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Fiat Kobelco EX355 Tier2 Technical Manual

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Table of Contents

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

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Summary of Contents for Fiat Kobelco EX355 Tier2

  • Page 1 EX355 Tier2 TECHNICAL MANUAL - OPERATIONAL PRINCIPLE TECHNICAL MANUAL - TROUBLESHOOTING WORKSHOP MANUAL WORKSHOP MANUAL - ENGINE...
  • Page 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. 604.13.206 - Edition - July 2002...
  • Page 3 FIAT KOBELCO CONSTRUCTION - Be sure to thoroughly read this manual for correct MACHINERY S.p.A. information concerning the service procedures.
  • Page 4 IN-2 EX355 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 : Technical Manual W : Workshop Manual...
  • Page 5 TECHNICAL MANUAL EX355 OPERATIONAL PRINCIPLE SECTION AND GROUP CONTENTS Section 1 - GENERAL Group 1 Specifications Group 2 Component Layout Section 2 - SYSTEM Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System Section 3 - COMPONENT OPERATION Group 1 Pump Device Group 2...
  • Page 6 SECTION 1 EX355 GENERAL CONTENTS Group 2 - Component layout Group 1 - Specifications Main components ........ T1-2-1 Excavator Dimensions (Monoblock version) ......T1-1-1 Electrical system (Overall system) ........T1-2-2 Escavator Dimensions (BEH version) ........T1-1-2 Electrical system Excavator Dimensions (Cab) ............
  • Page 7 EX355 T1-1-1 SPECIFICATIONS EXCAVATOR DIMENSIONS (Monoblock version) D/D' ▲ ▲ ▲ ▲ ▲ OM0553 VERSION D'(*) F (**) 1) 3490 EX355 EL (mm) 4052 4952 1250 3280 3300 11040 3000 3020 1020 2) 3420 3) 3170 EX355 LC (mm) 4052 4952 1250 3280...
  • Page 8 T1-1-2 EX355 SPECIFICATIONS EXCAVATOR DIMENSIONS (BEH version) ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ D/D' ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ OM0660 ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ ➤ VERSION D'(*) E (**)
  • Page 9 EX355 T1-1-3 SPECIFICATIONS EXCAVATOR DIMENSIONS (Triple articulation version) D/D' ▲ ▲ ▲ ▲ OM0556 VERSIONS D'(*) F (**) 1) 3275 EX355 EL (mm) 4052 4952 1250 3280 3300 10980 3000 3020 1020 2) 3291 3) 3237 EX355 LC (mm) 4052 4952 1250 3280...
  • Page 10 T1-1-4 EX355 SPECIFICATIONS EXCAVATOR PERFORMANCE GRADEABILITY ......................35° (70%) in continuous TRAVEL SPEED ....................2.2 / 3.4 mph (3.6/5.5 km/h) - Slow ........................0 to 2.2 mph (0 to 3.6 km/h) - Fast ........................0 to 3.4 mph (0 to 5.5 km/h) ENGINE MAIN SPECIFICATIONS - Manufacturer ............................
  • Page 11 EX355 T1-1-5 SPECIFICATIONS ENGINE ACCESSORY RADIATOR ASSEMBLY - Type ....................Radiator/Oil Cooler tandem type assembly - Weight ............................. 155 kg (342 lb) - Radiator Capacity............................15 L - Oil Cooler Capacity ............................ 8 L BATTERY - Capacity ............................160 Ah x 2 - Voltage ...............................
  • Page 12 T1-1-6 EX355 SPECIFICATIONS CYLINDERS Bucket Boom Positioning (*) Standard Rod diameter 105 mm 115 mm 95 mm 105 mm 105 mm Cylinder bore 150 mm 170 mm 145 mm 150 mm 170 mm Stroke 1507 mm 1795 mm 1250 mm 1250 mm 1335 mm Fully retracted length 2150 mm...
  • Page 13 EX355 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...
  • Page 14 T1-2-2 EX355 COMPONENT LAYOUT ELECTRICAL SYSTEM (Overall system) SM5602 1 - Wiper Motor 18 - N (Engine Speed) Sensor 2 - Monitor Panel 19 - Engine Oil Pressure Switch 3 - Relays, Relays box 20 - Coolant Temperature Switch (Engine Preheat Circuit) 4 - Windshield 21 - Engine Oil Level Switch (on oil pan) 5 - Horn...
  • Page 15 EX355 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 (R1) variant provision 3 - Connection for cab light (ceiling) 15 - L.H.
  • Page 16 T1-2-4 EX355 COMPONENT LAYOUT ELECTRICAL SYSTEM (Cab) SM5604 7 - Connector not used 1 - Connectors for monitor and switch panels 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...
  • Page 17 EX355 T1-2-5 COMPONENT LAYOUT ELECTRICAL SYSTEM (Monitor and Switch panels) T157-07-02-001 SM0610 T157-01-01-009 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...
  • Page 18 T1-2-6 EX355 COMPONENT LAYOUT ELECTRICAL SYSTEM (Batteries compartment) 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...
  • Page 19 EX355 T1-2-7 COMPONENT LAYOUT ELECTRICAL SYSTEM (Fuses) FUSES IN THE BOX Fuse PROTECTED Rating LABEL CIRCUIT Backup power SW. BACK UP source ENGINE C/U (Power Source) E.C. MOTOR Motor Auxiliary AUXILIARY Power supply REAR CAB Rear cab light LIGHT power supply OM0231 HAMMER Breaker...
  • Page 20 T1-2-8 EX355 COMPONENT LAYOUT OTHER COMPONENTS Pump device Travel device Pilot filter SM6004 7 - Pump Delivery Pressure Sensor (Pump 1) 8 - N (Engine Speed) Sensor 1 - Regulator (Pump 2) 9 - Counterbalance Valve 2 - Pilot Pump 10 - Travel Relief Valve 3 - Regulator (Pump 1) 11 - Pilot filter...
  • Page 21 EX355 T1-2-9 COMPONENT LAYOUT Swing Device Shockless Valve T157-01-01-011 T157-07-03-018 SM0626 SM6005 Solenoid Valve Unit SM5606 T157-01-01-012 1 - Swing Relief Valve 7 - Check Valve 2 - Pilot Pressure Sensor(Arm Roll-In) 8 - Solenoid Valve Unit (SC) 3 - Shockless Valve 9 - Solenoid Valve Unit (SD) 4 - Check Valve 10 - Solenoid Valve Unit (SI)
  • Page 22 T1-2-10 EX355 COMPONENT LAYOUT NOTES:...
  • Page 23 SECTION 2 EX355 SYSTEM CONTENTS Group 1 - Control system Group 3 - Electrical system Outline ............ T2-1-1 Outline ........... T2-3-1 Engine control ........T2-1-2 Electric power circuit (Key Switch: OFF) ......... T2-3-2 Pump control .......... T2-1-8 Bulb Check Circuit (Key Switch: ON) ..T2-3-4 Valve control ...........
  • Page 24 EX355 T2-1-1 CONTROL SYSTEM OUTLINE After processing the sensing signals in the logic Microcomputer built-in main controller (MC) is pro- circuits, the MC sends out the control signals to the vided to control machine operation. Electronic sens- ing signals from the engine control dial, various sen- EC motor and solenoid valve unit to control the sors and switches are sent to the MC.
  • Page 25 T2-1-2 EX355 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 switch...
  • Page 26 EX355 T2-1-3 CONTROL SYSTEM Normal Control Purpose: To control engine speed in response to the NOTE - Normally, the governor lever does not come operation angle of the engine control dial on the switch into contact with the full side stopper even if the engine panel.
  • Page 27 T2-1-4 EX355 CONTROL SYSTEM HP Mode Control Purpose: To instantaneously increase the engine speed only when a little more hydraulic power is Engine speed required for arm roll-in operation. For example, to HP mode operation increase the arm roll-in power while conducting a line deep digging work.
  • Page 28 EX355 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.
  • Page 29 T2-1-6 EX355 CONTROL SYSTEM Auto-Idle Control Purpose: To slow the engine speed when all control control levers are kept in neutral (the pressure levers are in neutral to reduce fuel consumption and switches for travel and front operations are off) for noise.
  • Page 30 EX355 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.
  • Page 31 T2-1-8 EX355 CONTROL SYSTEM PUMP CONTROL Speed Sensing Control Purpose: To control the pump driving torque in re- regulators to control the pump flow rate. sponse to the load variations on the engine or the When poor quality fuel is used or if the machine is output of the hydraulic pumps to utilize the engine operated at high altitudes, the engine output torque output more efficiently.
  • Page 32 EX355 T2-1-9 CONTROL SYSTEM VALVE CONTROL The valve control consists of the these controls: • Power boost control • Arm regenerative control • Travel motor swash angle control. Main Relief valve Travel Motor Swash Angle Control Servo Piston Pressure Switch (Front) Pressure Switch (Travel) Pilot pressure Sensor (Arm Roll-In)
  • Page 33 T2-1-10 EX355 CONTROL SYSTEM Power Boost Control Purpose: To increase hydraulic power by temporarily ON, the MC magnetizes solenoid valve unit (SG) for 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.
  • Page 34 EX355 T2-1-11 CONTROL SYSTEM Arm Regenerative Control is combined with the pump delivery oil and supplied to Purpose: To increase arm roll-in speed and prevent the arm cylinder bottom side, increasing the arm roll- the arm roll-in hesitation. in speed and preventing arm roll-in hesitation. Operation: When signals to the MC from the pump delivery pressure sensor (pump 2) and pilot pressure sensor (arm roll-in), fall into the following conditions,...
  • Page 35 T2-1-12 EX355 CONTROL SYSTEM Travel Motor Swash Angle Control Operation Conditions: Purpose: To change fast/slow travel speed. - Pressure Switch (Travel): ON Operation: When the travel mode switch is in - Pressure Switch (Front): OFF position, the travel motor swash angle is held at a - Pump Delivery Pressure Sensors (Pump 1 and 2): Pump delivery pressure is low.
  • Page 36 EX355 T2-1-13 CONTROL SYSTEM OTHER CONTROL FUNCTIONS Work Mode Control The work mode includes the four modes of GENERAL of the full speed set when the engine control dial is PURPOSE, GRADING, PRECISION, and ATTACH- placed in the full position. The main relief pressure is increased in boom raise MENT, which can be selected by the work mode switch.
  • Page 37 T2-1-14 EX355 CONTROL SYSTEM NOTES...
  • Page 38 EX355 T2-2-1 HYDRAULIC SYSTEM MAIN CIRCUIT The main pumps (pump 1 and pump 2) draw hydraulic the hydraulic oil tank via the control valves and the oil oil from the hydraulic oil tank. Pump 1 delivers oil to cooler. When oil temperature is low (viscosity is high), the 4-spool control valve while pump 2 delivers oil to return oil flowing through the oil cooler will be ham- the 5-spool control valve.
  • Page 39 T2-2-2 EX355 HYDRAULIC SYSTEM PILOT CIRCUIT Pressure oil from the pilot pump is supplied to each of the following circuits. • Pilot Operating Circuit • Swing Parking Brake Release Circuit Pressure oil from the pilot pump with the regulated (Refer to the Swing Device group in the COMPO- pilot valve moves the control valve spool.
  • Page 40 EX355 T2-2-3 HYDRAULIC SYSTEM Positioning Pilot Valve (*) Travel Pilot Right Pilot Left Pilot Valve Valve Valve Pilot Operating Circuit Pilot Shut-off Manifold for Shockless Valves, Pressure Hydraulic Oil Valve Sensor, and for Pressure Switch Tank Hydraulic Oil Heat Swing Parking Circuit Suction Filter Swing Motor...
  • Page 41 T2-2-4 EX355 HYDRAULIC SYSTEM NEUTRAL CIRCUIT flows to the spools (Swing, Arm 1, Boom 2 , Auxiliary, and Travel (L)) in the 5-spool section in the control valve. When the control levers are in neutral, pressure oil When arm (roll-in, roll-out) or boom (raise) levers are from the main pumps returns to the hydraulic oil tank via the control valves and the pump control valves.
  • Page 42 EX355 T2-2-5 HYDRAULIC SYSTEM Left Travel Motor Right Travel Motor Travel (L) Travel (R) Bucket Bucket Auxiliary Cylinder Boom 2 Boom Boom 1 Cylinder Cylinder Arm 1 Arm 2 Swing Hydraulic Oil Tank 5-Spool Side Swing Motor 4-Spool Side Pump 2 Pump 1 SM6015A...
  • Page 43 T2-2-6 EX355 HYDRAULIC SYSTEM COMBINED OPERATION Swing and Boom Raise Operation When combined swing and boom raise operation is upperstructure. At the same time, pressure oil flows performed, pilot pressure shifts the swing, boom 1, from boom 2 spool via the parallel passage into the and boom 2 spools in the control valve.
  • Page 44 EX355 T2-2-7 HYDRAULIC SYSTEM Parallel Passage Boom 2 Boom 1 Boom Cylinder Swing Parallel Passage Swing Motor Pump 2 Pump 1 SM6016...
  • Page 45 T2-2-8 EX355 HYDRAULIC SYSTEM Travel and Arm Roll-In Operation When combined travel and arm roll-in operation is At the same time, pressure oil flows from the flow performed, pilot pressure shifts the travel, arm 1, and combiner valve into the left travel motor via the travel arm 2 spools.
  • Page 46 EX355 T2-2-9 HYDRAULIC SYSTEM Flow Combiner Front Att. Pilot From Pilot Pump Valve Left Travel Motor Signal Circuit Right Travel Motor Travel (L) Travel (R) Cylinder Arm 1 Arm 2 Pump 1 Pump 2 SM6017...
  • Page 47 T2-2-10 EX355 HYDRAULIC SYSTEM NOTES...
  • Page 48 EX355 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.
  • Page 49 T2-3-2 EX355 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)
  • Page 50 EX355 T2-3-3 ELECTRICAL SYSTEM SM5607...
  • Page 51 T2-3-4 EX355 ELECTRICAL SYSTEM BULB CHECK CIRCUIT (Key switch: ON) Then, the battery power is routed to the monitor When the key switch is turned to the ON position, key through the battery relay, the fuse box and the wiper switch terminal B connects with key switch terminals M and ACC.
  • Page 52 EX355 T2-3-5 ELECTRICAL SYSTEM SM5608...
  • Page 53 T2-3-6 EX355 ELECTRICAL SYSTEM ACCESSORY CIRCUIT (Key Switch: ACC) Then, the battery current flows through the fuse box When the key switch is turned to the ACC position, terminal ACC is connected to terminal B in the key terminal 15, 16 and 17, to each accessory circuits switch.
  • Page 54 EX355 T2-3-7 ELECTRICAL SYSTEM SM5609...
  • Page 55 T2-3-8 EX355 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.
  • Page 56 EX355 T2-3-9 ELECTRICAL SYSTEM SM5610...
  • Page 57 T2-3-10 EX355 ELECTRICAL SYSTEM STARTING CIRCUIT (Key Switch: START) When the key switch is turned to the START position, Starter Relay Operation terminal B on the key switch is connected to terminals, M, and ST. The current from terminal M magnetizes •...
  • Page 58 EX355 T2-3-11 ELECTRICAL SYSTEM SM5611...
  • Page 59 T2-3-12 EX355 ELECTRICAL SYSTEM CHARGING CIRCUIT (Key Switch: ON) After the engine starts and the key switch is released, generation. Current from terminal B on the alternator the key switch is returned to the ON position. With the flows to the batteries through the battery relay re- key switch kept ON, key switch terminal B is con- charging the batteries.
  • Page 60 EX355 T2-3-13 ELECTRICAL SYSTEM SM5612...
  • Page 61 T2-3-14 EX355 ELECTRICAL SYSTEM Power Generation At first, the current does not flow to field coil FC. The alternator consists of field coil FC, stator coil SC, When the rotor starts to rotate, alternating voltage is and diodes D. The regulator consists of transistors T1 and T2, zener generated in stator coil SC due to residual magnetism diode ZD, and resistors R1 and R2.
  • Page 62 EX355 T2-3-15 ELECTRICAL SYSTEM Regulator Operation When the generating voltage increases higher than Then, when the voltage to be applied to zener diode the set voltage of zener diode ZD, the current from the ZD becomes lower than the set voltage of zener diode alternator flows through the zener diode to base B for ZD, transistor T2 is turned OFF, turning transistor T1 transistor T2, connecting collector C to emitter E.
  • Page 63 T2-3-16 EX355 ELECTRICAL SYSTEM SURGE VOLTAGE PREVENTION CIRCUIT When the engine is stopped (key switch is OFF), the While the batteries are being recharged, the generat- current from key switch terminal M is cut so that ing current from terminal L on the alternator is led to terminal #42 on the monitor, turning the output tran- battery relay is turned OFF.
  • Page 64 EX355 T2-3-17 ELECTRICAL SYSTEM SM5613...
  • Page 65 T2-3-18 EX355 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.
  • Page 66 EX355 T2-3-19 ELECTRICAL SYSTEM SM5614...
  • Page 67 T2-3-20 EX355 ELECTRICAL SYSTEM ENGINE AND PUMP CONTROL CIRCUIT The main controller (MC) monitors all digging func- The EC angle sensor detects the position of EC tions, travel functions, and hydraulic pump functions motor and supplies signals to the main controller to Further the main controller stores possible malfunc- indicate the position of the governor lever.
  • Page 68 EX355 T2-3-21 ELECTRICAL SYSTEM SM5615...
  • Page 69 T2-3-22 EX355 ELECTRICAL SYSTEM • Pump control circuit As result of the position of the Work mode selector, The pump control circuit consists of pilot pressure travel mode selector and the actual condition de- switches related to boom up, Front attachment and travel, Pump 1 and 2 delivery pressure sensors, tected from various pressure switches and sen- Arm roll-in pilot pressure sensor , Pump 1 and 2...
  • Page 70 EX355 T2-3-23 ELECTRICAL SYSTEM SM5615...
  • Page 71 T2-3-24 EX355 ELECTRICAL SYSTEM MONITOR CIRCUIT Monitor controller provides voltages to transistors if The monitor circuit consists of circuits to operate the hour meter, coolant temperature gauge, fuel gauge, temperature, pressures or levels are outside normal engine oil level indicator, engine oil pressure indica- limits to illuminate indicator lights.
  • Page 72 EX355 T2-3-25 ELECTRICAL SYSTEM SM5616...
  • Page 73 T2-3-26 EX355 ELECTRICAL SYSTEM NOTES:...
  • Page 74 SECTION 3 EX355 COMPONENT OPERATION CONTENTS Group 1 - Pump device Group 4 - Pilot valve Outline ..........T3-1-1 Outline ............ T3-4-1 Main pump ..........T3-1-2 Operation ..........T3-4-3 Regulator ..........T3-1-4 Group 5 - Travel device Pilot pump ........... T3-1-11 N sensor (Engine speed sensor) ..
  • Page 75 EX355 T3-1-1 PUMP DEVICE OUTLINE The pump device consists of the transmission, main The main pump is a bent-axis type variable dis- pumps, and pilot pump. The transmission transfers placement axial plunger pump. The pilot pump is a engine power to gears via the coupling and drives the gear type.
  • Page 76 T3-1-2 EX355 PUMP DEVICE MAIN PUMP When the engine rotates, the shaft, plungers, and The main pump supplies pressure oil to the hydraulic actuators such as motors, and cylinders. Each pump cylinder blocks are rotated. The plungers are tilted to is equipped with a regulator to control the delivery oil the shaft so that the plungers reciprocate in the cylin- der block, by which hydraulic oil is suctioned and dis-...
  • Page 77 EX355 T3-1-3 PUMP DEVICE Flow Rate Control The main pump delivery flow rate is controlled by changing the cylinder block tilt angle. The tilt angle of the cylinder block is changed by moving the servo piston up and down. The servo piston is connected to the valve plate by a pin.
  • Page 78 T3-1-4 EX355 PUMP DEVICE REGULATOR According to variable command signal pressure, the When various command signal pressures reach the regulator controls the main pump flow rate so that the regulator, spools (3 and 6) are moved so that the pilot pump driving power does not exceed the engine oil pressure is routed to either the large diameter power.
  • Page 79 EX355 T3-1-5 PUMP DEVICE Regulator Functions The regulator has the three following functions: • Control by Pump Control Pressure The pump control valve equipped in the control valve regulates the pump control pressure in re- sponse to the movements of the spool. The regula- Flow rate tor receives this pump control pressure signal and controls the pump flow rate as follows.
  • Page 80 T3-1-6 EX355 PUMP DEVICE Control by Pump Control Pressure Flow rate increase: 1. When the pump control valve spool is moved, 5. As servo piston (4) is moved, the cylinder block tilt pump control pressure Pi increases. angle changes, increasing the flow rate. 2.
  • Page 81 EX355 T3-1-7 PUMP DEVICE Flow rate decrease: 1. When the pump control valve spool is returned to 5. As servo piston (4) is moved, the cylinder block tilt neutral, pump control pressure Pi decreases. angle changes, decreasing the flow rate. 2.
  • Page 82 T3-1-8 EX355 PUMP DEVICE Control by Pump Delivery Pressure Flow rate increase: 1. Pump delivery pressure (Pd1 or Pd2) decreases. 5. As servo piston (4) is moved, the cylinder block tilt 2. Load piston (9) and spool A (10) are pushed by angle changes, increasing the flow rate.
  • Page 83 EX355 T3-1-9 PUMP DEVICE Flow rate decrease: 1. Pump delivery pressure (Pd1 or Pd2) increases. 5. As servo piston (4) is moved, the cylinder block tilt 2. Load piston (9) and spool A (10) pushes inner angle changes, decreasing the flow rate. spring (11) and outer spring (12) so that spool A 6.
  • Page 84 T3-1-10 EX355 PUMP DEVICE Control by Pilot Pressure from Solenoid Valve Unit (SD) Flow Rate Decrease: 5. Due to the difference in area between small diam- 1. Solenoid valve unit (SD) is activated by the signal eter chamber (8) and large diameter chamber (7), from MC (main controller), increasing pilot pres- servo piston (4) is moved in the direction of the sure Pps.
  • Page 85 EX355 T3-1-11 PUMP DEVICE PILOT PUMP Suction port Drive gear (1) is driven via the transmission so that driven gear (2) meshed with drive gear (1) is also ro- tated. 1 - Drive Gear 2 - Driven Gear Delivery port SM0022 N SENSOR (ENGINE SPEED SENSOR) The N sensor monitors the engine speed which is re-...
  • Page 86 T3-1-12 EX355 PUMP DEVICE NOTES...
  • Page 87 EX355 T3-2-1 SWING DEVICE OUTLINE The swing device consists of the valve unit, the swing motor (with a built-in parking brake for swing), and is motor, and the swing reduction gear. driven by the pressure oil from the pump to rotate the The valve unit prevents cavitation and overload of the swing reduction gear.
  • Page 88 T3-2-2 EX355 SWING DEVICE SWING MOTOR The swing motor consists of the swashplate, rotor, The shoe of the plunger slides along swash plate, and plungers, valve plate, housing and swing parking rotation occurs in rotor. The shaft end is connected to brake (consists of spring, brake piston, plate, friction first stage sun gear of the swing reduction gear by a plate and switch valve).
  • Page 89 EX355 T3-2-3 SWING DEVICE Swing speed varies depending on the amount of oil Turning force is transmitted to the swing reduction delivered from the pump. From port A, high pressure gear unit via shaft (6). The return oil flows to outlet port oil is fed so that plunger (3) is pushed from the top to B and returns to the hydraulic oil tank.
  • Page 90 T3-2-4 EX355 SWING DEVICE SWING PARKING BRAKE The parking brake is a wet-type multiple disc brake. The brake is released only when brake release pres- sure enters into brake piston chamber (b), (negative type brake). When swing and/or front attachment operation is made brake release pressure is supplied from the pilot pump.
  • Page 91 EX355 T3-2-5 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 swinging is stopped, if the upperstructure tends...
  • Page 92 T3-2-6 EX355 SWING DEVICE Relief Valve When starting or stopping swing operation, oil pres- sure in the swing circuit becomes high. The relief valve prevents the circuit pressure from rising higher than the specified pressure. Plunger is pushed to the left by pressure (Pp) force of the swing circuit in pressure-receiving area A However, plunger is also pushed back to the right by...
