gear
INSPECTION
Visually inspect the crankshaft gear.
Replace the crankshaft gear if excessive wear
or damage is discovered.

REMOVAL
Use the crankshaft gear remover to remove the
crankshaft gear.
Remover
Crankshaft Gear Remover: 9-8521-0141-0

SM7559

INSTALLATION
Use the crankshaft gear installer to install the
crankshaft gear.
Crankshaft Gear Installer: 9-8522-0033-0

Installer

SM7560
EX255-EX285 W5-4-25

ENGINE INSPECTION AND REPAIR

FLYWHEEL AND FLYWHEEL HOUSING

Ring Gear Inspection
Inspect the ring gear.
If the ring gear teeth are broken or excessively
worn, the ring gear must be replaced.
Ring Gear Replacement
REMOVAL
Strike around the edges of the ring gear with a
hammer and chisel to remove it.

INSTALLATION
1. Heat the ring gear evenly with a gas-burner SM7561
to invite thermal expansion. Do not allow
the temperature of the ring gear to exceed
200 °C (390 °F).
2. Use a hammer to install the ring gear when
it is sufficiently heated.

SM7562

TIMING GEAR CASE COVER

Crankshaft Front Oil Seal Replacement
REMOVAL
Use an adapter and a hammer to remove the
crankshaft front end oil seal.

INSTALLATION
Use the crankshaft front oil seal installer to
install the crankshaft front oil seal.
Crankshaft Front Oil Seal Installer:
9-8522-0034-0

SM7563
W5-4-26 EX255-EX285

ENGINE INSPECTION AND REPAIR

NOTE
EX255-EX285 W5-5-1

ENGINE REASSEMBLY

PISTON AND CONNECTING ROD

SM7564

Reassembly Steps
▲ 1. Piston ▲ 4. Piston ring
▲ 2. Connecting-rod ▲ 5. Connecting rod bearing
▲ 3. Piston pin, Snap ring
W5-5-2 EX255-EX285

ENGINE REASSEMBLY

Important Operations
1. Piston Conventional
Use a piston heater to heat the pistons to piston heater
approximately 60 °C (140 °F).

2. Connecting Rod
1) Install the connecting rod to the piston
with setting the marks as illustrated.
2) Install the piston pin into the piston and
the connecting rod bushing.
Refer the description of piston pin in
page W5-4-16. SM7565

3. Piston Pin, Snap Ring

1) Use a pair of snap ring pliers to install Piston head
the piston pin snap ring.
2) Check that the piston moves smoothly Front mark
on the piston pin. (▲)

Put cylinder
4. Piston Ring number
marked side in
1) Use a piston ring installer to install the this position
three piston rings.
Piston Ring Installer
Install the piston rings in the following
order. SM7566
(1) Oil ring
(2) 3rd compression ring
(3) 2nd compression ring
(4) 1st compression ring
The marked side of the three compres-
sion rings must be facing up.
rd
The undercut side of the 3 compres-
sion ring will be facing down.
As the oil ring has no any facing mark,
it may face in either direction.
2) Lubricate the piston ring surfaces with
engine oil.
3) Check that the piston rings rotate
smoothly in the piston ring grooves.
SM7489

5. Connecting Rod Bearing

1) Install the connecting rod bearings to
the connecting rod large-end and the Marked side up
connecting rod cap.
2) Install the bearing cap to the connecting 1st comp
rod with semi-tightening the cap bolts.
2nd comp
3) Lubricate the bearing with engine oil.
3rd comp

Oil

SM7567
EX255-EX285 W5-5-3

ENGINE REASSEMBLY

CYLINDER HEAD

* : Repair kit

SM7568

Reassembly Steps
▲ 1. Valve stem oil seal 7. Thermostat housing and gasket
▲ 2. Intake and exhaust valves 8. Thermostat
3. Spring seat (Lower) 9. Water outlet pipe
▲ 4. Intake and exhaust valve springs ▲ 10. Intake manifold and gasket
5. Spring seat (Upper) or valve rotator ▲ 11. Exhaust manifold and gasket
▲ 6. Spring seat split collar
W5-5-4 EX255-EX285

ENGINE REASSEMBLY

Important Operations
Installer
1. Valve Stem Oil Seal
1) Lubricate the oil seals and valve stem
sealing areas with engine oil.
2) Use a valve stem oil seal installer to
install the oil seal.
Valve Stem Oil Seal Installer:
1-85221-005-0
SM7569

2. Intake and Exhaust Valves

1) Place the cylinder head on a flat wooden
surface.
2) Lubricate valve stems with engine oil.
3) Install the valves to the intake or ex-
haust guides.
Install the valves to their original lapped
valve seats.
SM7570

4. Intake and Exhaust Valve Springs

Install the valve springs with their painted
end (the close pitched end) facing down.

Painted portion
SM7508

6. Spring Seat Split Collar

1) Use a spring compressor to push the
valve spring into position.
2) Install the spring seat split collar.
Set the spring seat split collar by tap-
ping lightly around the head of the collar
with a rubber hammer.
Spring Compressor: 1-85235-006-0
Spring compressor SM7485

SM7571
EX255-EX285 W5-5-5

ENGINE REASSEMBLY

10. Intake Manifold and Gasket

1) Install the intake manifold gasket. Unchamfered corner
The intake manifold gasket must be
installed with its unchamfered corner
facing up and to the front of the engine.
Refer to the illustration.
2) Install the intake manifold.
3) Tighten the intake manifold bolts to the
specified torque a little at a time in the Rear
numerical order shown in the illustration. SM7572

N•m (kgf•m/Ib.ft)
Intake Monifold
Bolt Torque 21-30 (2.1-3.1/15-22)

SM7573

11. Exhaust Manifold and Gasket

1) Install the exhaust manifold gasket.
The “TOP” mark must be facing up.
2) Install the exhaust manifold.
3) Tighten the exhaust manifold bolts to
the specified torque a little at a time in
the numerical order shown in the illustra-
tion. TOP

SM7574
N•m (kgf•m/Ib.ft)
Exhaust Manifold
25-31 (2.6-3.2/19-23)
Bolt Torque

SM7575

4) Install either end of the distance tube to

the spot facing. Distance tube

Spot facing
SM7576
W5-5-6 EX255-EX285

ENGINE REASSEMBLY

ROCKER ARM AND ROCKER ARM SHAFT

SM7577

Reassembly Steps
▲ 1. Rocker arm shaft 3. Rocker arm
2. Spring 4. Bracket

Important Operation

1. Rocker Arm Shaft

The rocker arm shaft must be installed with the oil
ports facing up.
EX255-EX285 W5-5-7

ENGINE REASSEMBLY

MAJOR COMPONENT

* : Repair kit
SM7578

Reassembly Steps-I
▲ 1. Oil jet ▲ 9. Idler gear shaft
▲ 2. Crankshaft bearing (upper half) ▲ 10. Idler gear
3. Crankshaft ▲ 11. Piston and connecting rod
▲ 4. Thrust bearing ▲ 12. Oil pump and coupling
▲ 5. Crankshaft bearing (lower half) and crankshaft ▲ 13. Flywheel housing
bearing cap ▲ 14. Rear oil seal
▲ 6. Timing gear case ▲ 15. Oil pan
* 7. Tappet ▲ 16. Oil cooler
▲ 8. Camshaft * The tappet must be installed before the cam-
shaft installation.
W5-5-8 EX255-EX285

ENGINE REASSEMBLY

Important Operations

1. Oil Jet
Install the oil jets taking care not to damage
the oil jet nozzles.

N•m (kgf•m/lb.ft)
Oil Jet Torque 16-25 (1.6-2.6/12-19)

2. Crankshaft Bearing (Upper Half)

5. Crankshaft Bearing (Lower Half) and SM7579

Crankshaft Bearing Cap

The Crankshaft Bearing Configuration

With Oil Without Oil

With oil hole and Fit correctly
Groove Groove groove (upper)
Bearing All Upper
Upper Half Halves –
Bearing – All Lower
Lower Half Halves

Take care not to misinstall the bearing halves.

No oil groove and
hole (lower)

SM7580

4. Thrust Bearing
Install the thrust bearings with the oil
groove side facing the crankshaft sliding
face.

Oil groove side

SM7581

5. Crankshaft Bearing Cap

1) Lubricate the bearing cap bolts with
Arrow mark (Position
engine oil. No. punched)
2) Install the bearing caps to the crank-
shaft. The arrow mark must be pointing
to the front of the engine.
3) Tighten the bearing cap bolts to the
specified torque a little at a time in the
numerical order shown in the illustration. Front

SM7582
EX255-EX285 W5-5-9

ENGINE REASSEMBLY

N•m (kgf•m/Ib.ft)
Crankshaft Bearing 226-245
Cap Bolt Torque (23.0-25.0/166-181)

4) Check that the crankshaft turns

smoothly by manually rotating it.

6. Timing Gear Case

1) Apply liquid gasket to the timing gear
Lubricate with engine oil
case surfaces contacting the cylinder SM7583

body.
2) Tighten the timing gear case bolts to the
specified torque.

N•m (kgf•m/Ib.ft)
Timing Gear Case 21-30
Bolt Torque (2.1-3.1/15-22)

SM7584
8. Camshaft
Tighten the thrust plate bolts through the
camshaft gear hole.

N•m (kgf•m/Ib.ft)
Thrust Plate Bolt 21-30
Torque (2.1-3.1/15-22)

N•m (kgf•m/Ib.ft)
Camshaft Gear Bolt 142-172
Torque (14.5-17.5/105-127) Camshaft gear SM7585

Oil port
9. Idler Gear Shaft
Use the thrust collar fixing bolt as a guide
to install the idler gear shaft.
The oil port must be facing the camshaft.

10. Idler Gear

SM7586
1) Install the idler gear.
Set the timing marks A and B as shown
in the illustration.
2) Tighten the idler gear bolts seating the Injection pump Idle gear "B" mark
thrust collar to the specified torque. gear
The thrust collar must be installed with
the chamfered side facing the front of
the engine.

N•m (kgf•m/Ib.ft)
"C" mark Camshaft gear
Idle Gear Bolt 44-64 "A" mark
Torque (4.5-6.5/33-47) Crankshaft gear SM7587
W5-5-10 EX255-EX285

ENGINE REASSEMBLY

11. Piston and Connecting Rod

1) Set the piston ring gaps as shown in the
illustration.
2) Lubricate the piston, the piston rings,
and the connecting rod bearings with
engine oil.
3) Position the piston front mark towards
the front of the engine.