  • Page 93 EX355 T3-2-7 SWING DEVICE SWING REDUCTION GEAR The swing reduction gear is a two-stage planetary gear (6) via first stage planetary gear (1) and first gear type. stage carrier (7). Second stage sun gear (6) rotates Ring gear (2) is provided on the inside of the housing, shaft (4) (output shaft) via second stage planetary it is fixed and does not rotate.
  • Page 94 T3-2-8 EX355 SWING DEVICE NOTES...
  • Page 95 EX355 T3-3-1 CONTROL VALVE OUTLINE The spool arrangement in the 4-spool section (seen The control valve controls oil pressure, flow rate and from the front) is the travel (right), bucket, boom 1 and flow direction in the hydraulic circuit. The major com- ponents of the control valve are the flow combiner arm 2.
  • Page 96 T3-3-2 EX355 CONTROL VALVE System Layout Travel Motor (Left) Travel Motor (Right) Bucket Cylinder Cylinder Boom Cylinders Swing Motor Pump 1 Pump 2 SM6041 1 - Pump Control Valve 15 - Arm Regenerative Valve 28 - Load Check Valve (Swing) (In 5-Spool Section) 16 - Check Valve 29 - Arm Anti-Drift Valve:...
  • Page 97 EX355 T3-3-3 CONTROL VALVE Cross Section A Cross Section B Machine Front SM6042 SM6043 Cross Section C Cross Section D Travel (Left) Auxiliary Travel (Right) Bucket SM6044 SM6045...
  • Page 98 T3-3-4 EX355 CONTROL VALVE Travel Motor (Left) Travel Motor (Right) Bucket Cylinder Cylinder Boom Cylinders Swing Motor Pump 1 Pump 2 SM6041 1 - Pump Control Valve 15 - Arm Regenerative Valve 28 - Load Check Valve (Swing) (In 5-Spool Section) 16 - Check Valve 29 - Arm Anti-Drift Valve: 2 - Check Valve...
  • Page 99 EX355 T3-3-5 CONTROL VALVE Cross Section E Machine Front Boom 2 Boom 1 SM6042 SM6046 Cross Section G Cross Section F Arm 1 Arm 2 Swing SM6047 SM6048...
  • Page 100 T3-3-6 EX355 CONTROL VALVE HYDRAULIC CIRCUIT Main Circuit The pressure oil from pump 1 flows to the travel The oil pressure in the main circuit (between the pump (right), bucket, boom 1, and arm 2 spools in the 4- and the control valve) is controlled by the main relief spool section.
  • Page 101 EX355 T3-3-7 CONTROL VALVE Pump Control Valve (In 5-Spool Section) Main Relief Valve Travel (Left) Travel (Right) Auxiliary Neutral Passage Bucket Boom 1 Overload Relief Valves Boom 2 Overload Arm 1 Relief Valve Arm 2 Neutral Passage Swing Parallel Passages To the 5-Spool Section.
  • Page 102 T3-3-8 EX355 CONTROL VALVE Signal Pilot Pressure Circuit control valve so that the spool is operated. While The pressure oil from the pilot pump flows through the operating the spools, the pilot pressure oil functions as follows: control valve as signal pilot pressure. When traveling, •...
  • Page 103 EX355 T3-3-9 CONTROL VALVE Pressure Switch Pressure Switch (Travel) (Front Attachment) To the Swing Parking Brake. From the From the Main Relief Valve Pilot Pump. Pilot Pump. Signal Pilot Pressure Circuit From Solenoid Other Than Travel Valve Unit (SG). Travel Signal Pilot Circuit Flow Combiner Valve Front Main Pump 1.
  • Page 104 T3-3-10 EX355 CONTROL VALVE FLOW COMBINER VALVE When the front attachment and/or swing function is Consequently, the pressure oil from pump 1 is routed operated, the spools in the control valve restrict the simultaneously to both right and left travel spools. The signal pilot pressure oil other than travel so that the pressure oil from pump 2 is routed to the front attach- circuit pressure is increased and the flow combiner...
  • Page 105 EX355 T3-3-11 CONTROL VALVE From the Signal Pilot Circuit Pilot Pump. Travel Motor (Left) Flow Combiner Valve other than Travel Travel Motor (Right) Travel (Right) Travel (Left) Cylinder Arm 1 Arm 2 Pump 2 Pump 1 SM6052...
  • Page 106 T3-3-12 EX355 CONTROL VALVE PUMP CONTROL VALVE notch. Then, the pump control pressure which was The pump control valves are located down stream of routed to the regulator via port PC is returned to the the neutral passages in both the 4 and 5-spool sec- hydraulic oil tank.
  • Page 107 EX355 T3-3-13 CONTROL VALVE When All Control Levers are in Neutral: Spool Neutral Passage To the Hydraulic Oil Tank. SM6053 When a Control Levers is Operated: Spool Neutral Passage To the Hydraulic Oil Tank. SM6054...
  • Page 108 T3-3-14 EX355 CONTROL VALVE MAIN RELIEF VALVE The main relief valve prevents the main circuit pres- sure from increasing more than the designed pres- sure. When traveling and/or the power boost switch is ON, the relief valve set pressure is increased. (Refer to the Control System group in the SYSTEM section.) SM6055 1 - Orifice...
  • Page 109 EX355 T3-3-15 CONTROL VALVE OVERLOAD RELIEF VALVE The overload relief valve prevents the actuator circuit pressure from increasing more than the designed pressure (Relief function). If the actuator pressure becomes negative, the valve makes up the hydraulic oil from the hydraulic oil tank (Make-up function). SM6059 1 - Piston 6 - Spring B...
  • Page 110 T3-3-16 EX355 CONTROL VALVE ARM REGENERATIVE VALVE The arm regenerative valve regulates the return oil When the arm regenerative valve is in neutral: flow from the cylinder rod side when rolling the arm in. Thereby, the arm roll-in speed is increased to improve the arm controllability so that the arm hesitation is prevented.
  • Page 111 EX355 T3-3-17 CONTROL VALVE Arm Regenerative Valve Port SC Arm Cylinder Port (b) Port (c) Port (a) Check Valve Port (d) Cylinder Bottom Side Circuit 2-Spool SM6066...
  • Page 112 T3-3-18 EX355 CONTROL VALVE BOOM REGENERATIVE VALVE The boom regenerative valve regulates the return oil If the pressure in the boom cylinder rod side is lower flow from the cylinder bottom side when the boom is than the bottom side, the pressure in the spool opens lowered.
  • Page 113 EX355 T3-3-19 CONTROL VALVE Port (b) Check Valve 2 Port (a) Boom Cylinder Port (c) Check Valve 1 SM6068...
  • Page 114 T3-3-20 EX355 CONTROL VALVE ARM ANTI-DRIFT VALVE (Bottom Side) Port B1 The arm ant-drift valve is provided to reduce cylinder drift. When the control lever is in neutral: Holding Op- eration The pressure in the arm cylinder bottom side is routed to port B1 and spring chamber (a) through the spool.
  • Page 115 EX355 T3-3-21 CONTROL VALVE When the arm is rolled in: When the control lever is operated: Deactivation When the arm is rolled in, the pressure oil from the arm spool pushes the check valve to open so that the pressure oil is routed to the arm cylinder through port B1.
  • Page 116 T3-3-22 EX355 CONTROL VALVE When the control lever is in neutral: Overload Poppet Prevention When the control lever is in neutral, if the pressure in Spring Check Valve Chamber (a) the arm cylinder bottom side is increased by an external force, hydraulic components may be dam- aged.
  • Page 117 EX355 T3-3-23 CONTROL VALVE ARM ANTI-DRIFT VALVE (On Rod Side) / Holding Operation BOOM ANTI-DRIFT VALVE The anti-drift valves (on the arm cylinder rod side and boom cylinder bottom side) are provided to reduce cylinder drift. Spool Arm Spool Boom Spool NOTE: The construction of the arm anti-drift valve is identical to the boom anti-drift valve.
  • Page 118 T3-3-24 EX355 CONTROL VALVE BUCKET FLOW RATE CONTROL VALVE Check Valve The bucket flow rate control valve consists of the poppet valve, switch valve A, and switch valve B. The bucket flow rate control valve restricts the bucket Poppet Valve oil flow to give priority to the boom raise operation Switch Valve B when the bucket, arm roll-in, and boom raise func-...
  • Page 119 EX355 T3-3-25 CONTROL VALVE Neutral Passage Bucket Spool Check Valve Poppet Port B2 Port A2 Spring Chamber (a) Switch Valve B Port SL2 Boom Raise Pilot Pressure Spool from Switch Valve A SM6084...
  • Page 120 T3-3-26 EX355 CONTROL VALVE TRAVEL FLOW RATE CONTROL VALVE When the travel and boom raise combined operation is performed, the flow combiner valve is opened so that the pressure oil from pump 1 flows to both right and left travel motors and the pressure oil from pump 2 flows to boom 2 spool.
  • Page 121 EX355 T3-3-27 CONTROL VALVE Travel (Left) Travel (Right) Parallel Passage P2' Piston Boom Raise Pilot Pressure Poppet Neutral Passage P2 SM6086...
  • Page 122 T3-3-28 EX355 CONTROL VALVE BYPASS SHUT-OUT VALVE When the attachment is operated, the pilot pressure The bypass shut-out valve is provided in the neutral is routed to port PBC. Then, the bypass shut-out passage of the 4-spool section control valve. The by- valve spool is moved to the right, closing the passage pass shut-out valve allows the pressure oil from pump from the neutral circuit to port T2.
  • Page 123 EX355 T3-3-29 CONTROL VALVE To the Auxiliary Attachment Spool Bypass Shut-Out Valve To the 5-Spool Section To the 4-Spool Section Control Valve Control Valve Pilot Pressure Pump 2 Pump 1 SM6088...
  • Page 124 T3-3-30 EX355 CONTROL VALVE NEEDLE VALVE Port DR2 The needle valve is provide to lower the boom in Needle Valve emergencies if the engine becomes difficult to re-start Boom Anti-Drift with the boom raised. Valve (Switch Valve) The pressure oil from the boom cylinder bottom side is routed to port B3 and is blocked by the boom anti- drift valve.
  • Page 125 EX355 T3-4-1 PILOT VALVE OUTLINE The construction of the reducing valves in both the The pilot valve controls pilot pressure oil to move the front attachment / swing and travel pilot valves are control valve spools. There are two types of pilot valves.
  • Page 126 T3-4-2 EX355 PILOT VALVE • Travel pilot valve Port No. Control Left travel forward Left travel reverse Right travel reverse Right travel forward SM0064 SM0066 • Positioning pilot valve (triple articulation version) Port No. Control Positioning raise (Positioning cylinder retraction) Positioning lower (Positioning cylinder extension) SM3043...
  • Page 127 EX355 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 (Corresponding to A to B in the output diagram): setting force of balance spring (6).
  • Page 128 T3-4-4 EX355 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 upward against setting force of balance spring (6). position where clearance (A) in section (a) reaches Once spool (8) moves upward, upper clarance at zero, and pusher (3) is pushed downward, spool (8) is section (a) is opened and lower notch section at...
  • Page 129 EX355 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) When spool (8) moves upward until the clearance at downward, spool (8) is pushed down to open the notch section (a) opens, the delivery port is opened to port T, at section (b), increasing oil pressure at the delivery...
  • Page 130 T3-4-6 EX355 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 spool (8) cannot move upward, closing the oil passage compressed, reducing clearance (B) between pusher from the delivery port to port T, and opening the oil (3) and the top of spool (8) (shown at section (c)), finally passage from the delivery port to port P.
  • Page 131 EX355 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 (d)) of the casing. pusher (3), spool (8) moves downward along with This position is the stroke end of pusher (3) (corre- pusher (3), only widening the notch at lower section (b) sponding to F position in the output diagram).
  • Page 132 T3-4-8 EX355 PILOT VALVE • Travel Pilot Valve In neutral Full stroke operation: (Corresponding to A to B in the output diagram): Lever - Full Stroke (Pusher Stroke) Lever - In Neutral (Pusher Stroke: A to B) When the control lever is moved full stroke, pusher (2) In neutral, spool (6) closes port P (the input port) and is moved down until spring guide (3) comes into tank port T is connected to delivery port through...
  • Page 133 EX355 T3-4-9 PILOT VALVE Pusher stroke: A to B Port T Clearance A: 0 Port P Delivery port SM0073 SM0075 Pusher stroke: C to D Pusher stroke: full stroke Port T Port T Port P Port P Delivery port Delivery port SM0074 SM0076 1 - Cam...
  • Page 134 T3-4-10 EX355 PILOT VALVE NOTES...
  • Page 135 EX355 T3-5-1 TRAVEL DEVICE OUTLINE The travel reduction gear is a third stage planetary gear The travel device consists of the travel motor, travel type which converts rotary power transferred from the reduction gear, and travel brake valve. The travel motor is a bent axle-type variable displace- travel motor into a slow and large torque to drive the ment axial plunger motor.
  • Page 136 T3-5-2 EX355 TRAVEL DEVICE TRAVEL MOTOR Rotor (14) is pre-loaded against valve plate (2) by The main parts of the motor are plate (1), valve plate spring (4). As oil pressure in the rotor bores increases, (2), rotor (14), plungers (13), center shaft (5), drive disc (7), servo piston (16), parking brake piston (12), friction the pressure acts on end faces (A) of the rotor bores plates (11), and plates (10).
  • Page 137 EX355 T3-5-3 TRAVEL DEVICE Pressure oil supplied to port AM of the valve plate (1) When the plungers (3) moves to port BM side, oil is flows into the rotor bores (2) underneath port AM, routed to the hydraulic oil tank. Whether pressure oil from the pump is supplied to port pushing the plungers (3).
  • Page 138 T3-5-4 EX355 TRAVEL DEVICE PARKING BRAKE The parking brake is a wet type multi-disc brake. This release pressure oil (K) is blocked by spool CB. brake a negative type which is released only when When oil pressure in chamber (G) increases, spool brake release pressure oil (K) is routed into the brake CB moves to the right, allowing parking brake re- piston chamber.
  • Page 139 EX355 T3-5-5 TRAVEL DEVICE 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...
  • Page 140 T3-5-6 EX355 TRAVEL DEVICE TRAVEL SPEED CONTROL Servo piston (1) is connected to valve plate (6) with link (5). When servo piston (1) is moved, rotor (7) is tilted via valve plate (6) so that travel speed is con-trolled. • Slow speed When the travel mode switch is turned to the slow chambers B and C.
  • Page 141 EX355 T3-5-7 TRAVEL DEVICE • Fast speed When the travel mode switch is turned to the fast po- Thus, section E is opened so that the oil in chamber sition, the MC sends signals to solenoid valve unit C is drained via the passages in spool (3). As pres- (SI) in response to travel loads.
  • Page 142 T3-5-8 EX355 TRAVEL DEVICE TRAVEL BRAKE VALVE The travel brake valve is located on the travel motor Overload relief valve (4): head and consists of the following valves. prevents overload and surge pressure from occurring in the motor circuit. Check valve (1): assists counterbalance valve (5) operations and pre- Counterbalance valve (5): vents cavitation from occurring.
  • Page 143 EX355 T3-5-9 TRAVEL DEVICE When traveling: When descending: Pressure oil from the control valve enters port BV, While descending a slope, the travel motor is forcibly flows around spool CB in the counterbalance valve, rotated by the machine weight (pump operation). When opens check valve BC, and flows into port BM.
  • Page 144 T3-5-10 EX355 TRAVEL DEVICE TRAVEL REDUCTION GEAR The travel reduction gear is a third stage planetary gear stage sun gear (3), and third stage planetary gear (10). type. Travel motor housing (14) is bolted to the track frame The travel motor rotates propeller shaft (7). This rota- and is also secured to ring nut (12) with third stage tion power is transmitted to third stage carrier (2) and carrier (2).
  • Page 145 EX355 T3-5-11 TRAVEL DEVICE SM5003 1 - Ring Gear 08 - First Stage Planetary Gear 2 - Third Stage Carrier 09 - Second Stage Planetary Gear 3 - Third Stage Sun Gear 10 - Third Stage Planetary Gear 4 - Second Stage Carrier 11 - Sprocket 5 - Second Stage Sun Gear 12 - Ring nut...
  • Page 146 T3-5-12 EX355 TRAVEL DEVICE NOTES...
  • Page 147 EX355 T3-6-1 OTHER COMPONENTS (Upperstructure) PILOT SHUT-OFF VALVE The pilot shut-off valve is a manually operated switch valve. The spool in the pilot shut-off valve is rotated by moving the pilot control shut-off lever to turn the pilot oil flow to the pilot valves ON or OFF. From pilot pump via pilot filter To hydraulic oil tank...
  • Page 148 T3-6-2 EX355 OTHER COMPONENTS (Upperstructure) SHOCKLESS VALVE Beside the shockless valve, a check valve, pressure sensor (arm roll-in), and pressure switch (boom raise) are provided in the shockless valve block. The shockless valve regulates the return oil from the control valve spool to the pilot valve, preventing abrupt and rapid movement of the respective control valve spools.
  • Page 149 EX355 T3-6-3 OTHER COMPONENTS (Upperstructure) Warm-up circuit Then, the pilot pressure oil is restricted and heated by When the pilot shut-off valve is closed (in the LOCK the orifice provided at the inlet port of the shockless position), the pilot pressure oil from the pilot pump flows through the pilot shut-off valve and is routed to valve.
  • Page 150 T3-6-4 EX355 OTHER COMPONENTS (Upperstructure) SOLENOID VALVE UNIT The solenoid valve unit controls the control valve, travel motor swash angle control servo piston, and pump regulator by delivering pilot signal pressure oil in response to electrical signals from the MC. The solenoid valve unit consists of four proportional solenoid valves (SC, SD, SI, and SG).
  • Page 151 EX355 T3-6-5 OTHER COMPONENTS (Upperstructure) Proportional Solenoid Valve The proportional solenoid valve is controlled by a Pressure in delivery port S acts on the stepped current signal from the MC and delivers oil pressure in flanges in section (a). Due to the difference in area proportion to the current signal value.
  • Page 152 T3-6-6 EX355 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 SM6004 SM6096 EC MOTOR The EC motor is used to control engine speed. A worm provided to detect the degrees of the EC motor rotation gear is incorporated into the EC motor to prevent a loss to calculate the governor lever position.
  • Page 153 EX355 T3-7-1 OTHER COMPONENTS (Undercarriage) SWING BEARING to the upperstructure and inner race (3) is bolted to the The swing bearing supports the upperstructure weight undercarriage. and allows it to swing smoothly. This bearing is a single-row shear ball-type bearing, The internal gear of inner race (3) meshes with the comprising outer race (1), inner race (3), balls (6), output shaft of the swing reduction gear.
  • Page 154 T3-7-2 EX355 OTHER COMPONENTS (Undercarriage) CENTER JOINT Hydraulic oil flows to the right and left travel motors via The center joint is a 360° rotating joint. When the spindle (1) and the oil ports of body (2). Seals (3) upperstructure is rotated, the center joint avoids twist- ing of hoses and allows hydraulic oil to flow smoothly prevent oil leaks between spindle (1) and body (2) into to or from the travel motors.
  • Page 155 EX355 T3-7-3 OTHER COMPONENTS (Undercarriage) TRACK ADJUSTER The track adjuster located on the side frame is com- CAUTION posed of spring (5) and adjuster cylinder (6). Track adjuster spring (5) absorbs loads applied to the front Grease pressure in the adjuster cylinder is very idler.
  • Page 156 T3-7-4 EX355 OTHER COMPONENTS (Undercarriage) NOTES...
  • Page 157 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. 604.13.211 - Edition - July 2002...
  • Page 158 FIAT KOBELCO CONSTRUCTION - Be sure to thoroughly read this manual for correct MACHINERY S.p.A. information concerning the service procedures.
  • Page 159 IN-2 EX355 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 : Technical Manual W : Workshop Manual...
  • Page 160 EX355 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.
  • Page 161 EX355 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...
  • Page 162 EX355 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;...
  • Page 163 EX355 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.
  • Page 164 EX355 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.
  • Page 165 EX355 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.
  • Page 166 EX355 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. •...
  • Page 167 EX355 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.
  • Page 168 EX355 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.
  • Page 169 S-10 EX355 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.
  • Page 170 EX355 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.
  • Page 171 S-12 EX355 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.
  • Page 172 EX355 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.
  • Page 173 - 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.
  • Page 174 EX355 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.
  • Page 175 S-16 EX355 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.
  • Page 176 EX355 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.
  • Page 177 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.
  • Page 178 EX355 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. S0153 F1462 STORE ATTACHMENTS SAFELY •...
  • Page 179 S-20 EX355 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”...
  • Page 180 EX355 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.
  • Page 181 S-22 EX355 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.
  • Page 182 EX355 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.
  • Page 183 S-24 EX355 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.
  • Page 184 - 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...
  • Page 185 S-26 EX355 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.
  • Page 186 TECHNICAL MANUAL EX355 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...
  • Page 187 SECTION 4 EX355 OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 - Introduction Travel parking brake function check ........... T4-4-4 Operational performance tests ..... T4-1-1 Swing speed ........T4-4-5 Preparation for performance tests ..T4-1-2 Swing function drift check ....T4-4-6 Swing motor leakage ......T4-4-7 Swing bearing play .......
  • Page 188 EX355 T4-1-1 INTRODUCTION OPERATIONAL PERFORMANCE TESTS Use operational performance test procedures 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.
  • Page 189 T4-1-2 EX355 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.
  • Page 190 EX355 T4-2-1 STANDARD OPERATIONAL PERFORMANCE STAND- ARD TABLES The standard performance values related to excavator tests unless otherwise instructed in each performance test are listed in the table 1 shown below. In table 2 are test procedure: listed the standard performance related to component Engine Control Dial : Fast Idle test.
  • Page 191 T4-2-2 EX355 STANDARD Ref. Performance test designation EX355 Remarks (Performance pag. standard) TRAVEL SPEED sec/20 m Fast speed 13.6 ± 1.2 Slow speed 20.0 ± 2.0 TRACK REVOLUTION 31.0 ± 2.0 SPEED sec/3 rev MISTRACK mm/20 m (Both fast and slow travel speed modes) 200 or less TRAVEL PARKING BRAKE FUNCTION CHECK...
  • Page 192 EX355 T4-2-3 STANDARD Performance test designation EX355 Remarks Ref. pag. (Performance standard) DIG FUNCTION DRIFT 3190 arm (mono), 2300 arm CHECK mm/5 min (triple articulation) or 2076 With the front attachment in the maximum (BEH) and 1.3 m bucket or reach position 2.08 m (BEH) (SAE heaped)
  • Page 193 T4-2-4 EX355 STANDARD Table 2 - Component performance standard Ref. Performance test designation EX355 Remarks pag. (Performance standard) PRIMARY PILOT PRESSURE ENGINE: Fast idle kgf/cm 45 ± 10 ENGINE: slow idle 40 ± 10 SECONDARY PILOT PRESSURE (Engine: Fast (Standard Mode) and slow idle) Value indicated on Dr.
  • Page 194 EX355 T4-2-5 STANDARD MAIN PUMP P-Q CURVE Check points on P-Q Curve (Reference: Measured at Test Stand) Delivery Pressure Flow Rate –1 kgf/cm L/min • Rated Engine Speed : 1900 min (rpm) • Hydraulic Oil Temperature : 50 ± 5 °C 258 ±...
  • Page 195 T4-2-6 EX355 STANDARD NOTES...
  • Page 196 EX355 T4-3-1 ENGINE TEST ENGINE SPEED Summary: 1. Use Dr.EX. if Dr.EX is not available, use an engine tachometer. 2. Measure the engine speeds in each mode. NOTE - Measure the engine speed before performing all other tests to check that the engine speed meets specification.
  • Page 197 T4-3-2 EX355 ENGINE TEST E Mode Measurement: Switch HP Mode 1. No Load Engine Speed 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.
  • Page 198 EX355 T4-3-3 ENGINE TEST ENGINE CHECK AND ADJUSTMENT To perform the compression pressure measurement, the check and adjustment of valve clearance, the check of injection nozzle and check and adjustment of injection timing, make reference to the Workshop Manual - Section 5.
  • Page 199 T4-3-4 EX355 ENGINE TEST NOTES...
  • Page 200 EX355 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. Arm Rolled-In, Bucket Rolled-In 2. Prepare a flat and solid test track 20 m (65.6 ft) in 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-...
  • Page 201 T4-4-2 EX355 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 to 110°...
  • Page 202 EX355 T4-4-3 EXCAVATOR TEST MISTRACK CHECK Summary: 1. Allow the machine to travel 20 m (65.5 ft). Measure the maximum tread deviation from the tread chord line drawn between the travel start and end points Maximum Distance to check the performance equilibrium between both sides of the travel device systems (from the main pump to the travel motor).
  • Page 203 T4-4-4 EX355 EXCAVATOR TEST TRAVEL PARKING BRAKE 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 0.2 to 0.3 m gradient of 20% (11.31°). 2.
  • Page 204 EX355 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.
  • Page 205 T4-4-6 EX355 EXCAVATOR TEST SWING FUNCTION DRIFT CHECK Summary: Measure the swing drift on the bearing outer circumfer- ence 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.
  • Page 206 EX355 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 % (15°).
  • Page 207 T4-4-8 EX355 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 looseness. 2. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise.
  • Page 208 EX355 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.
  • Page 209 T4-4-10 EX355 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.
  • Page 210 EX355 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.
  • Page 211 T4-4-12 EX355 EXCAVATOR TEST DIG FUNCTION DRIFT CHECK • Maximum Reach Position Extended Summary: Retracted Distance Distance Measure dig function drift, which can be caused by oil Retracted Distance leakage in the control valve and boom, (positioning for triple articulation) arm, and bucket cylinders, with the loaded bucket.
  • Page 212 EX355 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.
  • Page 213 T4-4-14 EX355 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 ±...
  • Page 214 EX355 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.
  • Page 215 T4-4-16 EX355 EXCAVATOR TEST NOTES...
  • Page 216 EX355 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.
  • Page 217 T4-5-2 EX355 COMPONENT TEST Primary Pilot Pressure Adjustment Adjustment: Adjust the setting pressure of relief valve (1) (the primary pilot pressure) as necessary. : 36 mm SM6004 1. Remove plug (3). 2. Install the estimated necessary number of shims (2). 3.
  • Page 218 EX355 T4-5-3 COMPONENT TEST SECONDARY 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. Install pressure gauge (75301518) and tee (75301520) to the end of pilot line (1) at the respective control valve spool end, as illustrated.
  • Page 219 T4-5-4 EX355 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.
  • Page 220 EX355 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.
  • Page 221 T4-5-6 EX355 COMPONENT TEST MAIN PUMP DELIVERY PRESSURE Pressure Check Ports The main pump delivery pressure can also be mea- sured 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.
  • Page 222 EX355 T4-5-7 COMPONENT TEST MAIN RELIEF VALVE SET PRESSURE Pressure Check Ports 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.
  • Page 223 T4-5-8 EX355 COMPONENT TEST Main Relief Set Pressure Adjustment Main Relief Valve IMPORTANT: When the high pressure main relief set pressure is adjusted, the lower pressure main relief set pressure is changed. Therefore, be sure to re-adjust the lower pressure main relief set pressure after adjusting the high pressure main relief set pressure.
  • Page 224 EX355 T4-5-9 COMPONENT TEST Swing Relief Valve Set Pressure Adjustment NOTE: For the check procedure, refer to paragraph "Measurement" step 2. 1. Loosen lock nut (2). Swing Relief Valve 2. Turn adjusting plug (1) to adjust the set pressure. 3. Tighten lock nut (2). 4.
  • Page 225 T4-5-10 EX355 COMPONENT TEST Travel Relief Pressure Setting Adjustment NOTE: For the check procedure, refer to paragraph "Measurement" step 3. 1. Loosen lock nut (2). 2. Turn adjusting screw (1) to adjust the set pressure. 3. Tighten lock nut (2). Travel Relief Valve : 19 mm SM0182...
  • Page 226 EX355 T4-5-11 COMPONENT TEST OVERLOAD RELIEF VALVE SET PRES- Pressure Check Ports SURE Summary: 1. The circuit pressure must be increased by applying 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.
  • Page 227 T4-5-12 EX355 COMPONENT TEST Measurement: 1. Select the following switch positions: Engine E Mode HP Mode Work Control Switch Switch Mode Dial Switch Fast 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.
  • Page 228 EX355 T4-5-13 COMPONENT TEST Overload Relief Valve Set Pressure Adjusting Pro- cedure Adjusting Screw Lock Nut NOTE - In principle, adjust the overload relief valve set pressure on a test stand. Adjustment: Adjust the pressure setting of the overload relief valve using adjusting screw after loosening lock nut.
  • Page 229 T4-5-14 EX355 COMPONENT TEST MAIN PUMP FLOW RATE Summary: Disconnect the vacuum pump. Loosen the air With a portable hydraulic tester installed at the main bleeding plug on the pump casing to bleed air until pump delivery port to be measured, the flow rate is oil flows out of the plug clearance.
  • Page 230 EX355 T4-5-15 COMPONENT TEST Evaluation: 1. Convert the measured flow rate into the one for 2. Standard Flow Rate the rated engine speed using the following for- Refer to the Pump P-Q curve in Group T4-2. mula. Qc = Ns x Q / Ne Where: Qc: Converted Flow Rate Q : Measured Flow Rate...
  • Page 231 T4-5-16 EX355 COMPONENT TEST Regulator Adjustment SM6031 1 - Lock Nut 6 - Adjusting Screw (For Pilot Pressure Characteristic Adjustment) (For Minimum Flow Adjustment) 2 - Adjusting 7 - Lock Nut (For P-Q Line Adjustment) Screw (For Minimum Flow Adjustment) 3 - Lock Nut 8 - Adjusting Screw (For P-Q Line Adjustment)
  • Page 232 EX355 T4-5-17 COMPONENT TEST Adjustment Procedure Remarks 1. Minimum Flow Rate After loosen ing lock nut (1), turn 1) Do not tighten adjusting screw adjusting screw (2). (2) more than one and half turns. Tightening adjusting screw (2) 1/4 2) Securely retighten lock nut (1) a turn increases the minimum after adjustment.
  • Page 233 T4-5-18 EX355 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 will change depending on hydraulic oil temperature. Maintain hydraulic oil temperature at 50 ±...
  • Page 234 EX355 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.
  • Page 235 T4-5-20 EX355 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 will change depending on hydraulic oil temperature.
  • Page 236 EX355 T4-5-21 COMPONENT TEST Measurement: Amount of oil drained while travel motor is rotating CAUTION 90° to 110° Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement. When working around moving parts is unavoid- able, pay special attention to ensure that hands, SM0139...
  • Page 237 T4-5-22 EX355 COMPONENT TEST NOTES...
  • Page 238 SECTION 5 EX355 TROUBLESHOOTING INDEX Group 1 - Diagnosing Procedure Relationship between Machine Trouble Introduction ........... T5-1-1 Symptoms and Parts in Trouble ..T5-4-2 Diagnosing Procedure ......T5-1-2 Correlation between Trouble Dr.EX ............ T5-1-4 Symptoms and Part Failures ...T5-4-12 Dr.EX Start-Up Procedure ....T5-1-4 Engine Troubleshooting .......T5-4-18 Fault Code ..........
  • Page 239 INDEX Malfunction of Hydraulic Oil Level Group 7 - Harness Check Indicator ......... T5-5-14 Circuit Check ........T5-7-1 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 .........
  • Page 240 EX355 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),...
  • Page 241 T5-1-2 EX355 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.
  • Page 242 EX355 T5-1-3 DIAGNOSING PROCEDURE 4. Operate the machine yourself. Try to identify the trouble by operating 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.
  • Page 243 T5-1-4 EX355 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.
  • Page 244 EX355 T5-1-5 DIAGNOSING PROCEDURE FAULT CODE FAULT CODE TROUBLE CORRECTIVE ACTION Abnormal EC Sensor Output Signal • Failure in MC. • Faulty Harness • Faulty EC Sensor Abnormal Pump 1 Delivery Pressure • Failure in MC Abnormal Pump 2 Delivery Pressure •...
  • Page 245 T5-1-6 EX355 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 Monitor signal Unit and/or display Form Pump 1 Control Pressure Input from the PC pressure sensor (4-spool section) kgf/cm ○...
  • Page 246 EX355 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 Key Switch...
  • Page 247 T5-1-8 EX355 DIAGNOSING PROCEDURE Service mode related to Dr.EX screen panels, be- ginning with the start screen, are shown along with Dr.EX the corresponding Dr.EX key operations. VER **** However, Dr.EX screen panels which are not related to the Dr.EX key operation are excluded. F1 : Start F10 : Model Menu Press...
  • Page 248 EX355 T5-1-9 DIAGNOSING PROCEDURE ▼ Select Functions F3 : Special Functions F5: ESC Press ▼ Select learning data to be displayed. Select Functions F6 : EC Motor Stop Position F6 : Press F7 : EC Motor Maximum Speed F7 : Learning Data Display Position F8 : Parameter Change F9 :...
  • Page 249 T5-1-10 EX355 DIAGNOSING PROCEDURE ▼ Select Item F6 : P1 Crusher Engine Speed Control F7 : F8 : F9 : F10 : ↓ ↑ F3: Next F4: Prev F5: ESC Press ▼ Return to screen (A) on the previous page.
  • Page 250 EX355 T5-1-11 DIAGNOSING PROCEDURE ▼ : Breaker Engine Speed Control Screen P1 Breaker Engine Speed is Con- Range : Controllable range is displayed. trolled. Standard : Uncontrolled value is displayed. Enter the control deviation value. Present : Present operating value is displayed. Range : -500 to +300 rpm Control Deviation : Enter the control deviation value.
  • Page 251 T5-1-12 EX355 DIAGNOSING PROCEDURE ▼ The deviation value entered in the previous screen is displayed in **Controlled Data Confirmation** the control deviation column. Controlled Data : Breaker Engine Speed Deviation Present : 0 rpm Control Deviation: -100 rpm F1 : Execute F5 : ESC ▼...
  • Page 252 EX355 T5-1-13 DIAGNOSING PROCEDURE • • • • • Check the engine performance (Check if the en- gine speed has been changed), as follows: IMPORTANT - Be sure to turn the learning switch to the OFF (Neutral) position before checking the en- gine performance.
  • Page 253 T5-1-14 EX355 DIAGNOSING PROCEDURE CONTROLLABLE DATA Data Minimum Control value Controllable Range Set value when the Note machine is shipped Li Mode Speed 10’s min (rpm) 0 to 120 min (rpm) 0 min (rpm) E Mode Speed 10’s min (rpm) -120 to 120 min (rpm) 0 min...
  • Page 254 EX355 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...
  • Page 255 T5-2-2 EX355 COMPONENT LAYOUT ELECTRICAL SYSTEM (Overall system) SM5602 1 - Wiper Motor 18 - N (Engine Speed) Sensor 2 - Monitor Panel 19 - Engine Oil Pressure Switch 3 - Relays, Relays box 20 - Coolant Temperature Switch (Engine Preheat Circuit) 4 - Windshield 21 - Engine Oil Level Switch (on oil pan) 5 - Horn...
  • Page 256 EX355 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 (R1) variant provision 3 - Connection for cab light (ceiling) 15 - L.H.
  • Page 257 T5-2-4 EX355 COMPONENT LAYOUT ELECTRICAL SYSTEM (Cab) SM5604 7 - Connector not used 1 - Connectors for monitor and switch panels 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...
  • Page 258 EX355 T5-2-5 COMPONENT LAYOUT ELECTRICAL SYSTEM (Monitor and Switch panels) SM0610 SM0612 SM0611 1 - Monitor Panel 17 - Fuel Level Indicator 18 - Overheat Indicator 2 - Switch Panel 3 - Power Boost Switch 19 - Alternator Indicator 20 - Engine Oil Pressure Indicator 4 - Key Switch 5 - Cigar Lighter 21 - Engine Oil Level Indicator...
  • Page 259 T5-2-6 EX355 COMPONENT LAYOUT OTHER COMPONENTS Pump device Travel device Pilot filter SM6004 7 - Pump Delivery Pressure Sensor (Pump 1) 8 - N (Engine Speed) Sensor 1 - Regulator (Pump 2) 9 - Counterbalance Valve 2 - Pilot Pump 10 - Travel Relief Valve 3 - Regulator (Pump 1) 11 - Pilot filter...
  • Page 260 EX355 T5-2-7 COMPONENT LAYOUT Swing Device Shockless Valve SM0626 SM6005 Solenoid Valve Unit SM5606 1 - Swing Relief Valve 7 - Check Valve 2 - Pilot Pressure Sensor(Arm Roll-In) 8 - Solenoid Valve Unit (SC) 3 - Shockless Valve 9 - Solenoid Valve Unit (SD) 4 - Check Valve 10 - Solenoid Valve Unit (SI) 5 - Check Valve...
  • Page 261 T5-2-8 EX355 COMPONENT LAYOUT Control Valve Travel Motor (Left) Travel Motor (Right) Bucket Cylinder Cylinder Boom Cylinder Swing Motor Pump 1 Pump 2 SM6041 1 - Pump Control Valve 15 - Arm Regenerative Valve 28 - Load Check Valve (Swing) (In 5-Spool Section) 16 - Check Valve 29 - Arm Anti-Drift Valve:...
  • Page 262 EX355 T5-2-9 COMPONENT LAYOUT Cross Section A Cross Section B Machine Front SM6042 SM6043 Cross Section C Cross Section D Travel (Left) Auxiliary Travel (Right) Bucket SM6044 SM6045...
  • Page 263 T5-2-10 EX355 COMPONENT LAYOUT Travel Motor (Left) Travel Motor (Right) Bucket Cylinder Cylinder Boom Cylinder Swing Motor Pump 1 Pump 2 SM6041 1 - Pump Control Valve 15 - Arm Regenerative Valve 28 - Load Check Valve (Swing) (In 5-Spool Section) 16 - Check Valve 29 - Arm Anti-Drift Valve: 2 - Check Valve...
  • Page 264 EX355 T5-2-11 COMPONENT LAYOUT Cross Section E Machine Front Boom 2 Boom 1 SM6042 SM6046 Cross Section G Cross Section F Arm 1 Arm 2 Swing SM6047 SM6048...
  • Page 265 T5-2-12 EX355 COMPONENT LAYOUT NOTES...
  • Page 266 EX355 T5-3-1 TROUBLESHOOTING A TROUBLESHOOTING A PROCEDURE Use troubleshooting A procedure when fault codes are shown on Dr.EX. • How to Read the Troubleshoting Flow Charts YES(OK) After checking or measuring item (1), select either YES (OK) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.
  • Page 267 T5-3-2 EX355 TROUBLESHOOTING A FAULT CODES FAULT CODE TROUBLE CORRECTIVE ACTION Abnormal EC Sensor Output Signal • Failure in MC. • Faulty Harness • Faulty EC Sensor Abnormal Pump 1 Delivery Pressure • Failure in MC Abnormal Pump 2 Delivery Pressure •...
  • Page 268 EX355 T5-3-3 TROUBLESHOOTING A FAULT CODE 01 (ABNORMAL EC SENSOR OUTPUT SIGNAL) Faulty MC Check if harness between MC 22P • After replacement, connector terminal refer to page T5-4-60. No.D15 and EC sensor terminal No.2 is broken or short- Broken harness circuited.
  • Page 269 T5-3-4 EX355 TROUBLESHOOTING A FAULT CODE 02 (ABNORMAL PUMP 1 DELIVERY PRESSURE) FAULT CODE 03 (ABNORMAL PUMP 2 DELIVERY PRESSURE) 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.
  • Page 270 EX355 T5-3-5 TROUBLESHOOTING A FAULT CODE 04 (ABNORMAL PUMP 1 CONTROL PRESSURE) FAULT CODE 05 (ABNORMAL PUMP 2 CONTROL PRESSURE) Checking Instruction: • It is unlikely for both pump control pressure sen- sors (for 4-spool section side and in 5-spool section side control valves) to fail simultaneously.
  • Page 271 T5-3-6 EX355 TROUBLESHOOTING A FAULT CODE 06 (ABNORMAL ROLL-IN PILOT PRESSURE) Faulty harness between MC and pilot Check if harness pressure sensor. between MC 22P connector terminal No.D18 and pilot pressure sensor terminal No.2, is Faulty MC broken or short Disconnect pilot circuited.
  • Page 272 EX355 T5-3-7 TROUBLESHOOTING A FAULT CODE 07 (ENGINE CONTROL DIAL FAILURE) Faulty harness between MC and Check if harness engine control dial. between MC 22P connector terminal No.D21 and engine control dial terminal No.6 is broken or Faulty MC Disconnect engine short circuited.
  • Page 273 T5-3-8 EX355 TROUBLESHOOTING A SENSOR OPERATING RANGE LIST 1. Preconditions for measurement ± ° ± ° • Hydraulic Oil Temperature: 50 C (122 • Unless otherwise instructed, set the switches as follows: Engine E Mode Work Auto-Idle Control Dial Switch/HP Mode Switch Mode Switch...
  • Page 274 EX355 T5-4-1 TROUBLESHOOTING B TROUBLESHOOTING B PROCEDURE Apply troubleshooting B procedure when no fault Start the troubleshooting with more probable causes codes are displayed on the Dr.EX even though the selected by referring to these tables. machine’s operation is abnormal. At the front section of this group, are tables indicating the relationship between machine trouble symptoms and related parts which may cause such trouble if...
  • Page 275 T5-4-2 EX355 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...
  • Page 276 EX355 T5-4-3 TROUBLESHOOTING B Pump Control Pump Delivery N Sensor Solenoid Valve Unit Pressure Sensor Pressure Sensor (SG) • To detect pump control valve • To detect engine speed to • To increase relief setting • To detect both right and left pressure in control valve to control speed sensing system.
  • Page 277 T5-4-4 EX355 TROUBLESHOOTING B Part Name Solenoid Valve Unit (SD) Solenoid Valve Unit (SC) Solenoid Valve Unit (SI) • To reduce pump swash angle • When arm is rolled in, arm • To increase travel speed by by guiding pilot pressure to speed is increased by guiding decreasing travel motor Part function...
  • Page 278 EX355 T5-4-5 TROUBLESHOOTING B Pressure Switch (Travel) Pressure Switch (Front) Pressure Switch Pilot Pressure Sensor (Boom Raise) (Arm Roll-In) • To detect that travel spool • To detect that front and/or • To detect boom raise pilot • To detect arm roll-in pilot is operated (for auto-idle swing spool is operated (for pressure (for arm...
  • Page 279 T5-4-6 EX355 TROUBLESHOOTING B Part Name Learning Switch Power Boost Switch HP Mode Switch • To start learning engine control • To operate power boost function • To control HP mode operation ON: 0 V → Learning ON: 0 V → Boost function works. OFF: 5 V →...
  • Page 280 EX355 T5-4-7 TROUBLESHOOTING B E Mode Switch Travel Mode Switch Pump Control Valve • To select E mode. • To change travel speed at two • To control engine, pump, and • To develop pump control stages. valve operations. pressure in response to the ON: 0 V →...
  • Page 281 T5-4-8 EX355 TROUBLESHOOTING B Part Name Flow Combiner Valve Restriction in Arm 1 Check Valve and Restriction in Parallel Passage 4-Spool Side Parallel Circuit • To ensure lateral thrust force of • To supply hydraulic oil to both • To supply pressure to arm the front by swing function.
  • Page 282 EX355 T5-4-9 TROUBLESHOOTING B Arm Regenerative Boom Regenerative Bucket Flow Control Valve Travel Flow Control Valve Control Valve Control Valve • To increase arm speed by • To increase boom lower • To ensure pressure oil to raise • To restrict the bucket circuit allowing the return oil from the speed, to improve controlla- boom when travel and boom raise...
  • Page 283 T5-4-10 EX355 TROUBLESHOOTING B Part Name Arm Anti-Drift Valve Arm Anti-Drift Valve Boom Anti-Drift Valve (Rod Side) (Bottom Side) • To prevent the arm drift • To prevent the arm drift caused by • To prevent the boom drift caused by inner leakage of inner leakage of hydraulic oil in con- caused by inner leakage of hydraulic oil in control valve.
  • Page 284 EX355 T5-4-11 TROUBLESHOOTING B NOTE - The measurement of the control voltage of proportional solenoid valves SG, Bypass Shut-Off Valve 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 •...
  • Page 285 T5-4-12 EX355 TROUBLESHOOTING B CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES Engine System Failed Part Engine Control Pump / Valve Control Engine Coolant Sole- Pump Pump Motor Sensor Control Temp. Con- noid Deliv. Deliv. Sensor Dial troller Valve Press. Press. (Pre- Unit Sensor...
  • Page 286 EX355 T5-4-13 TROUBLESHOOTING B Pump/Valve Control Switch Panel Engine Pump Press. Press. Press. Auto- Engine Engine Engine Gov- Main Sensor Switch Switch idle leam. Mode Mode Switch (Main Elec- Unit ernor Pump (Arm (Travel) (Front Switch Switch Switch Switch Con- trical Unit Roll-In)
  • Page 287 T5-4-14 EX355 TROUBLESHOOTING B Front Attachment System / Swing System Failed Part Switch Pump/Valve Control Control Valve Panel Sole- Sole- Pump Press. Press. Power Spool Main Over- Load noid noid Deliv. Sensor Sensor Boost Relief load Check Valve Valve Press. (Arm (Boom Switch...
  • Page 288 EX355 T5-4-15 TROUBLESHOOTING B Control Valve Others Boom Restric- Check Boom Travel Bucket Swing Shock- Pilot Cylinder tion Valve/ Anti- Anti- Anti- Flow Flow Device less Valve gener- gener- (Arm 1 Restriction Drift Drift Drift Control Control Valve ative ative Parallel (4-Spool Valve...
  • Page 289 T5-4-16 EX355 TROUBLESHOOTING B Travel System / Others Failed Part Switch Pump/Valve Control Control Valve Panel Sole- Pump Pump Pump Pump Press. Travel Spool Load Flow noid Control Control Deliv. Deliv. Switch Mode Check Com- Valve Press. Press. Press. Press. (Travel) Switch Valve...
  • Page 290 EX355 T5-4-17 TROUBLESHOOTING B Others Travel Center Pilot Device Joint Valve : being linked closely. Checking the part is re- NOTE - The above table shows the correlation quired. between machine operation trouble and related parts : being linked, but if this part is faulty another type which may cause trouble.
  • Page 291 T5-4-18 EX355 TROUBLESHOOTING B ENGINE TROUBLESHOOTING E-1 Starter Does Not Rotate. Related Fault Code: None Faulty starter or disconnected starter ground Checking Instructions line. • Measure each voltage by referring to the tables below. • Electronic system such as MC has nothing to do Regardless of key switch position ON or START, with the trouble obstructing the rotation of starter.