SM7588
4) Use the piston ring compressor to com-
press the piston rings.
Piston Ring Compressor:
Piston ring compressor
9-8522-1251-0
5) Use a hammer grip to push the piston in
until it makes contact with the crankpin.
At the same time, rotate the crankshaft Front mark
until the crankpin reaches its highest (▲)
point.

SM7589
6) Set the bearing cap cylinder number
marks and the connecting rod cylinder
number marks.
The marks must be facing the exhaust
manifold.

Cylinder
number

7) Lubricate the connecting rod cap bolt

threads and setting fases with Mos
grease. SM7590

8) Use the angular tightening method to

tighten the connecting rod cap bolts to
the specified torque.

N•m (kgf•m/lb.ft)
st
1 step 2nd step
Connecting Rod
Bolt Torque 39 60°-90°
and Angle (4/29)

12. Oil Pump and Coupling SM7591

1) Lubricate the oil pump with the specified
grade of engine oil.
2) Install the oil pump with the coupling.
3) Tighten the oil pump bolts to the speci- Coupling
fied torque.

N•m (kgf•m/Ib.ft)
Oil Pump Bolt
Torque 42-62 (4.3-6.4/31-46)

SM7592
EX255-EX285 W5-5-11

ENGINE REASSEMBLY

13. Flywheel Housing

1) Apply a sealant to the shaded area of the
illustration.
2) Install the flywheel housing.
Tighten the flywheel housing bolts to the
specified torque.
N•m (kgf•m/Ib.ft)
147-167
Flywheel Housing Outer Bolt (15.0-17.0/108-123)
Bolt Torque 21-30
Inner Bolt (2.1-3.1/15-22)
SM7593

14. Rear Oil Seal (Axial Type)

1) Tighten the adapter to the crankshaft
rear end section with 2 bolts.
2) Insert the oil seal into the peripheral 11.6±0.3mm (0.457±0.012in)
section of adapter.
3) Insert the sleeve into the adapter sec-
tion, and tighten it with a bolt until the
adapter section hits the sleeve.
4) Remove the adapter and the sleeve.
5) With the seal pressed in, check the
dimension of the oil seal section.
Standard Dimension = 11.6 ± 0.3 mm
(0.457 ± 0.012 in)
Oil Seal Installer: 5-8840-9025-0
SM7594

15. Oil Pan

1) Apply sealant to the area indicated by
the arrows in the illustration.
2) Install the oil pan gasket
3) Install the oil pan.
Tighten the oil pan bolts to the specified
torque.

N•m (kgf•m/Ib.ft)
Oil Pan Bolt Torque 21-30 (2.1-3.1/15-22)

SM7595

16. Oil Cooler

1) Apply sealant to the oil cooler gasket.
2) Install the oil cooler gasket to the oil
cooler body case.
3) Install the oil cooler.
Tighten the oil cooler bolts to the speci-
fied torque.
Start from the middle and work out to
either side.
Refer to the illustration

N•m (kgf•m/lb.ft)
Oil Cooler Torque 14-24 (1.4-2.4/10-17) SM7596
W5-5-12 EX255-EX285

ENGINE REASSEMBLY

* : Repair kit
SM7597

Reassembly Steps-II
▲ 1. Flywheel ▲ 9. Tappet chamber cover
▲ 2. Injection pump and injection pump gear ▲ 10. Water pump
3. Oil thrower ▲ 11. Cylinder head gasket
4. Timing gear cover ▲ 12. Cylinder head
5. Crankshaft pulley and dust thrower ▲ 13. Cylinder head bolt
6. Taper bushing 14. Push rod
▲ 7. Crankshaft pulley nut ▲ 15. Rocker arm and rocker arm shaft
8. Oil pump driving pinion 16. Rubber hose (Water by-pass)
EX255-EX285 W5-5-13

ENGINE REASSEMBLY

Important Operations
1. Flywheel
1) Lubricate the flywheel bolt threads.
2) Install the flywheel.
The crankshaft rear end dowel pin and
the flywheel dowel hole must be aligned.
3) Tighten the flywheel bolts to the speci-
fied torque in the numerical order shown
in the illustration.

N•m (kgf•m/lb.ft) Lubricate with

engine oil
Flywheel
197-240(20.1-24.5/145-177)
Bolt Torque SM7598

2. Injection Pump and Injection Pump

Gear Assembly
1) Install the injection pump bracket with
the injection pump to the timing gear
case.
Dowel the injection pump bracket with
the timing gear case.
2) Tighten the injection pump bolts to the
specified torque.

N•m (kgf•m/Ib.ft)
Injection Pump 21 - 30
Bolt Torque (2.1 - 3.1/15 - 22) SM7468

3) Align the injection pump gear “C” timing

mark with the idler gear “C” timing mark.
Injection pump Idle gear "B" mark
gear

"C" mark Camshaft gear

"A" mark
Crankshaft gear

SM7587
W5-5-14 EX255-EX285

ENGINE REASSEMBLY

7. Crankshaft Pulley Nut

Pulley
1) Apply MoS2 to the crankshaft pulley nut
threads and fitting face.
2) Use the appropriate wrench to tighten
the crank shaft pulley nut to the speci-
fied torque.

N•m (kgf•m/Ib.ft)
Wrench
Crankshaft Pulley 539-637
Nut Torque (55-65/378-470) SM7474

9. Tappet Chamber Cover

1) Apply sealant (TB 1207B) to the tappet
chamber cover.
2) Install the tappet chamber cover and
tighten the bolts to the specified torque.

N•m (kgf•m/lb.ft)
Tappet Chamber
Cover 21-30 (2.1 - 3.1/15 - 22) SM7601
Bolt Torque

10. Water Pump

Apply sealant (Belco Bond No. 4) to the Apply sealant to the
cylinder body side only
water pump gasket before installing the
water pump.

SM7602

11. Cylinder Head Gasket Front, Top mark

12. Cylinder Head
13. Cylinder Head Bolt
1) Carefully place the cylinder head gasket
on the cylinder body upper surface. Front
The gasket “TOP” mark must be facing
up.
2) Align the cylinder body dowels and the
cylinder head dowel holes.
SM7603
EX255-EX285 W5-5-15

ENGINE REASSEMBLY

3) Carefully place the cylinder head on the

cylinder body.
4) Apply molybdenum disulfide grease to
the cylinder head bolt threads and set-
ting faces.
5) Use the “Angular Tightening Method”.
6) Tighten the cylinder head bolt as fol- Front
lows.
1) As cylinder head bolts have two
kinds of length, install them at
proper location.
The shorter ones (6 bolts) must be
used at the injection pump side.
2) Follow the numerical sequence SM7604
shown in the illustration.

N•m (kgf•m/lb.ft)
1st step 2nd step 3rd step
Bolt 69 88 90°-120°
Torque (7.0/51) (9.0/65)

15. Rocker Arm and Rocker Arm Shaft

1) Check that the rocker arm shaft bracket
lower surface oil port is free from ob-
struction.
2) Install the rocker arm shaft with the
bracket to the cylinder head.
3) Tighten the rocker arm bracket bolts to
the specified torque a little at a time in
the numerical order shown in the illustra-
tion.
4) Lubricate the rocker arm and the rocker
arm shaft with engine oil.

N•m (kgf•m/Ib.ft) SM7605

Rocker Arm Shaft

Bracket Bolt and 25-35 (2.6-3.6/19-26)
Nut Torque

5) Adjust the valve clearance.

Refer to MAINTENANCE for the valve
clearance adjustment procedure.
W5-5-16 EX255-EX285

ENGINE REASSEMBLY

EXTERNAL PARTS

SM7606

Left-hand Side Reassembly Steps

▲ 1. Cylinder head cover ▲ 7. Turbocharger
2. Fan pulley ▲ 8. Oil drain pipe
3. Alternator ▲ 9. Oil feed pipe
▲ 4. Fan belt 10. Air breather
▲ 5. Starter 11. Dipstick and guide tube
▲ 6. Turbocharger mounting flange gasket.
EX255-EX285 W5-5-17

ENGINE REASSEMBLY

Important Operations
1. Cylinder Head Cover
1) Check that the rocker arms, the rocker
arm shafts, and the valve springs are
thoroughly lubricated with engine oil.
If required, relubricate these parts.
2) Place the cylinder head cover gasket on
the cylinder head cover.
Check the head cover gasket for loose-
ness.
3) Tighten the cylinder head cover bolts to
the specified torque a little at a time in
the sequence shown in the illustration.
SM7607

N•m (kgf•m/lb.ft)
Cylinder Head
Cover 7.8 - 9.8
Bolt Torque (0.8 - 1.0/5.8 - 7.2)

4. Fan Belt
Adjust the fan belt tension.
Refer to MAINTENANCE for the fan belt
tension adjustment.

5. Starter
Install the starter to the flywheel housing
and tighten the bolts to the specified
torque.

N•m (kgf•m/lb.ft)
Starter Fixing
Bolts 75 - 91
Torque (7.6 - 9.3/55 - 67)

SM7608

6. Turbocharger Mounting Flange Gasket

Carefully position the gasket with the
edged side facing up.

SM7609
W5-5-18 EX255-EX285

ENGINE REASSEMBLY

7. Turbocharger
Semitighten the turbocharger mounting
nuts.
The nuts will be fully tightened after instal-
lation of the oil pipes.

N•m (kgf•m/lb.ft)
Turbocharger Mounting 42-62
Nut Torque (4.3-6.3/31-46)

SM7610

8. Oil Drain Pipe

1) Remove the exhaust manifold distance
tube immediately beneath the turbo-
charger.
This will make it easier to install the oil
drain pipe.
Distance tube
2) Install the oil drain pipe and tighten the
oil drain pipe flange nuts to the specified
torque.

N•m (kgf•m/lb.ft)
Oil Drain Pipe 28 - 46
Torque (2.9 - 4.7/21 - 34)
SM7611
3) Reinstall the exhaust manifold distance
tube and tighten it to the specified
torque.
Exhaust manifold nut torque is shown in
the page W5-5-5.

9. Oil Feed Pipe

1) Pre-lubricate the turbocharger with CD
grade oil through the oil port shown by
the arrow in the illustration.
2) Install the oil feed pipe and tighten the
pipe flange bolts to the specified torque.

N•m (kgf•m/lb.ft)
Oil Feed Pipe Flange 16 - 25
Bolt Torque (1.6 - 2.6/12 - 19)

SM7612
EX255-EX285 W5-5-19

ENGINE REASSEMBLY

SM7613

Right-hand Side Reassembly Steps

1. Glow plug ▲ 9. Fuel pipe; feed pump to fuel filter
▲ 2. Injection nozzle ▲ 10. Fuel pipe; fuel filter to injection pump
▲ 3. Injection pipe and fuel leak off pipe ▲ 11. Fuel return pipe
▲ 4. Oil filter ▲ 12. Air duct
5. Oil pipe; filter to cooler 13. Not installed
6. Not installed ▲ 14. Cooling fan
7. Oil pipe; injection pump to engine body
8. Fuel filter
W5-5-20 EX255-EX285

ENGINE REASSEMBLY

Important Operation
2. Injection Nozzle
Install the injection nozzles with the injec-
tion nozzle gaskets. Dust cover
Be careful not to damage the nozzle tips.