  • Page 292 EX355 T5-4-19 TROUBLESHOOTING B 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 Faulty harness between Terminal No.1 fusible link and key switch. With key switch in voltage: 0 V START, voltage at...
  • Page 293 T5-4-20 EX355 TROUBLESHOOTING B 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.
  • Page 294 EX355 T5-4-21 TROUBLESHOOTING B • Governor Lever Position Key Switch OFF (Engine Stop Position) Key Switch ON (Engine Start Position) FULL A: STOP SM5631 • Fuel Shut-Off Lever Fuel Cut Handle Pulled Position Fuel Cut Handle Returned Position SM5632...
  • Page 295 T5-4-22 EX355 TROUBLESHOOTING B 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.
  • Page 296 EX355 T5-4-23 TROUBLESHOOTING B Check if governor Faulty engine or fuel system. lever comes in contact with the stopper when conducting engine learning Faulty control cable. Faulty engine operation. governor lever adjustment. • Refer to T5-4-60 after adjusting engine speed. Failure in MC.
  • Page 297 T5-4-24 EX355 TROUBLESHOOTING B Even If Engine Control Dial is Turned, Engine 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 broken harness between engine control dial and MC.
  • Page 298 EX355 T5-4-25 TROUBLESHOOTING B 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.
  • Page 299 T5-4-26 EX355 TROUBLESHOOTING B 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 •...
  • Page 300 EX355 T5-4-27 TROUBLESHOOTING B 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, per- form the troubleshooting of them beforehand. • Refer to the Control System group titled “E Mode Control”...
  • Page 301 T5-4-28 EX355 TROUBLESHOOTING B E-10 Engine Stalls When Machine is Operated under Adverse Conditions such as Opera- tion at High Altitude. Related Fault Code: None Checking Instruction • If speed sensing control does not function, engine Disconnect may stall under adverse operating conditions. harness from solenoid valve unit (SD) and...
  • Page 302 EX355 T5-4-29 TROUBLESHOOTING B Faulty solenoid valve unit (SD). Broken harness between solenoid 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.
  • Page 303 T5-4-30 EX355 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 •...
  • Page 304 EX355 T5-4-31 TROUBLESHOOTING B Faulty glow relay. 10 Ω or less Faulty engine. • Refer to engine shop section. • Refer to T5-4-60 after replacing the engine. Measure glow plug resistance. • Key switch: OFF • After removing copper plates connecting glow plugs, measure the glow Replace glow plug.
  • Page 305 T5-4-32 EX355 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.
  • Page 306 EX355 T5-4-33 TROUBLESHOOTING B After disassembling, cleaning, and adjusting pilot relief valve, check if an abnormal condition still remains. Faulty pilot pump or clogged pilot filter. Trace the causes of trouble by checking other symptoms.
  • Page 307 T5-4-34 EX355 TROUBLESHOOTING B During a Single Operation, Left Side Track and Swing are Slow, but Right Side Track and Bucket are Normal. Arm Speed is Slow When Leveling. (All these symptoms appear at the same time.) Related Fault Code: None Checking Instructions •...
  • Page 308 EX355 T5-4-35 TROUBLESHOOTING B During Single Operation, Right Side Track and Bucket are Slow but Left Side Track and Swing are Normal. (These symptoms appear at the same time.) Related Fault Code: None Checking Instructions • Due to some reasons, pump 1 flow rate is reduced to the minimum (approx.
  • Page 309 T5-4-36 EX355 TROUBLESHOOTING B 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. Faulty Pilot Valve.
  • Page 310 EX355 T5-4-37 TROUBLESHOOTING B Even if No Control Lever is Operated, a Relieving Noise is Heard from Relief Valve. Related Fault Code: None Checking Instructions • If this symptom appears only when an attachment such as hydraulic breaker is installed, seizure of the bypass shut-off valve may be the cause of the trouble.
  • Page 311 T5-4-38 EX355 TROUBLESHOOTING B FRONT ATTACHMENT CONTROL SYSTEM TROUBLESHOOTING All Front Cylinder Functions are Weak. Related Fault Code: None Checking Instructions • In case where the speed is normal and power is weak, main relief valve may be faulty (F-1). In case where the speed is extremely slow the pump control system may have malfunction (A-2, or A- NOTE - 1 kgf/cm...
  • Page 312 EX355 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.
  • Page 313 T5-4-40 EX355 TROUBLESHOOTING B 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.
  • Page 314 EX355 T5-4-41 TROUBLESHOOTING B During the Combined Operation of Travel and Boom Raise, Boom does not Rise. Related Fault Code: None Checking Instructions • Faulty travel flow rate control valve may be the cause of the trouble. • Refer to Control Valve group in COMPONENT OPERATION section.
  • Page 315 T5-4-42 EX355 TROUBLESHOOTING B 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 “Arm Regenerative Control” page in Control System group in the SYSTEM section. •...
  • Page 316 EX355 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.
  • Page 317 T5-4-44 EX355 TROUBLESHOOTING B F-6 Bucket roll-in Single Operation is Slightly Slow. Bucket roll-in Single Operation is Jerky. Related Fault Code: None Checking Instructions • Refer to A-3. • Refer to Control Valve group in the COMPONENT OPERATION section. Trace the cause of the trouble by checking other types of trouble.
  • Page 318 EX355 T5-4-45 TROUBLESHOOTING B Boom Starting Speed is Slow and/on Jerky during Combined Operations. During Boom Lower Single Operation, Boom speed is slightly Slow. Related Fault Code: None Checking Instructions • Refer to Control Valve group in the COMPONENT OPERATION section. Trace the cause of the trouble by checking other symptoms.
  • Page 319 T5-4-46 EX355 TROUBLESHOOTING B 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 Faulty anti-drift valve Check if anti-drift valve for arm or boom is sized or scored.
  • Page 320 EX355 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 malfunctioning, the oil in the bottom side of the boom cylinder flows back into the When the load check valve circuit through the load check valve, is malfunctioning:...
  • Page 321 T5-4-48 EX355 TROUBLESHOOTING B F-10 Front Attachment Cylinder Drift is Large. Related Fault Code: None Normal Check if each Close needle front attachment valve. Check if needle cylinder drift is valve in boom 1 within the section in 4-spool specified value. control valve is Check if the completely...
  • Page 322 EX355 T5-4-49 TROUBLESHOOTING B Scored spool or damaged spring in control valve or loose spool end. Check if internal leak-age exists in cylinder. Faulty cylinder (Replace seal kit.) Check if boom or arm anti-drift valve is seized or clogged. Clean or replace anti- drift valve.
  • Page 323 T5-4-50 EX355 TROUBLESHOOTING B SWING SYSTEM TROUBLESHOOTING 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. •...
  • Page 324 EX355 T5-4-51 TROUBLESHOOTING B Faulty swing reduction device Check if swing motor parking brake release valve is scored Faulty swing or seized. motor parking brake release valve Faulty swing motor...
  • Page 325 T5-4-52 EX355 TROUBLESHOOTING B...
  • Page 326 EX355 T5-4-53 TROUBLESHOOTING B TRAVEL SYSTEM TROUBLESHOOTING 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.
  • Page 327 T5-4-54 EX355 TROUBLESHOOTING B One Side Track does not Move or Move Slowly, or the Machine cannot Travel Straight (Mistracks). Related Fault Code: None Checking Instructions YES Check if travel • If one side system only does not operate, pilot motor oil drain valve, control valve, travel motor, or center joint amount is normal.
  • Page 328 EX355 T5-4-55 TROUBLESHOOTING B Faulty travel motor Faulty travel Disassemble and reduction gear clean travel motor servo piston. Disassemble and Check if same Faulty travel clean travel motor problem occurs motor servo counterbalance again. piston valve. Check, if same problem Faulty occurs again.
  • Page 329 T5-4-56 EX355 TROUBLESHOOTING B During a Combined Operation of Travel and Front Function, the Machine Mis- tracks. Faulty load check valve Related Fault Code: None Check if load check valve is normal. Trace the cause of the Check if flow combiner valve trouble by checking other is normal.
  • Page 330 EX355 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.
  • Page 331 T5-4-58 EX355 TROUBLESHOOTING B TROUBLESHOOTING FOR OTHER FUNC- TIONS 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.
  • Page 332 EX355 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...
  • Page 333 T5-4-60 EX355 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.
  • Page 334 EX355 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...
  • Page 335 T5-4-62 EX355 TROUBLESHOOTING B Exchange Inspection Method Application Fault Code Trouble Application EC Sensor Failure Not Applicable Pump 1 Delivery Pressure Sensor Failure Applicable Pump 2 Delivery Pressure Sensor Failure Applicable Pump 1 Control Pressure Sensor Failure Applicable Pump 2 Control Pressure Sensor Failure Applicable Arm Roll-In Pilot Pressure Sensor Failure Applicable (Pump Control Pressure Sensor)
  • Page 336 EX355 T5-4-63 TROUBLESHOOTING B BOOM LOWERING METHOD WHEN ENGINE 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.
  • Page 337 T5-4-64 EX355 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 Do not allow anybody standing under the front equipment, while carring on the procedure for the lowering of the boom.
  • Page 338 EX355 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) • After checking or measuring item (1), select either YES (OK) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.
  • Page 339 T5-5-2 EX355 TROUBLESHOOTING C MALFUNCTION OF COOLANT TEMPERATURE GAUGE Providing that: • Be sure to inspect wiring connections prior to troubleshooting. Remove coolant temperature sensor Gauge pointer does not terminal, ground harness move at all. (It does not rise side terminal to vehicle. from zero.) With sensor terminal Does pointer swing to the...
  • Page 340 EX355 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. (Continuity) Failure in monitor. Faulty harness (breakage) between monitor and NOT OK sensor. (No continuity) SM0647 Coolant Temperature Sensor Coolant...
  • Page 341 T5-5-4 EX355 TROUBLESHOOTING C MALFUNCTION FUEL GAUGE Providing that: • Be sure to inspect wiring connections prior to troubleshooting. Remove connector of fuel sensor, short-circuit Gauge pointer does not terminals C and A of swing. (It does not rise from harness side connector by zero.) using a jumper wire.
  • Page 342 EX355 T5-5-5 TROUBLESHOOTING C Fuel Sensor 1 mm=0.03937 in Float FULL 257 mm 22° 138.6 mm R370 33° Faulty fuel sensor. 70.5 mm (Continuity) 27° Failure in monitor. 228 mm 28° Resistance 292 mm Reserve Faulty harness (breakage) 338 mm between monitor and fuel NOT OK EMPTY...
  • Page 343 T5-5-6 EX355 TROUBLESHOOTING C MALFUNCTION OF FUEL LEVEL INDICATOR (RESERVE) Providing that: • Be sure to inspect wiring connections prior to troubleshooting. With fuel sensor connector removed, short Reconnect fuel circuit terminals B level sensor and A of harness connector Although fuel side connector by Check if indicator...
  • Page 344 EX355 T5-5-7 TROUBLESHOOTING C Faulty fuel level sensor. Failure in monitor. Faulty harness (breakage) between monitor and low fuel level switch. Burned out indicator light. Faulty fuel level sensor. Faulty harness (short circuit) between monitor and fuel level sensor. Failure in monitor.
  • Page 345 T5-5-8 EX355 TROUBLESHOOTING C MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM Check power line. • Fuse • Disconnect 20P monitor connector. Then, check continuity between harness side terminal No.30 and Indicator does not come ON fuse terminal No.6. Check if all indicators do not when indicator light check come ON.
  • Page 346 EX355 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.
  • Page 347 T5-5-10 EX355 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.
  • Page 348 EX355 T5-5-11 TROUBLESHOOTING C Engine Oil Level Switch 1 mm=0.03937 in Faulty in monitor. Engine Oil Level Switch Oil Level Gauge Indicator ON Broken harness be- tween engine oil level Indicator switch and monitor. Faulty engine oil level A: 3.5 mm switch.
  • Page 349 T5-5-12 EX355 TROUBLESHOOTING C MALFUNCTION OF COOLANT 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.
  • Page 350 EX355 T5-5-13 TROUBLESHOOTING C Coolant Level Switch Coolant Reservoir FULL Failure Radiator in monitor. SM0649 Faulty harness. (breakage) Connector (harness end connector terminals seen from the open end side) Faulty coolant level switch. Monitor (12P) Coolant Level Switch 3 4 5 6 9 10 11 12 Faulty harness.
  • Page 351 T5-5-14 EX355 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.
  • Page 352 EX355 T5-5-15 TROUBLESHOOTING C Hydraulic Oil Level Switch 1 mm=0.03937 in 6.2 mm Failure in monitor. Broken harness between hydraulic oil level switch SM0650 and monitor Connector (harness end connector terminals seen Faulty hydraulic from the open end side) oil level switch. Monitor (12P) Hydraulic Oil Level Switch Short-circuited...
  • Page 353 T5-5-16 EX355 TROUBLESHOOTING C MALFUNCTION OF ALTERNATOR INDICATOR 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.
  • Page 354 EX355 T5-5-17 TROUBLESHOOTING C Connector (harness end connector terminals seen Faulty monitor. from the open end side) Starter Relay Harness breakage between regulator terminal L and Monitor (20P) monitor terminal No.42. 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Faulty regulator or faulty alternator.
  • Page 355 T5-5-18 EX355 TROUBLESHOOTING C MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR Providing that: • Be sure to inspect wiring connections prior to troubleshooting. With engine oil pressure switch disconnected, check if indicator comes ON when terminal of wire number 33 is grounded to vehicle.
  • Page 356 EX355 T5-5-19 TROUBLESHOOTING C Engine Oil Pressure Switch Pressure Indicator Approx. 98 kPa (1.0 kgf/cm 14.2 psi) or Less More than Approx. 98 kPa (1.0 kgf/cm 14.2 psi) Faulty engine oil pressure switch. Reconnect engine oil Broken harness pressure switch. between monitor Check if indicator and engine oil...
  • Page 357 T5-5-20 EX355 TROUBLESHOOTING C MALFUNCTION OF OVERHEAT INDICATOR Providing that: • Be sure to inspect wiring connections prior to troubleshooting. With overheat switch disconnected, check if indicator comes ON when terminal of wire number 201 is grounded to vehicle. Check if indicator Indicator does not comes ON when •...
  • Page 358 EX355 T5-5-21 TROUBLESHOOTING C Overheat Switch Coolant Temperature Indicator Lower than 105 °C Faulty overheat (221 °F) switch. 105 °C (221 °F) or more Reconnect overheat switch. Broken harness Check if indicator between monitor comes ON when Connector (harness end connector terminals seen and overheat monitor 12P from the open end side)
  • Page 359 T5-5-22 EX355 TROUBLESHOOTING C MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR Providing that: • Be sure to inspect wiring connections prior to troubleshooting. With air filter restriction switch disconnected, check if indicator Reconnect comes ON when restriction switch. harness side Disconnect 12P terminal of wire connector of number 203 is...
  • Page 360 EX355 T5-5-23 TROUBLESHOOTING C Air Restriction Switch Pressure Indicator 62 ± 6 mbar (6.2 ± 0.6 kPa) (635 ± 58 mmH or Less More than 62 ± 6 mbar (6.2 ± 0.6 kPa) Faulty air (635 ± 58 mmH restriction switch. Connector (harness end connector terminals seen from the open end side) Faulty monitor.
  • Page 361 T5-5-24 EX355 TROUBLESHOOTING C MALFUNCTION OF BUZZER 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.
  • Page 362 EX355 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 39 40 41 42 43 44 45 46 47 48 Normal Failure in monitor.
  • Page 363 T5-5-26 EX355 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.
  • Page 364 EX355 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.
  • Page 365 T5-6-2 EX355 ELECTRICAL SYSTEM INSPECTION 4. Precaution for using a circuit tester. 1) Before using a circuit tester, refer to the in- Wind a Piece of Wire Tester Probe structions in the circuit tester manual. Then, set the circuit tester to meet the object to be measured, voltage range and current pola- rity.
  • Page 366 EX355 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.
  • Page 367 T5-6-4 EX355 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.
  • Page 368 EX355 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.
  • Page 369 T5-6-6 EX355 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.
  • Page 370 EX355 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...
  • Page 371 T5-6-8 EX355 ELECTRICAL SYSTEM INSPECTION CONTINUITY CHECK Harness Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends: Ω = If the ohm-meter reading is: 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 machine chassis using a clip.
  • Page 372 EX355 T5-6-9 ELECTRICAL SYSTEM INSPECTION...
  • Page 373 T5-6-10 EX355 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 Start checking in order up to the point where voltage measuring either voltage or current.
  • Page 374 EX355 T5-6-11 ELECTRICAL SYSTEM INSPECTION QOS Controller Key Switch Battery Battery Relay Starter Fuse Starter Relay Glow Relay Fuse Monitor Alternator Glow Plugs Relay box SM5619...
  • Page 375 T5-6-12 EX355 ELECTRICAL SYSTEM INSPECTION 5 Voltage Circuit Signal or • Voltage between terminal No.1 and the vehicle ground Two polarities Power source frame (ground) 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.
  • Page 376 EX355 T5-6-13 ELECTRICAL SYSTEM INSPECTION • Check Using False Signal Two polarities IMPORTANT - On three-polarity connectors, do not short-circuit terminals No.1 and No.2 to No.3 or the vehicle frame (ground), causing harnesses, control- lers and fuses to burn due to current overload. (Pressure switch) (N sensor) With the key switch turned OFF, disconnect the...
  • Page 377 T5-6-14 EX355 ELECTRICAL SYSTEM INSPECTION WIPER CONTROLLER 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...
  • Page 378 EX355 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).
  • Page 379 T5-6-16 EX355 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...
  • Page 380 EX355 T5-6-17 ELECTRICAL SYSTEM INSPECTION 5. Identify the relay on the terminal board. SM5622 6. Replace the relay.
  • Page 381 T5-6-18 EX355 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...
  • Page 382 EX355 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). 2. Identify the relay box (4). 3. Remove the hexagonal screw M6 and the two washer (5).
  • Page 383 T5-6-20 EX355 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). 3. Lift the support (6). 4.
  • Page 384 EX355 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.
  • Page 385 T5-6-22 EX355 ELECTRICAL SYSTEM INSPECTION NOTE...
  • Page 386 EX355 T5-7-1 HARNESS CHECK CIRCUIT INSPECTION To inspect the circuits of the machine, a test har- The test harness 75301514 is used to check the nesses kit 75301706 has been developed, including solenoid valves installed on solenoid valve unit. dedicated harnesses for the inspection of the various To check the circuits, connect the appropriate harness components of the machine, and the test harness between the male and female connectors of the...
  • Page 387 T5-7-2 EX355 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 Use this harness to measure the signal voltage of the EC angle sensor circuit.
  • Page 388 ELECTRICAL SYSTEM CIRCUIT DIAGRAM READING KEY GRADING work mode light (led) Batteries PRECISION work mode light (led) Battery relay ATTACHMENT work mode light (led) Starter motor SI solenoid valve (travel motor swash angle control) Starter relay SG solenoid valve (Power boost control) Key switch SD solenoid valve (Speed sensing control) Fuse link 2 (BOX A) 40 A...
  • Page 389 HYDRAULIC SYSTEM CIRCUIT DIAGRAM READING KEY Left travel motor Right travel motor Center joint Control valve Bucket cylinder Boom cylinders Hydraulic oil tank Pilot filter Pilot pump 10 Main pump 1 11 Main pump 2 12 Engine 13 Solenoid valve unit 14 Arm cylinder 15 Positioning pilot valve (*) 16 Positioning cylinder (*)
  • Page 390 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. 604.13.216 - Edition - July 2002...
  • Page 391 FIAT KOBELCO CONSTRUCTION - Be sure to thoroughly read this manual for correct MACHINERY S.p.A. information concerning the service procedures.
  • Page 392 IN-2 EX355 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 : Technical Manual W : Workshop Manual...
  • Page 393 EX355 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.
  • Page 394 EX355 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...
  • Page 395 EX355 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;...
  • Page 396 EX355 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.
  • Page 397 EX355 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.
  • Page 398 EX355 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.
  • Page 399 EX355 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. •...
  • Page 400 EX355 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.
  • Page 401 EX355 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.
  • Page 402 S-10 EX355 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.
  • Page 403 EX355 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.
  • Page 404 S-12 EX355 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.
  • Page 405 EX355 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.
  • Page 406 - 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.
  • Page 407 EX355 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.
  • Page 408 S-16 EX355 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.
  • Page 409 EX355 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.
  • Page 410 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.
  • Page 411 EX355 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. S0153 F1462 STORE ATTACHMENTS SAFELY •...
  • Page 412 S-20 EX355 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”...
  • Page 413 EX355 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.
  • Page 414 S-22 EX355 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.
  • Page 415 EX355 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.
  • Page 416 S-24 EX355 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.
  • Page 417 - 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...
  • Page 418 S-26 EX355 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.
  • Page 419 WORKSHOP MANUAL EX355 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...