N•m (kgf•m/lb.ft)
Injection Nozzle 17 - 21
Bolt Torque (1.7 - 2.1/12 - 15)

Nozzle gasket

SM7614

3. Injection Pipe and Fuel Leak Off Pipe

1) Install the fuel injection pipes (1) and
tighten the bolts to the specified torque.

N•m (kgf•m/lb.ft)
Injection Pipe 28 - 32
Torque (2.9 - 3.3/21 - 24)

2) Carefully position and set the clips (2).

It is very important that each clip be
positioned correctly.
An improperly positioned clip will result
in objectionable fuel pulsing noise and
SM7615
injection pipe breakage.
3) Install the fuel leak off pipes (3) .

4. Oil filter
(When the oil filter is being removed in
an oil filter assembly with the filter
cover.)
1) Before the installation, set the special
gaskets which are included within the
repair kit with the oil filter mounting
bolts.
2) Apply a coat of LOCTITE 271 on the bolt
threads to seal the oil leak from the SM7424

crankcase.
3) Install the oil filter assembly with tight-
ening the bolts securely.

N•m (kgf•m/lb.ft)
Oil Filter Assembly 42-62
Mounting Bolt Torque (4.3-6.3/31-46)
EX255-EX285 W5-5-21

ENGINE REASSEMBLY

9. Fuel Pipe (Feed Pump to Fuel Filter)

10. Fuel Pipe (Fuel Filter to Injection Pump)
11. Fuel Return Pipe
Install the fuel pipes and tighten the fuel
pipe joint bolts to the specified torque.
Take care not to interchange the check
valves and joint bolts.

N•m (kgf•m/lb.ft)
Fuel Pipe Joint 16 - 18
Bolt Torque (1.6 - 1.8/12 - 13)

SM7617

12. Air Duct

Install the air duct and tighten the air duct
flange bolts to the specified torque.

N•m (kgf•m/lb.ft)
Intake Pipe
Flange Bolt 21 - 30 (2.1 - 3.1/15 - 22)
Torque

SM7618
W5-5-22 EX255-EX285

ENGINE REASSEMBLY

ENGINE TUNING OPERATION

After reassembly, the engine must be tuned.
This will ensure that the engine operates at its
maximum efficiency.
1. Mount the engine on a test bench.
2. Fill the engine with the specified oil.
3. Connect the cooling pipes and the fuel
pipes.

Reference

Starter switch

PREHEAT

OFF

ON

START Glow plug

Control resistor
0.85 mm2

0.5 Charge Warning lamp

lamp
1.25
Fuse box 0.85

Ammeter
Oil pressure
0.85 0.5
Relay switch
Fusible link 1.25

0.85

Starter Regulator
Battery Alternator Condenser

SM7619

4. Connect the electrical wiring. Refer to the

wiring diagram.
5. Connect the air intake line to the air
cleaner.
6. Connect the exhaust pipe.
7. Manually operate the fuel feed pump to
feed fuel to the engine.
8. Bleed the fuel lines of air. Refer to Page
W5-2-5 of Section 2 MAINTENANCE for
the air bleeding procedure.
EX255-EX285 W5-5-23

ENGINE REASSEMBLY

9. Crank the engine with the starter

(non-ignition operation) for about twenty
seconds.
This will prelubricate the engine internal
components.
10. Start the engine and allow it to run at 750 to
800 rpm for five minutes.
11. Remove the cylinder head cover while the
engine is running.
12. Check that the engine oil is continuously
circulating from the oil pump to the valve
rockers through the cylinder head.
If there is no oil circulation or if the oil
circulation is sluggish, stop the engine and
make the appropriate repairs or adjust-
ments.
Reinstall the cylinder head cover.
13. Increase the engine speed to 1,500 rpm to
do the engine warming-up operation.
14. Check the engine for oil, fuel, coolant, and
air intake leakage.
15. Check for abnormal noise and odor.
16. Check for abnormal electrical charging.
17. Check the engine fastening parts for loose-
ness.
18. When the engine coolant temperature
reached to 75 °C (167 °F) or more, increase
the engine speed to 2,000 rpm and allow it
to run for twenty minutes.
This will give the engine the essential
run-in operating time.
19. Adjust the engine operation speed to the
specified value.
20. Stop the engine to complete the tuning
procedure.
W5-5-24 EX255-EX285

ENGINE REASSEMBLY

NOTE
EX255-EX285 W5-6-1

LUBRICATING SYSTEM

GENERAL DESCRIPTION

Valve opening
pressure 780 kPa

Full flow filter Oil pressure Starter

and oil filter switch Battery
By-pass warning light
valve
Valve opening By-pass
Oil pressure switch
pressure 98 kPa valve
Cylinder body oil gallery
Paper Oil
filter cooler
Tim-

charger
Turbo-
Valve opening pressure Crank Cam-

Oiling
pump
ing

Inj.

jet
196 kPa shaft shaft idle
Oil relief brgs. brgs. gear
valve valve sys.
conn. rod

Cyl. head
Oil relief

Partial Valve opening

Piston
valve

brgs.

Oil pump pressure 440 kPa

filter

Oil
strainer

Oil pan

SM7620

This family of engines uses a normal forced circulation lubricating system.

The gear type oil pump is driven by the camshaft oil pump drive.
The cartridge (spin-on) type oil filter is used.
W5-6-2 EX255-EX285

LUBRICATING SYSTEM

OIL PUMP

SM7621

Disassembly Steps
1. Strainer 4. Driven gear
2. Suction pipe 5. Drive shaft and gear
3. Cover and dowel 6. Driven gear shaft
EX255-EX285 W5-6-3

LUBRICATING SYSTEM

Inspection and Repair

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.

Visually inspect the disassembled parts for

excessive wear and damage
OIL PUMP DRIVE GEAR
Use a feeler gauge to measure the clearance
between the oil pump cover (oil pump case)
inside surface and the drive gear.
If the clearance exceeds the specified limit,
the drive gear and/or the oil pump cover must
be replaced.

mm (in)
Limit
Oil Pump Cover and SM7622

Oil Pump 0.20 (0.0079)

Drive Gear Clearance

SM7623

OIL PUMP DRIVEN GEAR

Use a feeler gauge to measure the clearance
between the oil pump case cover inside sur-
face and the driven gear.
If the clearance exceeds the specified limit,
the driven gear or the oil pump cover must be
replaced.

mm (in)
Limit
Oil Pump Body
and Driven 0.15 (0.0059) SM7624
Gear Clearance

Reassembly

To assemble, follow the disassembly proce-

dures in reverse order.
W5-6-4 EX255-EX285

LUBRICATING SYSTEM

OIL COOLER

SM7625

Disassembly Steps
4. O-ring; plug
1. Oil cooler element
5. By-pass valve spring
2. Element gasket
6. By-pass valve
3. By-pass valve plug

Inspection and Repair

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
EX255-EX285 W5-6-5

LUBRICATING SYSTEM

SM7626

Reassembly Steps
1. By-pass valve 4. By-pass valve plug
2. By-pass valve spring 5. Element gasket
3. O-ring; plug 6. Oil cooler element

Important Operation
6. Oil Cooler Element
Install the oil cooler element to the oil
cooler, and tighten the cooler element fix-
ing nuts to the specified torque.

N•m (kgf•m/lb.ft)
Oil Cooler Element
14-24 (1.4-2.4/10-17)
Fixing Nut Torque

SM7627
W5-6-6 EX255-EX285

LUBRICATING SYSTEM

NOTE
EX255-EX285 W5-7-1

COOLING SYSTEM

GENERAL DESCRIPTION

Water outlet pipe

Thermostat

Cylinder head
Radiator

Reserve tank

Cylinder body

Water pump

SM7628

This family of engines uses a pressurized, forced circulation cooling system with a V-belt driven centrifugal water
pump and a wax pellet thermostat with jiggle valve.
W5-7-2 EX255-EX285

COOLING SYSTEM

THERMOSTAT

Inspection and Repair

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.

Visually inspect the thermostat function refer-

ring Section 2 MAINTENANCE in page W5-2-6.
Thermometer

Agitating rod

Wood piece

SM7438
EX255-EX285 W5-8-1

FUEL SYSTEM

GENERAL DESCRIPTION

Nozzle holder

Fuel filter

Feed pump
Water sedimentor
Fuel tank

Injection pump

SM7629

The fuel system consists of the fuel tank, the water sedimentor, the fuel filter, the injection pump, and the injection
nozzle.
The fuel from the fuel tank passes through the water sedimentor and the fuel filter where water particles and other
foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum
timing for efficient engine operation.
W5-8-2 EX255-EX285

FUEL SYSTEM

INJECTION NOZZLE

SM7630

Disassembly Steps
1. Nozzle holder cap nut 6. Retaining nut
2. Cap nut gasket ▲ 7. Injection nozzle
3. Nozzle adjusting screw 8. Injection pipe connector
4. Push rod spring 9. Connector gasket
5. Nozzle holder push rod 10. Nozzle holder body

Important Operation
7. Nozzle
Remove the nozzle assembly from the
nozzle body.
Keep the parts separately to maintain the
proper needle valve to body combination.

SM7631
EX255-EX285 W5-8-3

FUEL SYSTEM

Inspection and Repair

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.

PUSH ROD SPRING

Check the push rod spring for wear, weakness,
and corrosion.

SM7632

NOZZLE HOLDER PUSH ROD

1. Check the nozzle holder push rod curva-
ture.
2. Check the nozzle holder push rod and
needle valve contact surfaces for exces-
sive wear and poor contact.

SM7633

INJECTION NOZZLE
1. Check the injection nozzle needle valve,
the valve seat, and the injection nozzle
hole for carbon deposits.
If carbon deposits are present, the injec-
tion nozzle and the needle valve must be
replaced.
2. Hold the nozzle body vertically.
Pull the needle valve about one-third of the
way out of the nozzle body.
Release the needle valve.
Check that the needle valve falls back into
the nozzle body as far as the valve seat.
If the needle valve does not fall back into SM7634
the nozzle body as far as the valve seat,
the injection nozzle and the needle valve
must be replaced.
W5-8-4 EX255-EX285

FUEL SYSTEM

SM7635

Reassembly Steps
1. Nozzle holder body 6. Nozzle holder push rod
2. Connector gasket 7. Push rod spring
▲ 3. Injection pipe connector 8. Nozzle adjusting screw
▲ 4. Injection nozzle 9. Cap nut gasket
▲ 5. Retaining nut ▲ 10. Nozzle holder cap nut
EX255-EX285 W5-8-5

FUEL SYSTEM

Important Operation
1. Injection Pipe Connector

N•m (kgf•m/lb.ft)
Nozzle Connector 49 - 59
Torque (5.0 - 6.0/36 - 43)

SM7636

4. Injection Nozzle
There must be no oil on the contact sur-
faces of the injection nozzle and the injec-
tion nozzle holder.
Clean these contact surfaces with diesel
fuel before installation.
The nozzle dowel pin must be aligned with
the dowel hole in the nozzle holder body.
SM7637

5. Retaining Nut

N•m (kgf•m/lb.ft)
Nozzle Retaining 59 - 78
Nut Torque (6 .0 - 8.0/43 - 58)

SM7638

Injection Starting Pressure Adjustment

The injection nozzle injection starting pres-
sure can be adjusted after the adjusting
screw is installed.
Refer to “FUEL SYSTEM” on Page W5-2-3
of the “MAINTENANCE” Section of this
Workshop Manual.

MPa (kgf/cm2/psi)
Injection Starting SM7639
18.1 (185/2630)
Pressure

10. Nozzle Holder Cap Nut

N•m (kgf•m/lb.ft)
29 - 39
Cap Nut Torque (3.0 - 4.0/22 - 29)

SM7427
W5-8-6 EX255-EX285

FUEL SYSTEM

INJECTION PUMP CALIBRATION DATA

Identification Plate and Product serial number

1. Injection pump adjustment and repair should be
made by the nearest ZEXEL CORPORATION or
ROBERT BOSCH Authorized Service Outlet.
2. When you ask such authorized service outlet the
adjustment or repair, the identification Plate and
Product Serial Number will give them a necessary
clue to get technical data distributed by the manu-
Pump No.
facturers previously. NP-PE
Without this data, the Service Outlet will be unable (LICENCE BOSCH)
to effectively service your injection pump.
If you are unable to locate the data applicable to Identification Number
your injection pump, please contact FIAT
KOBELCO Dealer. SM7423
3. Do not remove the Identification Plate and Product
Serial Number from the injection pump.
Keep the Identification Plate and Product Serial
Number clean at all times. Do not allow it to rust or
become illegible.

NOTE: Examples of test conditions and calibration

data are as follows.

Test conditions required for the fuel injection amount adjustment

Injection Nozzle *ZEXEL No.: 105160-5130

Bosch Type No.: NP-DLLA149SM304
Injection Nozzle Holder ZEXEL No.: 105030-4750
Injection Starting Pressure MPa (kgf/cm2/psi) 18.1 (185/2630)
Injection Line Dimensions LE
mm (in.)
P
M
EXA
Inside Diameter 1.8 (0.071)
Outside Diameter 6.0 (0.236)
Length 600.0 (23.6)
Transfer Pump Pressure kPa (kgf/cm2/psi) 157 (1.6/23)
Testing Diesel Fuel ISO4113 or SAE Standard Test Oil (SAEJ967D)
Operating Temperature °C (°F) 40 - 45 (104 - 113)
Pump Rotation Direction Clockwise (Viewed from the drive side)
EX255-EX285 W5-8-7

FUEL SYSTEM

INJ. PUMP CALIBRATION DATA Ass’y No. 000000-0000

Date : 2
MOTORE MODELLO 6BG1-T Company : ISUZU
No. 0-00000-0000
Injection pump : PES6AD Governor : EP/RSV Timing device :
000000-0000 000000-0000
1. Test Conditions:
Pump rotation: clockwise (viewed from drive side)
Nozzle & Nozzle Holder Ass’y : 000000-0000 (BOSCH Type No. EF8511/9A)
Nozzle: 000000-0000 Nozzle Holder: 000000-0000
(BOSCH Type N. DN12SD12T) (BOSCH Type N. EF8511/9)
Nozzle opening pressure: 17.2 MPa (175 kgf/cm2)
PLE Pump pressure: 157 kPa (1.6 kgf/cm2)

AM
Injection pipe: Outer Dia. 6 mm x Int. Dia. 2 mm - Length 600 mm

X
E
Test Oil: ISO4113 or SAE Standard Oil (SAE J967d)
Overflow valve opening pressure: 127 kPa (1.3 kgf/cm2)
Oil Temp. : 40+5 °C

2. Injection Timing:
Pre-stroke: No. 1 Plunger 3.6 ± 0.05 mm Note: Adjust with rack position of mm
Injection order: 1 ____ 5, 1 ____ 3, 1 ____ 6, 1 ____ 2, 1 ____ 4
60°±30' 120°±30' 180°±30' 240°±30 300°±30''

(interval: °±30')
Plungers are numbered from the Driver side.
Tappet clearance: Bolt adjustment type : More than 0.3 mm for all cylinders.
Shim adjustment type : Manually rotate the camshaft 2 ~ 3 times and confirm that
it rotates smoothly.
4. Injection Quantity :
Adjust- Rack Pump Injection q’ty Max. var
ing point Position Speed (cm3/1000 strokes) bet. cyl Fixed Remarks
(mm) (min-1) (%)

A 10.3 1,075 89.5 ± 1.5 ±2 Lever Basic

C Approx. 450 9.5 ± 1.3 ± 14 Rack
7.4
D – 100 85 ± 5 – Lever Rack limit

PLE
AM
EX
5. Timing advance specification:

Pump speed
(min-1)

Advance
angle (°)

ZEXEL CORPORATION 3-4-1 Kitano, Niiza-shi, Saitama-ken, 352

Service Department 1 Japan
W5-8-8 EX255-EX285

FUEL SYSTEM

3. Governor adjustment

Recommended speed droop adjustment screw position: 12

(notches from fully tightened position)

Above 14.0

13.0
Rack limit

Idle-sub spring setting

9.5 Governor spring setting
Rack position (mm)

9.1±0.1
8.5
8.0±0.1
6.5
6.0

6.0±30

0
300 475 1100 1130
145±30 350 1210
(430) (1120)

Pump speed (r/min)

SM7640

Speed control lever angle Stop lever angle

St
op
Full-speed

l
Norma
St
op

Idling

Dead point

SM7641
EX255-EX285 W5-9-1

TURBOCHARGER

GENERAL DESCRIPTION

RHG6

SM7642
W5-9-2 EX255-EX285

TURBOCHARGER

TURBOCHARGER IDENTIFICATION

The IHI Turbocharger nameplate gives the date of

manufacture and other important information required
to identify the unit when service inquiries or part orders
are made.
The arrow in the illustration indicates the location of the
Turbocharger nameplate.

SM7643

The turbocharger nameplate has the following informa-

tion stamped on it. Refer to the illustration at the left.
(1) Turbo Specification Number, Production Year and
Month
(2) Production Date, Daily Serial Number Turbo Spec.
(3) ISUZU Parts Number
Serial No. RHG6
Parts No.

SM7644
EX255-EX285 W5-9-3

TURBOCHARGER

INSPECTION AND REPAIR

If excessive wear or damage is discovered

during inspection, the appropriate parts must
be adjusted, repaired, or replaced. Damage or
improper adjustment of the turbocharger will
inhibit sufficient air flow to the engine, prevent-
ing it from delivering full performance.
If the engine demonstrates a significant drop in
performance, check for engine damage or
wear. If no significant engine damage or wear
can be found, it is likely that the turbocharger
is at fault.
When reduced performance is the result of a
faulty turbocharger, contact your nearest FIAT
KOBELCO Dealer for the proper repairs.
The following is primarily a description of the
particularly important rotor shaft end play, and
bearing clearance standard and limit values.

Rotor Shaft Axial Play Measurement

1) Install a dial indicator on the turbine hous-
ing as illustrated.
Magnet base
2) Use the dial indicator to measure the rotor Turbine
shaft axial play with moving the shaft push housing
and pull. Read the total indicator reading
(TIR).

mm (in)
Push and pull
IHI RHG6 Limit Dial indicator
Rotor Shaft Axial
Play TIR 0.11 (0.0043)
SM7645
3) If the measured value exceeds the speci-
fied limit the shaft must be replaced.

Rotor Shaft Radial Play Measurement

1) Turn over the turbocharger with the turbine
exhaust inlet flange facing up. Dial indicator Magnet base
2) Install a dial indicator to measure the rotor
shaft radial play.
3) Use the dial indicator to measure the play.
Read the TIR.

mm (in)
IHI RHG6 Limit Push and Push and
pull pull
Rotor Shaft Radial 0.205 (0.0081)
Play TIR Oil inlet
SM7646
4) If the measured value exceeds the speci-
fied limit replace the shaft.
W5-9-4 EX255-EX285

TURBOCHARGER

NOTE
EX255-EX285 W5-10-1

STARTING AND CHARGING

STARTER MOTOR

Starter identification

The starter identification plate is attached to the starter motor outside yoke. The ISUZU part number, the
manufacturer’s code number, and other important information are stamped on the plate.
Refer to the identification plate together with the “Main Data and Specifications” Tables and accompanying charts
in this Manual when requesting service assistance from a qualified electrical repair shop.
If you are unable to locate the data applicable to your starter motor, please contact your FIAT KOBELCO Dealer.

Identification Plate

STARTING MOTOR

SM7647

A: Isuzu part number

B: Manufacturer’s code number
C: Rated output
D: Manufacturer’s production mark
W5-10-2 EX255-EX285

STARTING AND CHARGING

Main Data and Specifications

Isuzu Part No. 897225-1990 1-81100-3420

Manufacturer’s code No. (HITACHI) S25-177 S25-172

Rated voltage (V) 24 24

Rated output (kW) 4.5 4.5
Rating (s) 30 30
Direction of rotation
(Viewed from the pinion side) Clockwise Clockwise
Clutch type Roller Roller
Terminal voltage (No load) (V) 24 24
Minimum current (No load) (A) Less than 100 100
Starter motor minimum operating speed
(No load) (min-1) More than 3500 More than 3500

Pinion gear
Modules 3 3
Number of teeth 11 11
Outside diameter mm (in.) 40.64 (1.60) 40.64 (1.60)
Travel distance mm (in.) 1.5 (0.032) 1.5 (0.032)

Yoke outside diameter mm (in.) 90 (3.54) 90 (3.54)

Number of poles 4 4

Magnetic switch (at 20 °C [68 °F])

Series coil resistance (Ω) 0.187 0.187
Shunt coil resistance (Ω) 1.31 1.31

Brush length
Standard mm (in.) 22 (0.866) 22 (0.866)
Limit mm (in.) 14 (0.551) 14 (0.551)

Brush spring standard fitting load N (kgf/lb.) 38 (3.85/8.49) 38 (3.85/8.49)

Commutator
Outside diameter
Standard mm (in.) 37.0 (1.457) 37.0 (1.457)
Limit mm (in.) 36.5 (1.437) 36.5 (1.437)
Difference between the largest and
smallest diameters (Run-out)
Limit mm (in.) 0.1 (0.004) 0.1 (0.004)
Depth of undercut mica
Standard mm (in.) 0.5-0.8 0.5-0.8
(0.020-0.031) (0.020-0.031)
Limit mm (in.) 0.2 (0.008) 0.2 (0.008)
EX255-EX285 W5-10-3

STARTING AND CHARGING

Starter motor sectional view

Magnetic switch
Gear shaft (Internal gear)

Shift lever
Yoke
Gear case
Armature

Brush
Pinion

Brush holder

Pinion gap
(0.3-1.5mm/0.012-0.059in.)