  • Page 420: Group

    Section 5 - ENGINE AND ACCESSORY Group 1 - General Information Group 2 - Maintenance Group 3 - Engine Overhaul Group 4 - Engine Lubrication Group 5 - Engine Cooling Group 6 - Engine Fuel Group 7 - Engine Induction Group 8 - Starting and Charging Group...
  • Page 421 SECTION 1 EX355 GENERAL INFORMATION CONTENTS Group 2 - Tightening Torque Group 1 - Precautions for Disassem- bly and Assembly Tightening Torque Specification ... W1-2-1 Precautions for Disassembly and Torque Chart ........W1-2-2 Assembly ..........W1-1-1 Pipe Thread Connection / Union joint Tightening Torque Specifications..
  • Page 422 EX355 W1-1-1 PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY Precautions for Disassembly and Assembly Preparations for Disassembly • Precautions for Disassembly • Clean the Machine - To prevent dirt from entering, cap or plug the Thoroughly wash the machine before bringing it removed pipes.
  • Page 423 W1-1-2 EX355 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: •...
  • Page 424 EX355 W1-1-3 PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY Floating Seal Precautions 1. In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together.
  • Page 425 W1-1-4 EX355 PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY NOTES:...
  • Page 426 EX355 W1-2-1 TIGHTENING TORQUE TIGHTENING TORQUE SPECIFICATIONS No. Descriptions Bolt Diam. Wrench Torque Size kgf m lbf ft Engine cushion rubber mounting bolt Engine bracket mounting bolt Hydraulic oil tank mounting bolt Fuel tank mounting bolt ORS fittings for hydraulic hoses and piping * 1-3/16"-12 * 1-7/16"-12 * 1-11/16"-12...
  • Page 427 W1-2-2 EX355 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.
  • Page 428 EX355 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.
  • Page 429 W1-2-4 EX355 TIGHTENING TORQUE Service Recommendations for Split Flange IMPORTANT (1) Be sure to clean and inspect sealing surfaces. Scratches / roughness cause leaks and seal SM1007 wear. Unevenness causes seal extrusion. If de- fects cannot be polished out, replace the compo- nent.
  • Page 430 EX355 W1-2-5 TIGHTENING TORQUE PIPING JOINT Pipe Thread Connection / Union Joint Tightening 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...
  • Page 431 W1-2-6 EX355 TIGHTENING TORQUE O-ring Seal Joint O-ring (6) seats against the end face of adaptor (7) to seal pressure oil. 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).
  • Page 432 EX355 W1-2-7 TIGHTENING TORQUE Screwed-In Connection 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...
  • Page 433 W1-2-8 EX355 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.

  • Page 434: Table Of Contents

    SECTION 2 EX355 UPPERSTRUCTURE CONTENTS Group 1 - Group 7 - Pilot Valve Remove and Install Cab ....... W2-1-1 Remove and Install Right Pilot Valve ..W2-7-1 Remove and Install Left Pilot Valve ..W2-7-4 Group 2 - Counterweight Remove and Install Travel Pilot Valve ... W2-7-7 Remove and Install Counterweight ..

  • Page 435: Cab

    EX355 W2-1-1 REMOVE AND INSTALL CAB Remove Cab 1. Remove nuts (2) and seat (1). : 13 mm SM1125 2. Loosen bolts (6) (3 used) and bolts (4) (4 used) behind the cab and remove rear cover (5). : 13 mm 3.
  • Page 436 W2-1-2 EX355 5. Disconnect cable connectors (11, relais), (12, antenna, ceiling lamp and windshield wiper), (13, loudspeaker) behind the cab and ground (14) inside the cab. 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).
  • Page 437 EX355 W2-1-3 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 : 8 mm SM1133 11.
  • Page 438 W2-1-4 EX355 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 : 49 N m (5 kgfm, 36 lbf ft) : 24 mm : 205 N m (21 kgf m, 152 lbf ft) : 8 mm...
  • Page 439 EX355 W2-1-5 5. Connect washer vinyl hose (15) at the rear of the cab inside. SM5509 6. Install rear under cover (7) with bolts (8). : 13 mm : 19.5 N m (2 kgf m, 14.5 lbf ft) 7. Install rear cover (5) with bolts (6) (3 used) and bolts (4) (4 used).
  • Page 440 W2-1-6 EX355 9. Install duct cover (16) with screws (17). Install caps (21) onto duct cover (16). SM1130 10. Secure seat (1) with nuts (2). : 13 mm : 19.5 N m (2 kgf m, 14.5 lbf ft) SM1125...

  • Page 441: Counterweight

    EX355 W2-2-1 COUNTERWEIGHT REMOVE AND INSTALL COUNTERWEIGHT Removal WARNING Approximate weight of counterweight: 7 560 kg (16 662 lb) 1. Remove caps (1) from counterweight. SM1135 Install eye-bolts to the counterweight. Eye-bolts: M42, Pitch 4.5 2. Attach wire rope (2) to eye-bolts using shackles. Take out slack of wire rope by applying tension slowly with a crane or hoist.
  • Page 442 W2-2-2 EX355 COUNTERWEIGHT Install counterweight WARNING Approx. weight of counterweight: 7 560 kg (16 662 lb) 1. Attach lifting tools to counterweight. Lift counterweight (4) and install it onto the frame. Install bolts (3) and washers to counterweight and tighten temporarily. : 55 mm SM1137 2.