Baffer spring

Rear cover Center bracket (2)

Ball bearing
Through bolt
Center bracket (1)

SM7648

Performance

Volt
age

Output e
rqu
To

Speed

SM7649
W5-10-4 EX255-EX285

STARTING AND CHARGING

ALTERNATOR

Alternator Identification

The alternator identification plate is attached to the alternator rear bracket. The ISUZU part number, the
manufacturer’s code number, and other important information are stamped on the plate.
Refer to the identification plate together with the “Main Data and Specifications” Tables and accompanying charts
in this Manual when requesting service assistance from a qualified electrical repair shop.
If you are unable to locate the data applicable to your alternator, please contact ISUZU MOTORS LIMITED through
your machine supplier.

Identification Plate

SM7650

A: Isuzu part number

B: Manufacturer’s short type name
C: System voltage output
D: Manufacturer’s lot no.
E: Bar code
EX255-EX285 W5-10-5

STARTING AND CHARGING

Main Data and Specifications

Isuzu Part No. 1-81200-5301

Manufacturer’s code No. (MITSUBISHI) A004T05486

Rated voltage (V) 24

Rated output (A) 50
-1
Rated speed (min ) 5000

Rated output at r.p.m (A/V/min-1) 50/27/5000

-1
No-load output at 0 Amp. (V/min ) 24/900

Direction of rotation as viewed Clockwise

from pulley side
Polarity grounded (–)
Pulley diameter mm (in.) 80 (3.15)

Coil resistance at 20°C

Field coil (Ω) 4.4-5.2

Regulator’s applicable
Isuzu part No. 1-81260-0170
Manufacturer’s code No. A866X38282
W5-10-6 EX255-EX285

STARTING AND CHARGING

Alternator Sectional Wiew

STARTER ROTOR
RECTIFIER
BEARING

PULLEY

BEARING

IC REGULATOR

REAR
BRACKET FRONT BRACKET
COIL ASSEMBLY
(FIELD COIL)

SM7651

Charging Circuit

ADDITIONAL
DIODES
DIODE TRIO INDICATOR LAMP
STARTER COIL

KEY
SWITCH

BATTERY (24V)

FIELD
COIL

IC REGULATOR

ALTERNATOR

SM7652
EX255-EX285 W5-11-1

TROUBLESHOOTING

HARD STARTING

1) STARTER INOPERATIVE

Checkpoint Trouble Cause Remedy

Neutral switch NG NG
Defective neutral switch Replace the neutral switch
(If so equipped)

NG Loose battery cable terminals NG Clean and/or retighten the

Battery Poor connections due to rust-
battery cable terminals
ing

NG NG Recharge or replace the bat-

Battery discharged or weak
tery

NG NG
Fan belt loose or broken Adjust or replace the fan belt

OK

NG NG
Fusible link Fusible link shorted Replace the fusible link

OK

NG Defective starter switch or NG Replace the starter switch or

Starter switch
starter relay the starter relay

OK

NG Defective magnetic switch or NG Repair or replace the mag-

Starter
starter relay netic switch

OK

NG NG Repair or replace the starter

Starter Defective starter motor
motor
W5-11-2 EX255-EX285

TROUBLESHOOTING

HARD STARTING

2) STARTER OPERATES BUT ENGINE DOES NOT TURN OVER

Checkpoint Trouble Cause Remedy

Loose battery cable terminals

NG NG Clean and/or retighten the
Battery Poor connections due to rust-
ing battery cable terminals

NG NG Recharge or replace the bat-

Battery discharged or weak
tery

NG NG
Fan belt loose or broken Adjust or replace the fan belt

OK

NG NG
Starter Defective pinion gear Replace the pinion gear

NG NG Repair or replace the mag-

Defective magnetic switch
netic switch

NG Brush wear NG Replace the brush and/or the

Weak brush spring brush spring

OK

NG Piston, crank bearing sei- NG Repair or replace the related

Engine
zure, or other damage parts
EX255-EX285 W5-11-3

TROUBLESHOOTING

HARD STARTING

3) ENGINE TURNS OVER BUT DOES NOT START

FUEL IS BEING DELIVERED TO THE INJECTION PUMP

Checkpoint Trouble Cause Remedy

Injection nozzle injection

NG NG Adjust or replace the injection
Injection nozzle starting pressure too low Im-
proper spray condition nozzle

OK

NG Defective fuel injection noz- NG

Injection pump zle resulting in fuel drippage Replace the delivery valve
after fuel injection

NG Defective injection pump NG Repair or replace the injec-

control rack operation tion pump control rack

NG Injection pump plunger worn NG Replace the injection pump

or stuck plunger assembly
W5-11-4 EX255-EX285

TROUBLESHOOTING

HARD STARTING

4) ENGINE TURNS OVER BUT DOES NOT START

Checkpoint Trouble Cause Remedy

Defective engine stop Replace the engine stop

NG NG
Engine stop mechanism mechanism control wire im- mechanism
properly adjusted Adjust the control wire

FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP

NG NG
Fuel Fuel tank is empty Fill the fuel tank

OK

Clogged or damaged fuel Repair or replace the fuel

NG NG
Fuel piping lines Loose fuel line connec- lines Retighten the fuel line
tions connections

OK

NG Fuel filter overflow valve does NG Repair or replace the fuel fil-
Fuel filter
not close ter overflow valve

NG Clogged fuel filter element NG Replace the fuel filter ele-

ment or the fuel filter cartridge

OK

NG NG Bleed the air from the fuel

Fuel system Air in the fuel system
system
EX255-EX285 W5-11-5

TROUBLESHOOTING

UNSTABLE LOW IDLING

Checkpoint Trouble Cause Remedy

NG Low idling improperly ad- NG

Low idling system Adjust the low idling
justed

OK

NG Defective low idling speed NG Repair or replace the low

Low idling speed control device
control device idling speed control device

OK

NG Throttle control system im- NG Adjust the throttle control sys-

Throttle control system
properly adjusted tem

OK

NG Fuel system leakage or block- NG Repair or replace the fuel sys-

Fuel system
age tem

NG NG Bleed the air from the fuel

Air in the fuel system
system

NG Water particles in the fuel sys- NG

Change the fuel
tem

OK

NG NG Replace the fuel filter ele-

Fuel filter Clogged fuel filter element
ment or the fuel filter cartridge

Continued on the next page

W5-11-6 EX255-EX285

TROUBLESHOOTING

UNSTABLE LOW IDLING

Checkpoint Trouble Cause Remedy

Continued from the previous page

OK

NG Defective governor lever op- NG Repair or replace the gover-

Injection pump
eration nor lever

NG NG
Broken plunger spring Replace the plunger spring

NG NG Replace the plunger assem-

Worn plunger
bly

NG NG
Worn camshaft Replace the camshaft

NG NG
Worn roller tappet Replace the roller tappet

OK

NG Valve clearance improperly NG

Valve clearance Adjust the valve clearance
adjusted

OK
Blown out cylinder head gasket
NG Worn cylinder liner NG
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat
EX255-EX285 W5-11-7

TROUBLESHOOTING

INSUFFICIENT POWER

Checkpoint Trouble Cause Remedy

NG NG Clean or replace the air

Air cleaner Clogged air cleaner element
cleaner element

OK

NG NG
Fuel Water particles in the fuel Replace the fuel

OK

NG NG Replace the fuel filter ele-

Fuel filter Clogged fuel filter element ment or the fuel filter cartridge

OK

NG NG Repair or replace the fuel

Fuel feed pump Defective fuel feed pump
feed pump

OK

NG NG Replace the injection noz-

Injection nozzle Injection nozzle sticking
zle

Injection nozzle injection

NG NG Adjust or replace the injection
starting pressure too low Im-
nozzle
proper spray condition

OK

NG Fuel injection pipes dam- NG Replace the fuel injection

Fuel injection pipes
aged or obstructed pipes

Continued on the next page

W5-11-8 EX255-EX285

TROUBLESHOOTING

INSUFFICIENT POWER

Checkpoint Trouble Cause Remedy

Continued from the previous page

OK

NG NG
Injection pump Defective delivery valve Replace the delivery valve

NG NG
Defective timer Repair or replace the timer

NG Improper control lever opera- NG Adjust or replace the control

tion lever

NG NG Adjust the injection timing

Defective injection timing Repair or replace the injec-
tion pump timer

NG NG Replace the governor

Weak governor spring
spring

NG NG Replace the plunger assem-

Worn plunger
bly

NG NG
Worn camshaft Replace the camshaft

Continued on the next page

EX255-EX285 W5-11-9

TROUBLESHOOTING

INSUFFICIENT POWER

Checkpoint Trouble Cause Remedy

Continued from the previous page
OK

NG NG
Injection pump Worn roller tappet Replace the roller tappet

OK

NG Exhaust gas leakage from the NG

Turbocharger Repair or replace the related
exhaust system Air leakage
parts
from the intake system

NG Defective turbocharger as- NG Replace the turbocharger

sembly assembly

Blown out cylinder head gas-

NG ket Worn cylinder liner Piston NG
Compression pressure ring sticking or broken Im- Replace the related parts
proper seating between the
valve and the valve seat

OK

NG Valve clearance improperly NG

Valve clearance Adjust the valve clearance
adjusted

OK

NG NG Replace the valve spring

Valve spring Valve spring weak or broken

OK

NG NG
Exhaust system Exhaust pipe clogged Clean the exhaust pipe

OK

NG Open and improperly set ad- NG Adjust and reseal the adjust-
Full load adjusting screw seal justing screw seal ing screw
W5-11-10 EX255-EX285

TROUBLESHOOTING

OVERHEATING

Checkpoint Trouble Cause Remedy

NG NG
Cooling water Insufficient cooling water Replenish the cooling water

OK

NG Fan belt loose or cracked NG

Fan belt Replace the fan belt
causing slippage

OK

Radiator NG Defective radiator cap or NG Replace the radiator cap or

clogged radiator core clean the radiator core

OK

NG NG Repair or replace the water

Water pump Defective water pump
pump

OK

Cylinder head and cylinder NG Defective sealing cap result- NG

Replace the sealing cap
body sealing cap ing in water leakage

OK

NG NG
Thermostat Defective thermostat Replace the thermostat

OK

NG Cooling system clogged by NG Clean the foreign material

Cooling system
foreign material from the cooling system

Continued on the next page

EX255-EX285 W5-11-11

TROUBLESHOOTING

OVERHEATING

Checkpoint Trouble Cause Remedy

Continued from the previous page

OK

NG Fuel injection timing improp- NG Adjust the fuel injection tim-

Fuel injection timing
erly adjusted ing
W5-11-12 EX255-EX285

TROUBLESHOOTING

WHITE EXHAUST SMOKE

Checkpoint Trouble Cause Remedy

NG NG
Fuel Water particles in the fuel Replace the fuel

OK

NG NG Adjust the fuel injection tim-

Fuel injection timing Delayed fuel injection timing
ing

OK
Blown out cylinder head gas-
ket. Worn cylinder liner
Compression pressure NG NG
Piston ring sticking or broken Replace the related parts
Improper seating between
the valve and the valve seat

OK

NG NG
Turbocharger Defective turbocharger Replace the turbocharger

OK

Defective valve seals Worn Replace the valve seals,

Inlet and exhaust valves NG NG
valves stems and valve the valves, and the valve
Valve seals guides guides

OK

NG Piston rings worn, broken or NG Replace the piston rings or

Piston rings
improperly installed properly install

OK

NG NG
Cylinder liners Cylinder lines scored or worn Replace the cylinder liners
EX255-EX285 W5-11-13

TROUBLESHOOTING

DARK EXHAUST SMOKE

Checkpoint Trouble Cause Remedy

NG NG Clean or replace the air

Air cleaner Clogged air cleaner element
cleaner element

OK

NG Injection nozzle injection NG

Injection nozzle starting pressure too low Adjust or replace the injection
Improper spray condition nozzle

OK

Fuel injection timing NG Fuel injection timing improp- NG

Adjust the fuel injection tim-
erly adjusted
ing

OK

NG Defective delivery valve re- NG

Injection pump sulting in fuel drippage after Replace the delivery valve
fuel injection

NG NG
Excessive injection volume Adjust the injection volume
W5-11-14 EX255-EX285

TROUBLESHOOTING

OIL PRESSURE DOES NOT RISE

Checkpoint Trouble Cause Remedy

NG Improper viscosity engine, oil NG Replace the engine oil

Engine oil
Too much engine oil Correct the engine oil volume

OK

NG Defective oil pressure gauge NG Repair or replace the oil pres-

Oil pressure gauge or unit
or unit Defective indicator sure gauge or unit
Oil pressure indicator light
light Replace the indicator light

OK

Oil filter NG NG Replace the oil filter element

Clogged oil filter element
or the oil filter cartridge

OK

NG Relief valve sticking and/or NG Replace the relief valve and/

Relief valve and by-pass valve
weak by-pass valve spring or the by-pass valve spring

OK

NG NG Clean the oil pump strainer

Oil pump Clogged oil pump strainer

NG NG Replace the oil pump related

Worn oil pump related parts
parts

OK

NG NG
Rocker arm shaft Worn rocker arm bushing Replace the rocker arm bush-
ing

Continued on the next page

EX255-EX285 W5-11-15

TROUBLESHOOTING

OIL PRESSURE DOES NOT RISE

Checkpoint Trouble Cause Remedy

Continued from the previous page

OK

NG Worn camshaft and camshaft NG Replace the camshaft and

Camshaft
bearing the camshaft bearings

OK

NG Worn crankshaft and bear- NG Replace the crankshaft and/

Crankshaft and bearings
ings or the bearings
W5-11-16 EX255-EX285

TROUBLESHOOTING

EXCESSIVE FUEL CONSUMPTION

Checkpoint Trouble Cause Remedy

NG NG Repair or replace the fuel sys-

Fuel system Fuel leakage
tem related parts

OK

NG NG Clean or replace the air

Air cleaner Clogged air cleaner element
cleaner element

OK

Low idling speed NG Poorly adjusted low idle NG

Adjust the low idle speed
speed

OK

NG Injection nozzle injection NG Adjust or replace the injection

Injection nozzle starting pressure too low Im-
nozzle
proper spray condition

OK

NG Fuel injection timing improp- NG Adjust the fuel injection tim-

Fuel injection timing erly adjusted ing

OK

NG Defective delivery valve re- NG

Injection pump sulting is fuel drippage after Replace the delivery valve
fuel injection

OK

NG Air leakage from the turbo- NG Repair the turbocharger in-

Turbocharger
charger intake side take side

Continued on the next page

EX255-EX285 W5-11-17

TROUBLESHOOTING

EXCESSIVE FUEL CONSUMPTION

Checkpoint Trouble Cause Remedy

Continued from the previous page

OK

NG Defective turbocharger as- NG Replace the turbocharger

Turbocharger
sembly assembly

OK

NG Valve clearance improperly NG

Valve clearance Adjust the valve clearance
adjusted

OK
Blown out cylinder head gas-
ket. Worn cylinder liner
Compression pressure NG Piston ring sticking or broken NG
Replace the related parts
Improper seating between
the valve and the valve seat

OK

NG NG
Valve spring Valve spring weak or broken Replace the valve spring
W5-11-18 EX255-EX285

TROUBLESHOOTING

EXCESSIVE OIL CONSUMPTION

Checkpoint Trouble Cause Remedy

NG Engine oil unsuitable NG Replace the engine oil

Engine oil
Too much engine oil Correct the engine oil volume

OK

NG Oil leakage from the oil seal NG Replace the oil seal and/or
Oil seal and gasket
and/or the gasket the gasket

OK

NG NG
Air breather Clogged air breather Clean the air breather

OK

NG Defective valve seals NG

Inlet and exhaust valves Replace the valve seals, the
Worn valve stems and valve
Valve seals valves, and the valve guides
guides

OK

NG Piston rings worn, broken or NG Replace the piston rings or

Piston rings improperly installed porperly install

OK

NG NG
Cylinder liners Cylinder lines scored or worn Replace the cylinder liners
EX255-EX285 W5-11-19

TROUBLESHOOTING

ABNORMAL ENGINE NOISE

1) ENGINE KNOCKING

Checkpoint Trouble Cause Remedy

Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.

NG NG
Fuel Fuel unsuitable Replace the fuel

OK

NG Fuel injection timing improp- NG Adjust the fuel injection tim-

Fuel injection timing
erly adjusted ing

OK

Improper injection nozzle

Injection nozzle NG NG Adjust or replace the injection
starting pressure and spray
nozzle
condition

OK

NG Blown out head gasket Bro- NG Replace the head gasket or

Compression pressure
ken piston ring the piston ring
W5-11-20 EX255-EX285

TROUBLESHOOTING

ABNORMAL ENGINE NOISE

2) GAS LEAKAGE NOISE

Checkpoint Trouble Cause Remedy

NG Loosely connected exhaust NG Tighten the exhaust pipe con-

Exhaust pipes nections
pipes Broken exhaust pipes
Replace the exhaust pipes

OK

NG NG Replace the washers Tighten

Injection nozzles and/or glow Loose injection nozzles and/
the injection nozzles and/or
plugs or glow plugs
the glow plugs

OK

Exhaust manifold NG Loosely connected exhaust NG Tighten the exhaust manifold

manifold and/or glow plugs connections

OK

NG Damaged cylinder head gas- NG Replace the cylinder head

Cylinder head gasket
ket gasket
EX255-EX285 W5-11-21

TROUBLESHOOTING

ABNORMAL ENGINE NOISE

3) CONTINUOUS NOISE

Checkpoint Trouble Cause Remedy

NG NG
Fan belt Loose fan belt Readjust the fan belt tension

OK

NG NG Retighten the cooling fan

Cooling fan Loose cooling fan

OK

Water pump bearing NG Worn or damaged water NG Replace the water pump
pump bearing bearing

OK

NG Defective alternator or NG Repair or replace the alterna-

Alternator or vacuum pump
vacuum pump tor or the vacuum pump

OK

NG Valve clearance improperly NG

Valve clearance Adjust the valve clearance
adjusted
W5-11-22 EX255-EX285

TROUBLESHOOTING

ABNORMAL ENGINE NOISE

4) SLAPPING NOISE

Checkpoint Trouble Cause Remedy

NG Valve clearance improperly NG

Valve clearance Adjust the valve clearance
adjusted

OK

NG NG
Rocker arm Damaged rocker arm Replace the rocker arm

OK

Flywheel NG NG
Loose flywheel bolts Retighten the flywheel bolts

OK

Crankshaft and thrust bear- NG Worn or damaged crankshaft NG Replace the crankshaft and/
ings and/or thrust bearings or the thrust bearings

OK

Worn or damaged crankshaft Replace the crankshaft

Crankshaft and connecting NG NG
and/or connecting rod bear- and/or the connecting rod
rod bearings ings bearings

OK

NG Worn or damaged connect- NG

Connecting rod bushing and Replace the connecting rod
ing rod bushing and piston
piston pin bushing and/or the piston pin
pin

OK

NG Worn or damaged piston and NG

Piston and cylinder liner cylinder liner Foreign mate- Replace the piston and the
rial in the cylinder cylinder liner
EX255-EX285 W5-12-1

REPAIR STANDARDS

GENERAL RULES

1. These tables provide standards relating the repair.

2. These Repair Standards are based on inspection items, together with dimensions, assembly standards, limit
values, and repair procedures.
(1) Nominal dimensions are the standard production values.
(2) Assembly standards considered to be the values used as objectives during the assembly procedures which
follow repairs; as a result, they may be somewhat at variance with the assembly dimensions of a new engine.
(3) Limit values refer to the measured values resulting from wear, etc., beyond which a part must not be used.
If a measured value falls beyond the limit value, the part involved must be repaired or replaced.
(4) "Repair Procedures" indicates normal repair methods.
(5) Unless otherwise stated, the unit of numerical values in tables should be taken to refer to millimeters mm
(in).