  • Page 443: Main Frame

    EX355 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.
  • Page 444 W2-3-2 EX355 MAIN FRAME WARNING Approx. weight of front attachment assembly: • monobloc version: 6 800 kg (14 990 lb) • BEH version: 6 100 kg (13 451 lb) • triple articulation version: 7 500 kg (16 530 lb) 3. Remove front attachment assembly from the upperstructure.
  • Page 445 EX355 W2-3-3 MAIN FRAME WARNING Approximate weight of main frame: 7 100 kg (15 650 lb) 5. Attach wire ropes to the front and rear of main frame. See wire ropes taut using a crane. Use chain blocks for easy adjustment of wire rope Rear lengths and to level the frame.
  • Page 446 W2-3-4 EX355 MAIN FRAME 7. Lift main frame slightly from undercarriage. Level main frame by adjusting the chain blocks. Remove main frame. SM1146...
  • Page 447 EX355 W2-3-5 MAIN FRAME Installation WARNING Approximate weight of main frame: 7 100 kg (15 650 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.
  • Page 448 W2-3-6 EX355 MAIN FRAME WARNING Approx. weight of front attachment assembly: • monobloc version: 6 800 kg (14 990 lb) • BEH version: 6 100 kg (13 451 lb) • triple articulation version: 7 500 kg (16 530 lb) 4. Install front attachment assembly (3). (See Front Attachment section) : 19 mm : 29.5 N m (3 kgf m, 21.5 lbf ft)
  • Page 449 EX355 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...
  • Page 450 W2-3-8 EX355 MAIN FRAME NOTES:...

  • Page 451: Pump Device

    EX355 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.

  • Page 452: Disassemble Pump Device

    W2-4-2 EX355 PUMP DEVICE DISASSEMBLE PUMP DEVICE SM5510 1 - Drive Gear (2 Used) 14 - Pipe 27 - Oil Seal 40 - Name Plate 2 - Retaining Ring (2 Used) 15 - Bolt 28 - Center Shaft 41 - Screw (2 Used) 3 - N Sensor 16 - Nut 29 - Coupling Assembly...
  • Page 453 EX355 W2-4-3 PUMP DEVICE Disassemble Pump Device Clean the outside of the pump device. 1. Remove socket bolts (6, 7) to remove N sensor. : 5 mm 2. Remove P sensor (49) (2 used). : 27 mm 3. Loosen bolts (E) (4 used) of coupling assembly (29), then remove inserts (H) from hub (A), : 6 mm 4.
  • Page 454 W2-4-4 EX355 PUMP DEVICE SM5510...
  • Page 455 EX355 W2-4-5 PUMP DEVICE 7. Remove bolt (15), nut (16), washer (17), and clamp (18). : 13 mm 8. Remove pipes (12, 14, 19, 20). : 19 mm, 22 mm 9. Remove adapter (36) from pilot pump (35). : 27 mm 10.
  • Page 456 W2-4-6 EX355 PUMP DEVICE SM5510...
  • Page 457 EX355 W2-4-7 PUMP DEVICE WARNING Flange assembly weight: 45 kg (99 lb) 16. Turn over flange (23), then remove retaining ring (26) from flange (23). 17. Remove seal cover (25) from flange (23). 18. Remove oil seal (27) from seal cover (25), using special tool (75298778).

  • Page 458: Assemble Pump Device

    W2-4-8 EX355 PUMP DEVICE ASSEMBLE PUMP DEVICE SM6205 SM6206...
  • Page 459 EX355 W2-4-9 PUMP DEVICE SM6207 1 - Drive Gear (2 used) 14 - Pipe 27 - Oil Seal 40 - Name Plate 2 - Retaining Ring (2 used) 15 - Bolt 28 - Center Shaft 41 - Screw (2 used) 3 - N Sensor 16 - Nut 29 - Coupling Assembly...
  • Page 460 W2-4-10 EX355 PUMP DEVICE SM6205 SM6206...
  • Page 461 EX355 W2-4-11 PUMP DEVICE Assemble Pump Device WARNING Flange weight: Approximate 34 kg (75 lb) 1. Face input shaft side upward of flange (23), then press in bearing (48) using special tool (75298780). 2. Insert center gear (39) into flange (23) from pump mounting hole to set it onto bearing (48).
  • Page 462 W2-4-12 EX355 PUMP DEVICE SM6205 SM6206...
  • Page 463 EX355 W2-4-13 PUMP DEVICE 9. Turn over flange (23) and place it on the work- bench, then apply THREEBOND 1215 on the pump mounting surface. Workbench : 75298762 WARNING Main pump weight : 67.5 kg (149 lb) 10. Install eyebolt (M12, Pitch 1.75, Length 30) to main pump (11) to install it to flange (23).
  • Page 464 W2-4-14 EX355 PUMP DEVICE SM6205 SM6206...
  • Page 465 EX355 W2-4-15 PUMP DEVICE 17. Install pipes (12, 14, 19, 20). : 19 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) : 22 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 18. Install clamp (18), bolt (15), nut (16), and washer (17).

  • Page 466: Disassemble Main Pump

    W2-4-16 EX355 PUMP DEVICE DISASSEMBLE MAIN PUMP SM6210 1 - Casing 15 - Oil Seal 29 - Servo Pin 43 - Spring Washer (8 used) 2 - Drive Disc 16 - Seal Cover 30 - Set Screw 44 - Regulator 3 - Roller Bearing 17 - O-Ring 31 - Head Cover...
  • Page 467 EX355 W2-4-17 PUMP DEVICE Disassemble Main Pump Clean the outside of the main pump, before disas- sembling. WARNING Main pump weight: 67.5 kg (149 lb) 1. Place main pump on the bed. Remove retaining ring (11). 2. Remove drive gear (10), using puller. 3.
  • Page 468 W2-4-18 EX355 PUMP DEVICE SM6210...
  • Page 469 EX355 W2-4-19 PUMP DEVICE 11. Pull up center shaft (9) straight to remove. NOTE - Be careful not lose pin (14). 12. Remove seven plungers (7). Place plungers (7) horizontally against drive disc (2), and remove. WARNING Casing weight: 20 kg (44 lb) 13.
  • Page 470 W2-4-20 EX355 PUMP DEVICE SM6210...
  • Page 471 EX355 W2-4-21 PUMP DEVICE 18. Place drive disc (2) and roller bearing (3) on special tool (75298340) to remove bearing nut (6). NOTE - When loosening bearing nut (6), loosen clockwise. SM6213 19. Install special tool (75298341) on the spline of drive disc (2) to loosen bearing nut (6).
  • Page 472 W2-4-22 EX355 PUMP DEVICE SM6210...
  • Page 473 EX355 W2-4-23 PUMP DEVICE 24. Install special tool (75301271) between drive disc (2) and roller bearing (3), and place the assembly in a vise. Tighten the vise as neces- sary to widen the clearance. SM6217 25. Remove two roller bearings (3) from drive disc (2) using a puller.

  • Page 474: Assemble Main Pump

    W2-4-24 EX355 PUMP DEVICE ASSEMBLE MAIN PUMP SM6219 SM5511...
  • Page 475 EX355 W2-4-25 PUMP DEVICE SM5512 1 - Casing 15 - Oil Seal 29 - Servo Pin 43 - Spring Washer (8 used) 2 - Drive Disc 16 - Seal Cover 30 - Set Screw 44 - Regulator 3 - Roller Bearing 17 - O-Ring 31 - Head Cover 45 - O-Ring (2 used)
  • Page 476 W2-4-26 EX355 PUMP DEVICE SM6219 SM5511...
  • Page 477 EX355 W2-4-27 PUMP DEVICE Assemble Main Pump NOTE - Assemble by following the disassemble procedures in reverse. (1) Before assembling, clean all parts with pure solvent and dry them with compressed air. (2) Do not mix the parts. 1. Install servo piston (28) into head cover (31). In- stall servo pin (29) into the pin bore on servo piston (28).
  • Page 478 W2-4-28 EX355 PUMP DEVICE SM6219 SM5511...
  • Page 479 EX355 W2-4-29 PUMP DEVICE WARNING Take care to avoid being burned when heating the bearings in an oil bath. 4. Heat two roller bearings (3) and the inner race of bearing (4) to 50 to 80 °C (122 to 176 °F). Apply hydraulic oil to roller bearing (3) (4).
  • Page 480 W2-4-30 EX355 PUMP DEVICE SM6219 SM5511...
  • Page 481 EX355 W2-4-31 PUMP DEVICE NOTE - When tightening bearing nut (6), tighten counterclockwise. 9. Tighten bearing nut (6) by turning drive disc (2) clockwise using tool (75298341). SM6226 10. Install a torquemeter and adapter (75301273) on the spline of drive disc (2) to measure bearing preload.
  • Page 482 W2-4-32 EX355 PUMP DEVICE SM6219 SM5511...
  • Page 483 EX355 W2-4-33 PUMP DEVICE 15. Install cover (75301275) on the spline of drive disc (2). Tap seal cover (16) into casing (1) using a plastic hammer until the retaining ring groove on casing (1) is visible. 16. Install retaining ring (18). 75301275 NOTE - Be sure to confirm that the ring seats well in the groove on casing (1) after installing.
  • Page 484 W2-4-34 EX355 PUMP DEVICE SM6219 SM5511...
  • Page 485 EX355 W2-4-35 PUMP DEVICE NOTE - Install pin into the groove of cylinder block (8) while rotating the end of center shaft. 22. Install center shaft (9) and seven plungers (7) into cylinder block (8). NOTE - Be sure to apply hydraulic oil to the matching surfaces of valve plate (19) and cylinder block (8).
  • Page 486 W2-4-36 EX355 PUMP DEVICE SM6219 SM5511...
  • Page 487 EX355 W2-4-37 PUMP DEVICE 29. Remove valve plate positioning tool (75298412) from casing (1) and install plug (47). Remove servo pin positioning tool (75298411) from head cover (31). Install O-ring (39) on stop- per L (38). Install stopper L (38), with four spring washers (43), and bolts (42).

  • Page 488: Disassemble Regulator

    W2-4-38 EX355 PUMP DEVICE DISASSEMBLE REGULATOR SM6232 3 - Stopper 15 - Nut 23 - Spring 31 - Socket Bolt (8 Used) 6 - O-Ring (3 Used) 16 - Screw 24 - Sleeve 32 - Spring Washer (8 Used) 9 - Sleeve 17 - Nut (2 Used) 25 - Spool 33 - Front Cover...
  • Page 489 EX355 W2-4-39 PUMP DEVICE Disassemble Regulator 1. Clean the regulator outside. 2. Clamp casing (11) with vise. 3. Remove air breather plug (36) and pilot line adapt- ers. : 19 mm, 41 mm 4. Remove eight socket bolts (31) to remove front cover (33) and rear cover (38).

  • Page 490: Assemble Regulator

    W2-4-40 EX355 PUMP DEVICE ASSEMBLE REGULATOR SM5513 SM6234 3 - Stopper 15 - Nut 23 - Spring 31 - Socket Bolt (8 Used) 6 - O-Ring (3 Used) 16 - Screw 24 - Sleeve 32 - Spring Washer (8 Used) 9 - Sleeve 17 - Nut (2 Used) 25 - Spool...
  • Page 491 EX355 W2-4-41 PUMP DEVICE Assemble Regulator NOTE - Assemble by following the disassemble pro- cedures in reverse. (1) Before assembling, Clean all parts with pure solvent and dry with compressed air. (2) Do not mix the parts. 1. Clamp casing (11) with vise. 2.

  • Page 492: Pilot Pump

    W2-4-42 EX355 PUMP DEVICE DISASSEMBLE PILOT PUMP SM5514 1 - Housing 5 - Seal (2 Used) 9 - O-Ring (2 Used) 13 - Bolt (4 Used) 2 - Flange 6 - Cover 10 - Gear 14 - Bushing (2 Used) 3 - Oil Seal 7 - Backup Ring (2 Used) 11 - Drive Gear...
  • Page 493 EX355 W2-4-43 PUMP DEVICE Disassemble Pilot Pump NOTE - (1) Clean the outside of the pilot pump before disassembling. (2) Make matching marks on cover (6), housing (1) and flange (2) before disas- sembling to aid reassembly. 1. Clamp pump flange (2) in vise with cover (6) up. 2.
  • Page 494 W2-4-44 EX355 PUMP DEVICE ASSEMBLE PILOT PUMP SM5514 1 - Housing 5 - Seal (2 Used) 9 - O-Ring (2 Used) 13 - Bolt (4 Used) 2 - Flange 6 - Cover 10 - Gear 14 - Bushing (2 Used) 3 - Oil Seal 7 - Backup Ring (2 Used) 11 - Drive Gear...
  • Page 495 EX355 W2-4-45 PUMP DEVICE Assemble Pilot Pump 1. Tap oil seal (3) in flange (2) using a plastic hammer and tool. 2. Install retaining ring (4) to flange (2). NOTE - Position the bushings in the correct direction when installing. 3.

  • Page 496: Maintenance Standard

    W2-4-46 EX355 PUMP DEVICE MAINTENANCE STANDARD Pump Device Unit: mm (inch) Standard Allowable Limit Remedy Gear backlash 0.48 (0.019) 1.5 (0.059) Replace Main Pump 1. Drive disc: Tooth thickness Unit: mm (inch) Standard Allowable Limit 4.9 (0.193) 3.5 (0.138) 2. Drive disc: Oil seal contact diameter Unit: mm (inch) Standard Allowable Limit...
  • Page 497 EX355 W2-4-47 PUMP DEVICE 5. Clearance between plunger and connecting rod Unit: mm (inch) Standard Allowable Limit 0.1 (0.0039) 0.4 (0.0016) 6. Clearance between center shaft and valve plate SM6238 Unit: mm (inch) Standard Allowable Limit 0.081 (0.0032) 0.3 (0.012) Center Shaft SM6239 7.
  • Page 498 W2-4-48 EX355 PUMP DEVICE NOTES:...

  • Page 499: Control Valve

    EX355 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.

  • Page 500: Disassemble Control Valve (1)

    W2-5-2 EX355 CONTROL VALVE DISASSEMBLE CONTROL VALVE (1) SM6244 1 - Casing A Boom Bottom, Arm 22 - Spool: Swing 35 - Spacer Bolt (8 Used) 2 - Casing B 23 - Spool: Arm 2 36 - Stopper 3 - Plug 12a- O-Ring (6 Used) 24 - Spool: Boom 2 37 - Spring (7 Used)
  • Page 501 EX355 W2-5-3 CONTROL VALVE Disassemble control valve (1) • Read carefully "Precautions for Disassembly and Lower Spool Cover Assembly" (W1-1-1) before starting repair work. IMPORTANT - Attach matching mark not to make a Anti-drift Valve and Needle Valve mistake in assembly of casing and spool cover. 1.

  • Page 502: Assemble Control Valve (1)

    W2-5-4 EX355 CONTROL VALVE ASSEMBLE CONTROL VALVE (1) Machine Front Control Valve Upper View Section B-B SM6245 SM6246 Machine Front Control Valve Lower View Section A-A SM6247 SM6248 1 - Casing A 12a- O-Ring (6 Used) 24 - Spool: Boom 2 37 - Spring (7 Used) 2 - Casing B 13 - Needle Valve...
  • Page 503 EX355 W2-5-5 CONTROL VALVE Assemble Control Valve (1) 9. Install spool (18) to (27) to casing A (1) and cas- ing B (2). • Read carefully "Precautions for Disassembly and Assembly" (W1-1-1) before starting repair work. Upper Spring Cover Lower Spool Cover 10.

  • Page 504: Disassemble Control Valve (2)

    W2-5-6 EX355 CONTROL VALVE DISASSEMBLE CONTROL VALVE (2) Casing SM5505 1 - Anti-Drift Valve Assembly Arm bottom 8 - O-Ring (2 Used) 15 - Plug 21a- O-Ring 2 - Casing 2 9 - O-Ring (2 Used) 16 - Poppet 22 - Piston 3 - Casing 3 10 - O-Ring 17 - Spring...
  • Page 505 EX355 W2-5-7 CONTROL VALVE Disassemble Control Valve (2) • Read carefully "Precautions for Disassembly and Assembly" (W1-1-1) before starting repair work. Arm Anti-drift Valve 1. Loosen four socket bolts (25) and remove casing 2 (2) from casing 4 (4). : 10 mm 2.

  • Page 506: Assemble Control Valve (2)

    W2-5-8 EX355 CONTROL VALVE ASSEMBLE CONTROL VALVE (2) Machine Front Control Valve Upper View Section Y SM6245A SM6250 Casing Casing Section F-F SM6251 1 - Anti-Drift Valve Assembly Arm bottom 8 - O-Ring (2 Used) 15 - Plug 21a- O-Ring 2 - Casing 2 9 - O-Ring (2 Used) 16 - Poppet...
  • Page 507 EX355 W2-5-9 CONTROL VALVE Assemble Control Valve (2) 10. Tighten four socket bolts (24) to install casing 3 (3) in casing 2 (2). • Read carefully "Precautions for Disassembly and : 5 mm Assembly" (W1-1-1) before starting repair work. : 9.8 to 13.5 N⋅m (1 to 1.4 kgf⋅m, 7.2 to 10 lbf⋅ft) Arm Anti-drift Valve 11.

  • Page 508: Disassemble Control Valve (3)

    W2-5-10 EX355 CONTROL VALVE DISASSEMBLE CONTROL VALVE (3) SM6252 1 - Plug (4 Used) 12 - Flange (2 Used) 20 - Spring (2 Used) 28a- O-Ring (3 Used) 2 - Plug 13 - Travel Flow Rate 21 - Spring 29 - Overload Relief Valve: 3 - Plug Control Valve 22 - Spacer...
  • Page 509 EX355 W2-5-11 CONTROL VALVE Disassemble Control Valve (3) Overload Relief Valve • Read carefully "Precautions for Disassembly and IMPORTANT - Note that there are two kinds of Assembly" (W1-1-1) before starting repair work. overload relief valves. Attach identification marks to each port and part to aid P3 Cover reassembly.

  • Page 510: Assemble Control Valve (3)

    W2-5-12 EX355 CONTROL VALVE ASSEMBLE CONTROL VALVE (3) Machine Front Control Valve Upper View Section B SM6245B SM6253 Section C Section D SM6254 SM6255...
  • Page 511 EX355 W2-5-13 CONTROL VALVE Section E Section F SM6256 SM6251A Section G Section X SM6257 SM6248A 1 - Plug (4 Used) 12 - Flange (2 Used) 20 - Spring (2 Used) 28a- O-Ring (3 Used) 2 - Plug 13 - Travel Flow Rate 21 - Spring 29 - Overload Relief Valve: 3 - Plug...
  • Page 512 W2-5-14 EX355 CONTROL VALVE Machine Front Control Valve Upper View Section B SM6245C SM6253A Section C Section D SM6255A SM6254A Section E Section F SM6256A SM6251B...
  • Page 513 EX355 W2-5-15 CONTROL VALVE Assemble Control Valve (3) Travel Flow Rate Control Valve (13) Assembly • Read carefully "Precautions for Disassembly and 7. Install O-ring (13a) to plug. Put piston, sleeve, Assembly" (W1-1-1) before starting repair work. poppet, and spring into casing A, and install plug. : 32 mm Pump Control Valve (5-Spool Section) : 147 to 177 N⋅m...