3. Explanation of Terms Used in Tables

(1) The dimension of "wear" refers to the difference between the dimensions of a part which is not worn (or the
"nominal dimension" of a part without wear) and the dimension of the part suffering from the most wear (the
dimension of the worn part).
(2) Uneven wear means the difference between the maximum and minimum wear values.

4. When repairs are requested on the overall engine, first perform bench tests to determine what parts require
repairs, then perform the minimum disassembly and repairs required to correct the problems.
When repairs on a specific engine part are requested, repairs to be made in reference to the relevant items in
accordance with the repair standards listed in this manual.
 W5-12-2
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value

Water temperature
70 - 85°C,
Cylinder compression pressure (158-185°F) engine
3.0 (31/440) 2.5 (26/370)
Time for engine MPa (kgf/cm2/psi) speed 200 min-1
disassembly Disassemble and (varies depending on
and repair repair engine altitude)

Fuel consumption L/h 100% 140% New engine perform-

ance is assumed
Lubricating oil consumption L/h 100% 200% 100%

Wear on liner bore

REPAIR STANDARDS
Measured at A-A

24.120 Upper step wear must (Ref)

be repaired, or replace Cylinder & liner
Dia 105 Dia 105.2 with standard dimen- interference
(4.1339) (4.1417) sion liner
0.001- 0.019
(0.00004 - 0.0007)
Cylinder Block
Engine Body

Liner projection
Difference in liner
projection between
0.03 - 0.10 Some projection must neighboring cylinders
(0.001- 0.004) be present not to exceed
0.03 (0.001)

0.05 or less 0.2

EX255-EX285
Cylinder block upper face warpage (0.0079) Must be repairable 0.3 (0.0118)
(0.002)

Pressure test: 3 minutes Leaks require repair or

490 (5/71.1)
kPa (kgf/cm2/psi) replacement
 EX255-EX285
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value

Valve seat depression: B

(both inlet and exhaust)

(Insert)
1.0 2.5 Replace insert Valve seat angle: α
(Cylinder (0.039) (0.098) 45°
head) Valve

Same for
Bottom inlet & exhaust
surface Must not protrude from
to cylinder lower surface of cylinder head

REPAIR STANDARDS
1.5 2.0 Repair with valve seat After repair, be sure
Contact width with valve seat: A (0.059) (0.079) cutter to lap contact surfaces

Warpage and flatness of cylinder Cannot be repaired:

Cylinder Head
Engine Body

0.075 or less 0.2

head lower face (mounting must replace cylinder
(0.003) 0.079
surface) head

Warpage of manifold mounting 0.05 or less 0.4 repair

surface (0.002) (0.016)

Water-pressure test, 3 minutes Leaks require repair or

490 (5/71.1)
kPa (kgf/cm2/psi) replacement

• Clean bolt mounting

surfaces and
69 threads, and apply
Cylinder head bolts tightening (7.0/51) molybdenum disul-
torque (angular tightening method) ↓ fide grease.
N•m (kgf-m/lb•ft) 88 • Never tighten again
(9.0/65) after using angular
↓ tightening method.
90° - 120° • Reuse bolts max. 2

W5-12-3
times
 W5-12-4
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value
Clearance with
Clearance with cylinder: major axis
grade position from upper face 0.051 - 0.085
Pistons 82 mm (3.228 in) (0.002 - 0.0033)

Piston pin and piston pin hole 0.010 - 0.023 0.05 Replace piston or
clearance (0.00039-0.0009) (0.00197) piston pin
35.000 - 35.005 34.95
Pin wear Replace piston pin
(1.3780 -1.3781) (1.3760)
No. 1 0.35 - 0.50
compression ring (0.014 - 0.020)

REPAIR STANDARDS
Main Operating Parts

No. 2 0.60 - 0.75 Replace rings when

(0.0236-0.0295) performing engine Gauge inner
compression ring 1.5
Piston Ring Gap standard diameter
(0.059) disassembly and
No. 3 0.60 - 0.75 repair 105 (4.134)
compression ring (0.0236 - 0.0295)
0.30 - 0.50
Oil ring
(0.014 - 0.020)
Piston Ring

20.4 - 30.6
No. 1 9.8
(2.08 - 3.12/
compression ring 4.59 - 6.88) (1.0/2.2)

No. 2 14.1- 21.2 4.9 Measure with ring

compression ring (1.44 - 2.16/ (0.5/1.1) Replace compressed to
3.17 - 4.76) standard ring gap
Tension N (kgf/lb)
No. 3 14.1- 21.2 4.9
compression ring (1.44 - 2.16/ (0.5/1.1)
3.17 - 4.76)
36.3 - 55.9 Measure with
31
Oil ring (3.7 - 5.7/ Replace
(3.2/7.05) expander attached
8.16 -12.6

EX255-EX285
 EX255-EX285
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value

No. 1 When assembling

– –
compression ring compression rings on
Main Operating Parts

Clearance piston, be sure ring´s

No. 2 0.070 - 0.110 0.15
between piston marked surface is up
Piston Ring

compression ring (0.0028 - 0.0043) (0.0059)

ring and ring Replace rings or Backwards installation
groove No. 3 0.050 - 0.090 0.15 piston will result in excessive
compression ring (0.0020 - 0.0035) (0.0059) oil consumption
No top/bottom to oil
0.030 - 0.070 0.15 ring
Oil ring
(0.0012 - 0.0028) (0.0059)

Ring gap orientation At 90° intervals

REPAIR STANDARDS
W5-12-5
 W5-12-6
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value
Dia. 80
Uneven wear on journal (3.1496) 0.05 Replace
and pins Dia. 64 (0.002)
(2.5197)
Center 79.905-79.925
Journal Diameter Bearing only (3.1459 - 3.1467)
Replace Do not attempt to grind:
Other 79.919 - 79.939 always replace with new
Bearing (3.1464 - 3.1472) parts
63.924 - 63.944
Pin Diameter Replace
(2.5167 - 2.5175)
Journal and pin finish Ellipse and

REPAIR STANDARDS
precision (taper and taper 0.007
ellipse) (0.0003)
Main Operating Parts

Journal bearing arc Use those with projection

spread and proper arc; take care
Crankshaft

with back side fit

Center 0.039 - 0.098
Clearance Bearing only (0.0015 - 0.0039) 0.11
between journal Replace bearing
Other 0.025 - 0.084 (0.0043)
and bearing
Bearing (0.0010 - 0.0033)

Journal bearing Undersize bearings cannot

undersize be used
0.15 - 0.33 0.4 Measure at crankshaft’s
Crankshaft end play Replace thrust bearings
(0.006 - 0.013) (0.016) No. 4 bearing thrust surface

Crankshaft runout 0.05 or less 0.4 Replace

(0.002) (0.016)
Perform lapping on gears
Ring gear with burrs; in cases of

EX255-EX285
severe damage, replace.

Crankshaft balance 36 or less (Ref. value)

Check dynamic balance
(g-cm) At ends of journal
 EX255-EX285
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value
Crankshaft bearing cap
Main Operating Parts

bolt torque Apply engine oil

226 - 245 to threads and Do not catch foreign matter
Crankshaft

(23-25/166-181) seating areas of bolts in bolts

before tightening
N•m (kgf-m/Ib• ft)

Crankshaft rear oil seal In case of oil leak, replace

Check for oil seal collapse
wear oil seal

REPAIR STANDARDS
W5-12-7
 W5-12-8
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value

Connecting rod bearing Use those with projection

arc spread and proper arc; take care with
back side fit
Clearance between
0.030 - 0.073 0.10 Replace bearing or Take special care with
connecting rod
(0.0012 - 0.0029) (0.0039) crankshaft crankpin precision
bearing and crankpin
Contact between con-
necting rod bearing Replace parts with poor
and crankpin contact or abrasions

Clearance between Sufficient gap to allow

smallend bushing and 0.012 - 0.025 0.05
smooth rotation when

REPAIR STANDARDS
Replace bushing or pin
piston pin (0.00047 - 0.00098) (0.00197)
holding big end
Connecting rod bearing Crank must not be ground
Main Operating Parts

undersize (no undersizes available)

Connecting Rod

Connecting rod and 0.17 - 0.30 0.35

Replace connecting rod
crankpin end play (0.0067 - 0.011) (0.014)
Center distance
192
between big end and Reference value
(7.559)
small end
Big end to small end hole 0.05 or less 0.2
Repair or replace
twist (per 100 mm) (0.002) (0.0079)
Big end to small end hole
0.05 or less 0.2
parallelism Repair or replace
(0.002) (0.0079)
(per 100 mm)
Piston weight difference
20 or less Repair or replace
after assembly g

Bearing cap bolt

EX255-EX285
tightening torque 39 Apply molybdenum disul-
(angular tightening (4.0/29) fide grease to bolts before
method) ↓ tightening
N•m (kgf-m/lb•ft) 60° - 90°
 EX255-EX285
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value
Dia. 56 0.05
Journal uneven wear Replace camshaft
(2.205) (0.002)
Clearance between journal and 0.03 - 0.09 0.15 Replace camshaft or
bearing (0.001- 0.004) (0.006) bearing
Dia. 56 Dia. 55.94 - 55.97 Dia. 56.6
Journal wear Replace camshaft
(2.205) (2.202 - 2.204) (2.189)
Cam height:
Main Operating Parts

A-B
Camshaft

7.71 7.21 Replace camshaft Minor step wear on

(0.304) (0.284) cams can be repaired

REPAIR STANDARDS
Measure with dial
0.12 gauge at No. 3 or
Camshaft runout Replace camshaft
(0.005) No. 4 journal, runout
during one rotation.

Camshaft play (front-back 0.050 - 0.114 0.2

direction) (0.002- 0.005) (0.008)

W5-12-9
 W5-12-10
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value
Inlet valve stem wear Dia. 9 Dia. 8.88 Replace valve and Measure valve stem
Exhaust valve stem wear (0.3543) (0.3496) valve guide together at three positions

Clearance between inlet valve 0.039 - 0.071 0.20

stem and valve guide (0.0015-0.0028) (0.008) Replace valve and
Clearance between exhaust valve 0.064 - 0.096 0.25 valve guide together
stem and guide (0.0025-0.0038) (0.0098)
Interference between valve guide 0.024 Apply oil to valve
and cylinder head (0.0009) guide and press in

Valve Thickness 1.5 1.00 Replace valve and

REPAIR STANDARDS
thickness (0.059) (0.039) valve guide together
Valve System

Valves

Height of valve
14.1
guide above Reference value
(0.555)
cylinder head
Dia. 8.5 Replace oil seal Don't damage lip
Valve stem oil seal lip (0.335) Dia. 8.8 (0.346)

Tension N (kgf/Ib)
(When compressed to installed 142 (14.5/30.9) 127 (13.0/28.7)
length) 44.5mm(1.752in)
Valve spring

Free height
60.6 (2.39) 58.0 (2.28) Replace valve spring

Inclination
less than
1.9 (0.075) 2.7 (0.106)

EX255-EX285
 EX255-EX285
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value
Valve clearance (inlet & exhaust) 0.4
Adjust
Valve System

(cold) (0.016)
Valves

Clearance between rocker arm 0.01 - 0.05 0.2 Replace bushing or

shaft and rocker arm (0.0004-0.002) (0.0079) shaft
18.98 - 19.00 Dia. 18.85
Rocker arm shaft wear Replace
(0.747- 0.748) (0.742)
Intake System

Air cleaner

Special order item

Air cleaner element condition from manufacturer

REPAIR STANDARDS
W5-12-11
 W5-12-12
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value

pressure
Lubricating oil pressure 290 - 590 196
Oil kPa (kgf/cm2/psi) (3.0 - 6.0/43 - 85) (2.0/28)

Clearance between pump body 0.075 - 0.150 0.2 Replace bushing,

inner wall and gear teeth (0.003 - 0.0059) (0.0079) gear or body

Pumping rate L/min

( )
1650 min-1, SAE #30,
pumping pressure 392 kPa 53.3
(4 kgf/cm2/57 psi)
oil temp. 80°C (176°F)
Oil pump and Relief valve

REPAIR STANDARDS
End gap between pump cover 0.040 - 0.094 0.15 Replace gear or
and gear (0.0016 - 0.0037) (0.0059) cover
Lubricating System

Clearance between drive shaft 0.032 - 0.070 0.15

and pump body (0.0013 - 0.0028) (0.0059)

Clearance between drive shaft 0.045 - 0.078 0.15

and bushing (0.0018 - 0.0031) (0.0059) Replace bushing

Dia. 16 Dia 15.9

Diameter of drive shaft (0.6299) Replace shaft
(0.626)

Initial operating Oil gallery 441 (4.5/64)

pressure of relief Reference value
valve kPa (kgf/cm2/psi) Oil pump 785 (8/114)

Replace cartridge
Clogging and damage to oil filter Replace every 500 hours of
Oil filter

operation

EX255-EX285
Initial operating pressure of main oil
filter relief valve kPa (kgf/cm2/psi) 196 (2.0/28)
 EX255-EX285
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value

Water pump ball bearing chatter 0.008 - 0.010 0.2 #6305 (2)
Replace
(radial direction) (0.0003-0.0004) (0.0079) #6205 (1)

Pumping rate L/min

( pumping speed 3720 min-1,

water temp 30°C (86°F)
Total head 13.5m(531.5in) or more
) 300

Clearance between pump impeller Repair or replace if

0.3 -1.0
and pump body impeller and pump
(0.0118 - 0.039)
body are touching

REPAIR STANDARDS
Press with finger

About 7 -10
Cooling System

(Reference)
Fan belt Adjust
Water pump

(0.276 - 0.394) 98N (10kgf/22lb)

deflection

Initial thermostat operating °C 82 ± 2 Replace thermostat if

temperature (at sea level) (°F) (179.6 ± 35.6) operation is incorrect.
Temperature at which
Thermostat full-open temperature °C 95
thermostat lift reaches
(at sea level) (°F) (203)
10mm(0.394in) or more.

Fan center and bearing shaft 0.07 - 0.11 Replace water

interference (0.003 - 0.004) pump ASM

Bearing shaft and impeller 0.020 - 0.060 Replace water

interference (0.0008 - 0.0024) pump ASM

W5-12-13
0.14 or less Replace water
Pulley and fan center clearance (0.006) pump ASM
 W5-12-14
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value

Clogged, cracked, loose fuel pipes,

Piping, etc.
injection pipes, nozzle holders; Repair or replace
defective seals.

Fuel filter element clogging or

Replace Cartridge type
damage

Inspect for damage to

Fuel System

valve's piston and seat;

replace in case of severe
vertical cracks on piston
Injection pump

or impact scars on seat

Delivery valve

REPAIR STANDARDS
with loss of finish gloss.
Delivery valve wear Immerse delivery valve in
clean diesel fuel, then
lightly press lower part of
valve seat with finger and
release; replace assembly
if valve does not return to
original state when finger
is released.

EX255-EX285
 EX255-EX285
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value

Pump Part No.

1-15603-328-0
Adjustment Item

Rotation Direction Clockwise

Clogged, (viewedloose
cracked, from fuel
drivepipes,
side)
injection pipes, nozzle holders;
defective seals.
105780-0000
Nozzle
(BOSCH Type No. DN12SD12T)
Adjustment Conditions

REPAIR STANDARDS
105780-2080
Nozzle holder assembly
(BOSCH Type No. EF8511/9)

Nozzle opening pressure MPa (kgf/cm2/psi) 17.2 (175/2490)

Injection pump
Fuel System

Fuel pumping pressure kPa (kgf/cm2/psi) 157 (1.6/23)

Pipe (o.d. x i.d. x lenght) Dia. 6(0.236) x Dia. 2(0.079) x 600(23.62)

Test fuel ISO4113 or SAE Standard Oil (SAE J967d)

Fuel temperature °C (°F) 40 - 45 (104 -113)

Adjustment Rack position Pump speed Injection q’ty Max. var

Injiection adjustment

mm -1 3 bet. cyl Fixed Remarks

point (min ) (mm /1000 strokes)
(in) (%)
10.3
A 1075 89 ± 1.5 ±2 Lever Basic
(0.4449)
Approx 7.5
C 450 9 ± 1.3 ± 14 Rack
(0.295)
D – 100 150 ± 5 – Lever Rack limit

W5-12-15
 W5-12-16
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value

Governor perfomance curve

Recommended speed droop adjustment screw position:9
(notched from fully tightened position)
Above 14.0

Rack limit

REPAIR STANDARDS
Idle-sub spring setting Stop lever angle Speed lever angle
11.0
Governor spring setting
10.9±0.1
Rack position (mm)
Injection pump
Fuel System

10.3

9.8±0.1

peed
al
8.0

St
Nomin
St

Full-s

op
op
7.5

10.2-0.5
7.3±0.3

Dead point

Idling

Pump speed (r/min)

EX255-EX285
 EX255-EX285
Major Name Nominal Assembly
Inspection Item Standard Limit Repair Procedure Comments
Category of Part Dimension
Value
Technology Needle valve seat: 7.8MPa Repair or replace parts
(80 kgf/cm2/138psi) with leaks from seat area

Needle valve shaft seat: s

Impress fuel pressure of 29.4Mpa Fuel used: diesel fuel;
Injection Nozzle

( )
Fuel System

(300kgf/cm2/4267psi) nozzle starting 37 - 40 s

5.0 or more Replace
pressure and measure time required for 120°C (248°F)
pressure to drop from 24.5MPa (250kgf/cm2
/3556psi) to19.6MPa (200kgf/cm2/2845psi).

Fuel spray and injection (1) Visually inspect, no relatively

large drops scattered.

( )
Impress fuel pressure of 19.1Mpa

REPAIR STANDARDS
(195kgf/cm2/2770psi) (needle valve (2) No drops scattered to one side. Replace faulty parts
opening pressure) (3) No unevenness of spray from
jets.
If warning indicator lights
Wiring Discharge
indication
Charge/

when engine is operating at

Warning lamp indication
normal speeds, check and
repair electrical system.
Check for looseness, cuts or damaged
Repair
insulation to wiring.
Electrical

0.06 or less 0.1

(MITSUBISHI 1-81200-530-1)

Shaft runout (0.0024) (0.0038) Replace rotor

Alternator 24V, 50A

Rotor

Rotate by hand and check

for smooth rotation; no
Bearing chatter Replace bearings
abnormal sound or resis-
tance should be felt.
Perform-
ance

Rated output current 27 V (5000 min-1) 50A

W5-12-17
 W5-12-18
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value

Loose mount Repair

22 14
Brush height Replace
Starter 24V, 7.4 kW (HITACHI 1-81100-342-0) (0.866) (0.551)
Series coil 0.187
resistance value (Ω) 20 °C (68 °F) If coil resistance value
Magnetic
is severely abnormal,
switch
Shant coil 1.31 replace switch.
resistance value (Ω) 20 °C (68 °F)
Dia. 37 Dia. 36.5
O. D. Replace armature
(1.457) (1.437)
Commutator

REPAIR STANDARDS
0.5 - 0.8 0.2
Undercut depth (0.02 - 0.031) (0.008) Repair

Rear side Dia. 28

6001 D
(armature) (1.102)
Electrical

Replace if rotation is
Ball Dia. 16 not smooth or if
bearings Front (armature) 6905 D abnormal sounds are
(0.630)
heard.
Dia. 16
Pinion shaft (shaft)
(0.630)
Unloaded Smooth pinion
Performance characteristics 3500 min-1 operation without
(24V, 100A or less) noise
Preheater

Replace if cut wiring

Control register, glow plug
or shorts are found

Battery terminals
Special order from
Battery

Plates, separator plates, container, original manufac-

EX255-EX285
etc. turer; manufacturer's
specs.
Electrolyte turbidity
 EX255-EX285
Major Name Nominal Assembly
Inspection Item Limit Repair Procedure Comments
Category of Part Dimension Standard Value

Electrolyte specific gravity

(at recharging, 20°C)
Electrical

Battery

Capacity (20 hours) Special order from

original manufacturer
Electrode voltage

Electrolye surface height

Engine run-in operation 30 minutes or more

REPAIR STANDARDS
Cylinder compression pressure
MPa (kgf/cm2/psi) 3.0 (31/441) 2.5 (26/370) Inspect Warm engine
[water temp. 70 - 85 °C, (158 -185 °F)
about 200 min-1]
Final Inspection

Difference in compression
between cylinders,
kPa (kgf/cm2/psi) 290
Inspect Warm engine
[water temp. 70 - 85 °C, (158 -185 °F) (3 0/43)
about 200 min-1]

Lubricating oil pressure 290 - 590 200 or less

kPa (kgf/cm2/psi) (3.0 - 6.0/43 - 85) (2.0/28) Adjust

Output check 85% or more

When new engine
output is 100%
Fuel consumption check 110% or less

W5-12-19
W5-12-20 EX255-EX285
REPAIR STANDARDS
NOTE
COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.
Documentation Centre
Strada di Settimo, 323 - S. MAURO T.SE ( TO ) ITALY

Reproduction of text or illustrations,

in whole or in part, is strictly prohibited

Print No. 604.13.201 - VII - 2002

Printed by Satiz - Turin (Italy)

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