  • Page 514: Disassemble Control Valve (4)

    W2-5-16 EX355 CONTROL VALVE DISASSEMBLE CONTROL VALVE (4) Casing B SM6258 1 - Plug (2 Used) 8 - O-Ring (2 Used) 13 - Poppet 20 - Plug 2 - Plug 9 - Switch Valve 14 - Poppet 21 - O-Ring (6 Used) 3 - Plug (3 Used) 9a - O-Ring (2 Used) 15 - Spring (2 Used)
  • Page 515 EX355 W2-5-17 CONTROL VALVE Disassemble Control Valve (4) • Read carefully "Precautions for Disassembly and Assembly" (W1-1-1) before starting repair work. Bucket Flow Rate Control Valve 1. Loosen four socket bolts (23) and remove switch valve (9). : 8 mm 2.

  • Page 516: Assemble Control Valve (4)

    W2-5-18 EX355 CONTROL VALVE ASSEMBLE CONTROL VALVE (4) Machine Front Control Valve Upper View Section C SM6245D SM6254B Section D Section E SM6255B SM6256B Section F Section G SM6251C SM6257A 1 - Plug (2 Used) 8 - O-Ring (2 Used) 13 - Poppet 20 - Plug 2 - Plug...
  • Page 517 EX355 W2-5-19 CONTROL VALVE Assemble Control Valve (4) Bucket Flow Rate Control Valve • Read carefully "Precautions for Disassembly and 8. Install two O-rings (9a) to selector valve (9). Poppet Assembly" (W1-1-1) before starting repair work. valve (10) is put into casing. Tighten socket bolt (23) to install selector valve (9).

  • Page 518: Disassemble Control Valve (5)

    W2-5-20 EX355 CONTROL VALVE DISASSEMBLE CONTROL VALVE (5) Casing SM6259 1 - Flow Combiner Valve Assembly 6 - O-Ring (4 Used) 12 - Spring 18 - Spring (3 Used) 2 - Block 7 - O-Ring (2 Used) 13 - Spring 19 - Plug (3 Used) 3 - Plug 8 - O-Ring...
  • Page 519 EX355 W2-5-21 CONTROL VALVE Disassemble Control Valve (5) • Read carefully "Precautions for Disassembly and Assembly" (W1-1-1) before starting repair work. Flow Combiner Valve 1. Loosen five socket bolts (22) and remove flow combiner valve assembly (1). : 14 mm 2.

  • Page 520: Assemble Control Valve (5)

    W2-5-22 EX355 CONTROL VALVE ASSEMBLE CONTROL VALVE (5) Machine Front Machine Lower Control Valve Upper View SM6245E Control Valve Front View SM6260 Section A SM6261 1 - Flow Combiner Valve Assembly 7 - O-Ring (2 Used) 13 - Spring 19 - Plug (3 Used) 2 - Block 8 - O-Ring 14 - Stopper...
  • Page 521 EX355 W2-5-23 CONTROL VALVE 10. Install three O-rings (5) to block (2), four O-rings Assemble Control Valve (5) (6), two O-rings (7) and O-ring (11) to block (2). • Read carefully "Precautions for Disassembly and 11. Tighten five socket bolts (22) to install flow Assembly"...

  • Page 522: Disassemble Control Valve (6)

    W2-5-24 EX355 CONTROL VALVE DISASSEMBLE CONTROL VALVE (6) Casing B Casing A SM6262 1 - Plug (2 Used) 7 - Overload Relief Valve 8 - Overload Relief 9b - O-Ring 2 - Plug (3 Used): Valve:Bucket Rod 9c - O-Ring 3 - O-Ring (2 Used) Bucket Bottom, 8a - O-Ring...
  • Page 523 EX355 W2-5-25 CONTROL VALVE Disassemble Control Valve (6) • Read carefully "Precautions for Disassembly and Assembly" (W1-1-1) before starting repair work. Pump Control Valve (4-Spool Section) 1. Loosen and remove pump control valve (9) from base. : 36 mm Overload Relief Valve IMPORTANT - Note that there are 2 kinds of over-load relief valve.

  • Page 524: Assemble Control Valve (6)

    W2-5-26 EX355 CONTROL VALVE ASSEMBLE CONTROL VALVE (6) Machine Front Control valve Upper View Section E SM6245F SM6256C Section C Section F SM6254C SM6251D Section D Section G SM6255C SM6257B 1 - Plug (2 Used) 7 - Overload Relief Valve 8 - Overload Relief 9b - O-Ring 2 - Plug...
  • Page 525 EX355 W2-5-27 CONTROL VALVE Assemble Control Valve (6) • Read carefully "Precautions for Disassembly and Assembly" (W1-1-1) before starting repair work. Casing 1. Install six O-rings (4), six O-rings (5) and five O- rings (6) to casing B. 2. Connect casing A and casing B and tighten socket bolt (10) and eight socket bolts (11).

  • Page 526: Structure Of Valves

    W2-5-28 EX355 CONTROL VALVE STRUCTURE OF VALVES ITEM PART NAME REMARKS Lock Nut Main Relief Valve Lock Nut M14×1.5 O-Ring O-Ring O-Ring Adjusting Screw Spring Piston Stopper Poppet Backup Ring O-Ring Seat Spring Plunger O-Ring Filter Filter Stopper C-Ring Spacer C-Ring Adjusting Plug Plug...
  • Page 527 EX355 W2-5-29 CONTROL VALVE Switch Valve (Bucket Flow Rate Control Valve) ITEM PART NAME REMARKS Spring Spring Spool Spring Seat Plug Plug Socket Bolt O-Ring O-Ring O-Ring Casing SM6265 Anti-drift Valve ITEM PART NAME REMARKS Bushing Spring Spool Plug O-Ring O-Ring O-Ring Casing...
  • Page 528 W2-5-30 EX355 CONTROL VALVE Travel Flow Rate Control Valve ITEM PART NAME REMARKS O-Ring Spring Plug Poppet Sleeve Piston SM6267 Poppet Valve (Bucket Flow Rate Control Valve) ITEM PART NAME REMARKS Spring Spring Plug Spring Seat Poppet Logic Poppet SM6268 Arm 2 Load Check Valve ITEM PART NAME...
  • Page 529 EX355 W2-5-31 CONTROL VALVE Needle Valve SM6271 ITEM PART NAME REMARKS O-Ring O-Ring Plug PT-1/16 Plating PN-M10 SM6270 Adjusting Screw Poppet Casing Blank Flange ITEM PART NAME REMARKS Socket Bolt M10, L=35 Blank flange O-Ring O-Ring Arm 1 Plug with Orifice ROH Plug PF-1/4...
  • Page 530 W2-5-32 EX355 CONTROL VALVE Boom 1 Spool Assembly SM6273 ITEM PART NAME REMARKS Plug 2 Plug 1 Spring B3 Spring B2 Spring B1 Plunger 3 Plunger 2 Plunger 1 Spool Arm 2 Spool Assembly SM6274 ITEM PART NAME REMARKS Spring Seat (1) Plug Plug Stopper (2)
  • Page 531 EX355 W2-5-33 CONTROL VALVE Pump Control Valve SM6275 ITEM PART NAME REMARKS Lock Nut O-Ring Adjusting Plug Spring Spool O-Ring O-Ring O-Ring Body...
  • Page 532 W2-5-34 EX355 CONTROL VALVE NOTES:...

  • Page 533: Swing Device

    EX355 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.

  • Page 534: Disassemble Swing Device

    W2-6-2 EX355 SWING DEVICE DISASSEMBLE SWING DEVICE SM6276 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)
  • Page 535 EX355 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. 204 kg (450 lb) starting the disassembly work. 1. Remove plug (23) to drain oil and disconnect drain 8.
  • Page 536 W2-6-4 EX355 SWING DEVICE SM6276...
  • Page 537 EX355 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 three spring pins (6) out of first stage carrier (21) using a round bar and a hammer.

  • Page 538: Assemble Swing Device

    W2-6-6 EX355 SWING DEVICE ASSEMBLE SWING DEVICE SM5506 23 - Drain Plug 1 - Swing Motor 12 - Spring Pin (3 Used) 24 - Bolt (10 Used) 2 - Socket Bolt (12 Used) 13 - Thrust Plate (6 Used) 25 - Oil Seal 3 - First Stage Sun Gear 14 - Second Stage Planetary Gear (3 Used) 26 - Cover...
  • Page 539 EX355 W2-6-7 SWING DEVICE Assemble Swing Device WARNING 1. Install needle bearing (8) in each of first stage Housing weight: 102 kg (225 lb) planetary gears (9) (3 used). 9. Attach housing (31) to a crane using eye bolts. IMPORTANT - Set thrust plate (4) with the grooved Lift and mount housing (31) onto shaft (27).
  • Page 540 W2-6-8 EX355 SWING DEVICE SM6277...
  • Page 541 EX355 W2-6-9 SWING DEVICE 12. Apply THREEBOND 1215 to oil seal (25) mount- 18. Install first stage carrier (21) assembly into ring ing part of cover (26). Install oil seal (25) onto gear (19). cover (26). IMPORTANT - Be sure to position the sun gear with 13.
  • Page 542 W2-6-10 EX355 SWING DEVICE SM6277...
  • Page 543 EX355 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.

  • Page 544: Disassemble Swing Motor

    W2-6-12 EX355 SWING DEVICE DISASSEMBLE SWING MOTOR 6 7 8 SM5507 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)
  • Page 545 EX355 W2-6-13 SWING DEVICE Disassemble Swing Motor • Be sure to thoroughly read “Precautions for Disas- IMPORTANT - If a screwdriver or similar tool is used sembly and Assembly” on page W1-1-1 before to separate (pry) valve plate (9) from the rotor side, starting the disassembly work.
  • Page 546 W2-6-14 EX355 SWING DEVICE 6 7 8 SM5507...
  • Page 547 EX355 W2-6-15 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).

  • Page 548: Assemble Swing Motor

    W2-6-16 EX355 SWING DEVICE ASSEMBLE SWING MOTOR 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...
  • Page 549 EX355 W2-6-17 SWING DEVICE Assemble Swing Motor 1. Install retaining ring (47) and spacer (45) onto 11. Attach plungers (34) (9 used) on retainer plate shaft (37). (35). Insert plungers (34) into rotor (27). Install the inner race of roller bearing (39) onto shaft (37) using a press.
  • Page 550 W2-6-18 EX355 SWING DEVICE SM5508...
  • Page 551 EX355 W2-6-19 SWING DEVICE 22. Install parking brake release valve (46) onto IMPORTANT - Be sure that the model stamped end casing (43) using socket bolts (19) (3 used). of roller bearing (1) faces upwards when installing. : 10 mm : 9.8 N m (1 kgf m, 2 lbf ft) 17.
  • Page 552 W2-6-20 EX355 SWING DEVICE DISASSEMBLE AND ASSEMBLE PARKING BRAKE RELEASE VALVE SM5106 31 - Housing 35 - Bushing 38 - Orifice 41 - O-Ring (2 Used) 32 - Spool 36 - Filter 39 - Spring 42 - Steel Ball 33 - Spring 37 - Spacer 40 - O-Ring 43 - Bolt (3 Used)

  • Page 553: Maintenance Standard

    EX355 W2-6-21 SWING DEVICE MAINTENANCE STANDARD Swing motor 1. Plunger and rotor bore clearance (d, D) Unit: mm (in) Standard Clearance Allowable Limit 0.032 (0.0013) 0.062 (0.0024) SM1030 SM1031 2. Plunger and shoe clearance (a) Unit: mm (in) Standard Clearance Allowable Limit 0.3 (0.012) NOTE: 1 mm = 0.03937 in...
  • Page 554 W2-6-22 EX355 SWING DEVICE 3. Thickness of shoe (t) Unit: mm (in) Standard Clearance Allowable Limit 6.0 (0.24) 5.8 (0.23) SM1034 4. Thickness of friction plate Unit: mm (in) Standard Clearance Allowable Limit 4 (0.157) 3.6 (0.142) SM1035 5. Combination of retainer plate (1) and holder (2) Thickness of Retainer (1) T Unit: mm (in) Standard Clearance...

  • Page 555: Pilot Valve

    EX355 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.
  • Page 556 W2-7-2 EX355 PILOT VALVE 4. Loosen screw joint (13) to remove the lever. : 24 mm IMPORTANT - Attach an identification tag on each hose to aid in reassembly. 5. Disconnect hoses (15) to (20). : 22 mm NOTE - Attach a cap on each of disconnected hose ends.
  • Page 557 EX355 W2-7-3 PILOT VALVE 4. Install cover (11) using screws (10) and (12). SM1107 5. Secure stand (9) using bolts (8) (2 used). : 17 mm : 49 N m (5.0 kgf m, 36 lbf ft) SM1106 6. Install frame (2) using screws (1) (2 used) and screws (5) (2 used).

  • Page 558: Remove And Install Left Pilot Valve

    W2-7-4 EX355 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.
  • Page 559 EX355 W2-7-5 PILOT VALVE 5. Loosen screws (10) and (12) to dislocate cover (11) to the right. SM1107 6. Loosen screw joint (17) to remove the lever. : 24 mm IMPORTANT - Attach an identification tag on each hose to aid in reassembly. 7.
  • Page 560 W2-7-6 EX355 PILOT VALVE 4. Install cover (11) using screws (10) and (12). SM1107 5. Secure stand (9) using bolts (8) (2 used). : 17 mm : 49 N m (5.0 kgf m, 36 lbf ft) SM1106 6. Install cover (14) using screws (15) (2 used) and screws (16) (2 used).

  • Page 561: Remove And Install Travel Pilot Valve

    EX355 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.

  • Page 562: Disassemble Right And Left Pilot Valve

    W2-7-8 EX355 PILOT VALVE DISASSEMBLE RIGHT AND LEFT PILOT VALVE 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)
  • Page 563 EX355 W2-7-9 PILOT VALVE Disassemble Right and Left Pilot Valve • Be sure to thoroughly read “Precautions for Dis- 10. Remove spools (19) (4 used) from casing (17). assembly and Assembly” on page W1-1-1 before starting the disassembly work. 11. Compress balance spring A (23) or B (25) to •...

  • Page 564: Assemble Right And Left Pilot Valve

    W2-7-10 EX355 PILOT VALVE ASSEMBLE RIGHT AND LEFT PILOT VALVE 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)
  • Page 565 EX355 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.
  • Page 566 W2-7-12 EX355 PILOT VALVE SM1114...
  • Page 567 EX355 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).

  • Page 568: Disassemble Travel Pilot Valve

    W2-7-14 EX355 PILOT VALVE DISASSEMBLE TRAVEL PILOT VALVE SM1117 10 - Bushing (2 Used) 1 - Cover 19 - Balance Spring (4 Used) 11 - Bushing (2 Used) 2 - Sems Bolt (2 Used) 20 - Spring Guide (4 Used) 12 - Plug 3 - Spring Pin (2 Used) 21 - Pusher (4 Used)
  • Page 569 EX355 W2-7-15 PILOT VALVE Disassemble Travel Pilot Valve • Be sure to thoroughly read “Precautions for Disas- sembly 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.

  • Page 570: Assemble Travel Pilot Valve

    W2-7-16 EX355 PILOT VALVE ASSEMBLE TRAVEL PILOT VALVE SM1119 12-13 1 - Cover (2 Used) 10 - Bushing (2 Used) 19 - Balance Spring (4 Used) 11 - Bushing (2 Used) 2 - Sems Bolt (2 Used) 20 - Spring Guide (4 Used) 12 - Plug 3 - Spring Pin (2 Used) 21 - Pusher (4 Used)
  • Page 571 EX355 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.
  • Page 572 W2-7-18 EX355 PILOT VALVE SM1119...
  • Page 573 EX355 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.

  • Page 574: Positioning Pilot Valve

    W2-7-20 EX355 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.
  • Page 575 EX355 W2-7-21 PILOT VALVE SM3521 - Return spring 11C- O-Ring 24 - Plate 35 - Screw - Balance spring 11D- Piston 25 - Socket Bolt 36 - Plug - Spacer 11E - Oil seal 27 - Cam 37 - O-Ring - Shim 13 - Spring guide 28 - Pin...
  • Page 576 W2-7-22 EX355 PILOT VALVE Disassemble positioning pilot valve 1. Remove the two screw (35) and cover (31). SM3523 2. Remove plug (17) and (36) and extract O-rings (16) and (37). SM3524 3. Remove plunger (15). SM5518...
  • Page 577 EX355 W2-7-23 PILOT VALVE 4. Pull-out the two spring pins (29) and (30), pin (28) and remove cam (27), bushings (39) and plate (24). 5. Remove one of the socket bolt (25) from the valve SM3526 body, and install tool 75298319 in the valve body. 6.
  • Page 578 W2-7-24 EX355 PILOT VALVE 9. Extract the two tappet assemblies (11). Separate piston (11D) from bushing (11A). SM3529 10. Remove O-ring (11C) from bushing (11A). SM3530 11. Remove dust seal (11B). SM3531 12. Remove oil seal (11E). SM3532...
  • Page 579 EX355 W2-7-25 PILOT VALVE 13. Remove the two spool assemblies. Remove spacer (5) from spool (38) pushing on balance spring (2). SM3533 14. Pull-out balance spring (2) and shims (6) from spool (38). SM3534 15. Remove spring guide (13) and return spring (1) from seat.
  • Page 580 W2-7-26 EX355 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). NOTE - The quantity of shims is established during the performance test.
  • Page 581 EX355 W2-7-27 PILOT VALVE 5. Insert return spring (1) and spring guide (13) into body (40). NOTE - Make sure that the spring seat is positioned toward the spring. SM3537 6. Insert the spool assemblies into spring guide (13). NOTE - Insert the single assemblies making reference to the cylinder number.
  • Page 582 W2-7-28 EX355 PILOT VALVE 9. Mount O-ring (11C) in bushing (11A). SM3530 10. Insert piston (11D) into bushing (11A) from the oil seal side (11E). NOTE - Smear some grease inside the bushing. SM3529 11. Position the two tappet assemblies into their 75298319 seats, install plate (24) and mount the two tools 75298319 in the valve body.
  • Page 583 EX355 W2-7-29 PILOT VALVE 12. Remove tool 75298319 from the left side and 75298319 temporary tighten socket bolt (25). SM3541 13. Remove other tool 75298319 and temporary tighten other socket bolt (25). Tightening both socket bolts (25). Tightening torque: 39 N m (4 kgf m, 29 lbf ft). SM3542 14.
  • Page 584 W2-7-30 EX355 PILOT VALVE 15. Lock the valve body into a vise and insert plunger (15). SM5518 16. Position O-rings (37) and (16) on plugs (36) and (17). 17. Install plugs (36) and (17). SM3524 Tightening torque: 49 N m (5 kgf m, 36 lbf ft) 18.
  • Page 585 EX355 W2-7-31 PILOT VALVE Special Tools for Right and Left Pilot Valve SM5519 ITEM Tools No. Tool Name Remarks 75301504 Guide for assembling plate For assembling spools and holder 75301512 Valve holder For disassembling and assembling plate Special Tools for Travel Pilot Valve SM1123 SM1124 ITEM...
  • Page 586 W2-7-32 EX355 PILOT VALVE NOTES:...

  • Page 587: Pilot Shut-Off Valve

    EX355 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.

  • Page 588: Disassemble Pilot Shut-Off Valve

    W2-8-2 EX355 PILOT SHUT-OFF VALVE DISASSEMBLE PILOT SHUT-OFF VALVE 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...
  • Page 589 EX355 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.

  • Page 590: Assemble Pilot Shut-Off Valve

    W2-8-4 EX355 PILOT SHUT-OFF VALVE ASSEMBLE PILOT SHUT-OFF VALVE SM1313 1 - Retaining Ring 9 - Spring Pin 5 - O-Ring 13 - Steel Ball 2 - Washer 10 - Lever 6 - Backup Ring 14 - Body 3 - Backup Ring 11 - Spool 7 - Washer 4 - O-Ring...
  • Page 591 EX355 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.
  • Page 592 W2-8-6 EX355 PILOT SHUT-OFF VALVE NOTES:...

  • Page 593: Shockless Valve

    EX355 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.

  • Page 594: Disassemble And Assemble Shockless Valve

    W2-9-2 EX355 SHOCKLESS VALVE DISASSEMBLE AND ASSEMBLE SHOCKLESS VALVE SM1315...
  • Page 595 EX355 W2-9-3 SHOCKLESS VALVE Section V Section X 11 10 9 15 7 10 Section W 11 10 9 7 10 Section Z-Z Section Y SM1316...
  • Page 596 W2-9-4 EX355 SHOCKLESS VALVE Item Part Name Q.ty Wrench Size Torque Specification Remark (mm) kgf m lbf ft Plug PF 1/8 O-ring Spring Steel Ball Body Steel Ball Ring Orfice Plunger Spring O-ring Plug PF 3/8 Orifice PF 1/8 Plug PF 3/8 Orifice...

  • Page 597: Solenoid Valve Unit

    EX355 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.
  • Page 598 W2-10-2 EX355 SOLENOID VALVE UNIT DISASSEMBLE PROPORTIONAL SOLENOID VALVE SM1038 6 - Solenoid 1 - Socket Bolt (2 Used) 11 - Washer 16 - Sleeve 7 - Spring 2 - Lock Nut 12 - Spring 17 - Plate 8 - O-Ring 3 - O-Ring 13 - O-Ring 18 - Washer...
  • Page 599 EX355 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) provided in the groove of solenoid (6) when removing solenoid (6). Do not remove pressure control lock nut (2) and adjusting screw (4).

  • Page 600: Assemble Propotional Solenoid Valve

    W2-10-4 EX355 SOLENOID VALVE UNIT ASSEMBLE PROPORTIONAL SOLENOID VALVE SM1039 6 - Solenoid 1 - Socket Bolt (2 Used) 11 - Washer 16 - Sleeve 7 - Spring 2 - Lock Nut 12 - Spring 17 - Plate 8 - O-Ring 3 - O-Ring 13 - O-Ring 18 - Washer...
  • Page 601 EX355 W2-10-5 SOLENOID VALVE UNIT Assemble Proportional Solenoid Valve IMPORTANT - Apply a film of grease to O-rings (13), (14) and (15). Install sleeve (16) together with plate (17) and washer (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.
  • Page 602 W2-10-6 EX355 SOLENOID VALVE UNIT NOTES:...

  • Page 603: Pilot Relief Valve Unit

    EX355 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.

  • Page 604: Disassemble Pilot Relief Valve

    W2-11-2 EX355 PILOT RELIEF VALVE UNIT DISASSEMBLE PILOT RELIEF VALVE Port A Port P Port B Port T SM4226 3 - Body 5 - Spring 7 - O-Ring 1 - Plug 4 - Poppet 6 - Shim 8 - Plug 2 - O-Ring...
  • Page 605 EX355 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...

  • Page 606: Assemble Pilot Relief Valve

    W2-11-4 EX355 PILOT RELIEF VALVE UNIT ASSEMBLE PILOT RELIEF VALVE Section Section A - A B - B SM4277 3 - Body 5 - Spring 7 - O-Ring 1 - Plug 2 - O-Ring 4 - Poppet 6 - Shim 8 - Plug...
  • Page 607 EX355 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).
  • Page 608 W2-11-6 EX355 PILOT RELIEF VALVE UNIT IMPORTANT - When pilot filter (13) for pilot relief valve unit (11) is replaced or disassembled, correctly tighten socket bolt (12). : 6 mm ± ± ± : 20 2 N m (2 0.2 kgf m, 14.5 1.5 lbf ft) SM6282A 11 - Pilot Relief Valve Unit...
  • Page 609 SECTION 3 EX355 UNDERCARRIAGE CONTENTS Group 1 - Swing Bearing Group 5 - Front Idler Remove and Install Swing Bearing ........W3-1-1 Remove and Install Front Idler .... W3-5-1 Disassemble Front Idler ....... W3-5-2 Assemble Front Idler ......W3-5-6 Group 2 - Travel Device Maintenance Standard ......

  • Page 610: Swing Bearing

    EX355 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 “Re- move and Install Main Frame” section. In this section, the procedure starts on the premise that the upperstructure has already been removed.
  • Page 611 W3-1-2 EX355 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: 500 kg (1100 lb) SM1309 IMPORTANT - Inner race soft zone (S) and the ball filler port should be placed on the same position (right Machine Front Soft Zone Position...

  • Page 612: Travel Device

    EX355 W3-2-1 TRAVEL DEVICE REMOVE AND INSTALL TRAVEL DEVICE WARNING E scaping 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.

  • Page 613: Disassemble Travel Device

    W3-2-2 EX355 TRAVEL DEVICE DISASSEMBLE TRAVEL DEVICE SM5107 1 - Third Stage Carrier 16 - Bolt (12 Used) 30 - Floating Seal 2 - Third Stage Sun Gear 31 - Roller Bearing (2 Used) 17 - Plug (3 Used) 3 - Thrust Plate (6 Used) 32 - Drum 18 - Spring Pin (3 Used) 4 - Second Stage...
  • Page 614 EX355 W3-2-3 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.
  • Page 615 W3-2-4 EX355 TRAVEL DEVICE SM5107...
  • Page 616 EX355 W3-2-5 TRAVEL DEVICE WARNING Weight of third stage carrier assembly: Approx. 51 kg (112 lb) 7. Remove third stage carrier (1) assembly. 8. Remove lock bolt (46), and lock plate (45), from bearing nut (36). : 19 mm 9. Remove bearing nut (36) using special tools. SM5109 Special Tools: 75301495, 75301496, 75301497 Bolt: M16 (60 to 90 mm in length): 2 pieces...
  • Page 617 W3-2-6 EX355 TRAVEL DEVICE SM5107...
  • Page 618 EX355 W3-2-7 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 15 to 17 above. 19.

  • Page 619: Assemble Travel Device

    W3-2-8 EX355 TRAVEL DEVICE ASSEMBLE TRAVEL DEVICE 8 13 12 1 2 23 8 9 10 30 31 32 45 46 28 27 25 26 24 3 4 33-34 SM5108 1 - Third Stage Carrier 16 - Bolt (12 Used) 30 - Floating Seal 2 - Third Stage Sun Gear 17 - Plug (3 Used)
  • Page 620 EX355 W3-2-9 TRAVEL DEVICE Assemble Travel Device 1. Align the travel motor (29) with the aligment mark 7. Warm the inner race of roller bearing (31) 50 to 70 °C (122 to 158 °F) using a heater. Install it on the housing (44) and install it with bolts (37) (4 Used) and spring washers (35) (4 Used).
  • Page 621 W3-2-10 EX355 TRAVEL DEVICE 12 1 30 31 45 46 28 27 25 26 24 SM5108...
  • Page 622 EX355 W3-2-11 TRAVEL DEVICE 10. Tap on drum (32) using a plastic hammer to secure appropriate play. Then, rotate sprocket (38) three turns clockwise and then counterclockwise. 11. Repeat step 10 above. Then, tighten bearing nut 75301496 (36) to specification. 75301497 Special Tools: 75301495, 75301496, 75301497 75301495...
  • Page 623 W3-2-12 EX355 TRAVEL DEVICE 13 12 23 8 9 10 30 31 SM5108...
  • Page 624 EX355 W3-2-13 TRAVEL DEVICE WARNING WARNING Ring gear weight: Approx. 54 kg (119 lb) Travel device weight: Approx. 475 kg (1050 lb) 32. Turn over the travel device. Remove spacer 20. Install ring gear (12) onto drum (32) using a crane. (75301498).

  • Page 625: Disassemble Travel Motor

    W3-2-14 EX355 TRAVEL DEVICE DISASSEMBLE TRAVEL MOTOR 39 38 37 SM5501 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...
  • Page 626 EX355 W3-2-15 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.
  • Page 627 W3-2-16 EX355 TRAVEL DEVICE SM5502...
  • Page 628 EX355 W3-2-17 TRAVEL DEVICE WARNING Be sure to reduce air pressure to 98 to 196 kPa (1 to 2 kgf/cm , 14 to 28 psi) when using com- pressed air. Cover piston (4) with cloths when removing the piston using compressed air to avoid sudden flying off.

  • Page 629: Assemble Travel Motor

    W3-2-18 EX355 TRAVEL DEVICE ASSEMBLE TRAVEL MOTOR 34,35 28 Cross Section A 22 21 19 SM5111 36 38 40 24,23 32 1 - O-Ring 15 - O-Ring 28 - Bushing 2 - Disc Spring 16 - Bearing Nut 29 - Valve Plate 3 - D-Ring 17 - Plunger (7 Used) 30 - Plate...
  • Page 630 EX355 W3-2-19 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 (75298960) and a press.
  • Page 631 W3-2-20 EX355 TRAVEL DEVICE 34,35 28 Cross Section A SM5111 36 38 40 24,23...
  • Page 632 EX355 W3-2-21 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.
  • Page 633 W3-2-22 EX355 TRAVEL DEVICE 34,35 28 Cross Section A 22 21 19 SM5111 24,23...
  • Page 634 EX355 W3-2-23 TRAVEL DEVICE 22. Attach piston rings (37) onto servo piston (36). Then, install that to special tool (75301530). 23. Insert servo piston (36) into brake valve (33). NOTE - Note the facing direction of the oil groove side when removing the bushing (28).
  • Page 635 W3-2-24 EX355 TRAVEL DEVICE 34,35 Cross Section A SM5111 36 38 40 24,23 32...
  • Page 636 EX355 W3-2-25 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 WARNING Brake valve weight: 43 kg (95 Ib) 33.

  • Page 637: Disassemble Brake Valve

    W3-2-26 EX355 TRAVEL DEVICE DISASSEMBLE BRAKE VALVE SM5504 A - Parking Brake Shuttle Valve 6 - Spring (2 Used) 14 - Ball (2 Used) B - Servo Piston Shuttle Valve 7 - Poppet (2 Used) 15 - Seat (2 Used) 1 - O-Ring (2 Used) 8 - Plug (2 Used) 16 - O-Ring (2 Used)
  • Page 638 EX355 W3-2-27 TRAVEL DEVICE Disassemble Brake Valve • Parking Brake Release Shuttle 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.

  • Page 639: Assemble Brake Valve

    W3-2-28 EX355 TRAVEL DEVICE ASSEMBLE BRAKE VALVE Section B Section C Section A-A SM5113 1 - O-Ring (2 Used) 16 - O-Ring (2 Used) 8 - Plug (2 Used) 2 - Overload Relief Valve (2 Used) 17 - Plug (2 Used) 9 - O-Ring (2 Used) 3 - Casing 18 - Plug...
  • Page 640 EX355 W3-2-29 TRAVEL DEVICE Assemble Brake Valve 5. Install O-ring (16) to plug (17), then install it to casing (3). • Reducing Valve : 6 mm : 34 N m (3.5 kgf m, 25 lbf ft) 1. Insert spring (21) and spool (20) into casing (3), and tighten plug (18) with O-ring (19) to casing (3).

  • Page 641: Maintenance Standard

    W3-2-30 EX355 TRAVEL DEVICE MAINTENANCE STANDARD Sprocket SM1103 IMPORTANT - Consult FIAT KOBELCO for any inqueries concerning welding procedures. Standard Allowable Limit (mm) (mm) Remedy 87.0 3.43 3.03 659.3 25.96 25.55 After cladding by PCD732.5 28.84 welding, finish manually. 748.1 29.45...
  • Page 642 EX355 W3-2-31 TRAVEL DEVICE Parking Brake SM1104 Standard (Thickness) Allowable Limit Part Name of Height (Thickness) Remedy mm (in) mm (in) Friction Plate 3.3 (0.13) 3.25 (0.128) Spacer 9.0 (0.35) Disk Spring 6.5 (0.26) 6.10 (0.24) Piston (Height) *46.0 (1.81) Plate 1.8 (0.071) 1.75 (0.069)
  • Page 643 W3-2-32 EX355 TRAVEL DEVICE NOTES:...

  • Page 644: Center Joint

    EX355 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.

  • Page 645: Disassemble Center Joint

    W3-3-2 EX355 CENTER JOINT DISASSEMBLE CENTER JOINT 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...
  • Page 646 EX355 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) 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).

  • Page 647: Assemble Center Joint

    W3-3-4 EX355 CENTER JOINT ASSEMBLE CENTER JOINT SM1152 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...
  • Page 648 EX355 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.
  • Page 649 W3-3-6 EX355 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). 2. Press bushing (5) into body (6), using pressing tool (75301507). Pressing force: 4.9 to 14.7 kN (500 to 1500 kgf, 1100 to 3300 lbf) SM1154...

  • Page 650: Maintenance Standard

    EX355 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...
  • Page 651 W3-3-8 EX355 CENTER JOINT NOTES:...

  • Page 652: Track Adjuster

    EX355 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.

  • Page 653: Disassemble Track Adjuster

    W3-4-2 EX355 TRACK ADJUSTER DISASSEMBLE TRACK ADJUSTER SM6284 3 - Wiper Ring 11 - Plug 14 - Washer 17 - Seal 8 - Rod 4 - Piston Rod 12 - Valve 15 - Spacer 18 - Holder 9 - O-Ring 6 - U-Ring 13 - Nut 16 - Spring...
  • Page 654 EX355 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- 75301508 bly / disassembly of the track adjuster. WARNING Prevent personal injury.
  • Page 655 W3-4-4 EX355 TRACK ADJUSTER SM6284...
  • Page 656 EX355 W3-4-5 TRACK ADJUSTER 4. Install the plate on the spring holder. Remove valve (12) with grease fitting. Piastra SM1163 5. Set an oil jack as illustrated. Jack up the specified amount below to compress the spring. NOTE - Specified Amount: A - B = 122 mm. A = Free length: 679 mm B = Set length: 557 mm SM1164...
  • Page 657 W3-4-6 EX355 TRACK ADJUSTER SM6284...
  • Page 658 EX355 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). WARNING Spring assembly weight: 168 kg (370 lb) SM1168 10. Remove the track adjuster, using an eyebolt (M16, Pitch1.5) and hoist.
  • Page 659 W3-4-8 EX355 TRACK ADJUSTER SM6284...
  • Page 660 EX355 W3-4-9 TRACK ADJUSTER IMPORTANT - Note that holder (18) is pressed to piston rod (4). 14. Press out holder (18) from piston rod (4) using a press. 15. Remove rod (8) and O-ring (9) from cylinder (10). 16. Remove wear ring (3), and U-ring (6) from cylin- SM6285 der (10).

  • Page 661: Assemble Track Adjuster

    W3-4-10 EX355 TRACK ADJUSTER ASSEMBLE TRACK ADJUSTER 12 11 13 557 mm (free length, 679 mm) 1 ft, 9.9 in (free length, 2 ft 2.7 in) 778 mm (2ft, 6.6 in) SM6286 1 - Idler 6 - U-Ring 11 - Plug 15 - Spacer 2 - Flange 8 - Rod...
  • Page 662 EX355 W3-4-11 TRACK ADJUSTER Assemble Track Adjuster 1. Apply grease to inner face of holder (18). Press holder (18) to piston rod (4). 2. Clean all parts. Install U-ring (6), and wiper ring (3) to cylinder (10). 3. Apply a firm of grease to O-ring (9) and install it into cylinder (10).
  • Page 663 W3-4-12 EX355 TRACK ADJUSTER 11 13 557 mm (free length, 679 mm) 1 ft, 9.9 in (free length, 2 ft 2.7 in) 778 mm (2ft 6.6 in) SM6286...
  • Page 664 EX355 W3-4-13 TRACK ADJUSTER 8. Install washer (14) on spring (16). Install the plate. Piastra SM1168 9. Align the jack and track adjuster with the hole in plate. Tighten the nuts to secure the track adjuster. : 46 mm SM1165 10.
  • Page 665 W3-4-14 EX355 TRACK ADJUSTER 11 13 557 mm (free length, 679 mm) 1 ft, 9.9 in (free length, 2 ft 2.7 in) 778 mm (2ft 6.6 in) SM6286...
  • Page 666 EX355 W3-4-15 TRACK ADJUSTER 12. Install valve (12) to rod (8). : 24 mm : 147 N m (15 kgf m, 110 lbf ft) 13. Lower the jack. SM1164 Piastra 14. Remove the nuts and plate. : 46 mm SM1163 WARNING Track adjuster weight: 180 kg (397 lb) 15.
  • Page 667 W3-4-16 EX355 TRACK ADJUSTER NOTES:...

  • Page 668: Front Idler

    EX355 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.

  • Page 669: Disassemble Front Idler

    W3-5-2 EX355 FRONT IDLER DISASSEMBLE FRONT IDLER SM6290 1 - Bearing (2 Used) 5 - Axle 09 - 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)
  • Page 670 EX355 W3-5-3 FRONT IDLER Disassemble Front Idler • Be sure to thoroughly read “Precautions for Disassembly and Assembly” on page W1-1-1 before starting the disassembly work. WARNING Yoke (9) weight: 24.5 kg (54 lb) 1. Loosen bolts (10) to remove yoke (9). Remove plug (8) from bearing (1) to drain oil into a container.
  • Page 671 W3-5-4 EX355 FRONT IDLER SM6290...
  • Page 672 EX355 W3-5-5 FRONT IDLER WARNING Axle (5) and bearing (1) weight: 16.5 kg (36.5 lb) + 13.2 (29 lb) 5. Press out axle (5) to remove bearing (1) and O-ring (3). SM1182 75301509 6. Remove bushings (6), using special tool. Special Tool: 75301509 SM1183...

  • Page 673: Assemble Front Idler

    W3-5-6 EX355 FRONT IDLER ASSEMBLE FRONT IDLER 8-12 10-11 SM5116 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)
  • Page 674 EX355 W3-5-7 FRONT IDLER Assemble Front Idler 1. Install bushing (6) into idler (7) using a press. 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 damage O-ring (3).

  • Page 675: Maintenance Standard

    203 (7.99) Cladding by welding and finish 572 (22.51) 559 (22.01) or replace 616 (24.25) 22 (0.87) IMPORTANT - Consult FIAT KOBELCO for any inqueries concerning welding procedures. Axle and Bushing Unit: mm (in) Standard Allowable Limit Remedy Axle Outside Dia.

  • Page 676: Upper And Lower Roller

    EX355 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).
  • Page 677 W3-6-2 EX355 UPPER AND LOWER ROLLER 4. Remove bolts (2) from upper roller (1). : 24 mm SM1233 WARNING Upper roller weight: 16 kg (35 lb) 5. Remove upper roller (1) from track frame (3). SM1233 Installation WARNING Upper roller weight: 16 kg (35 lb) 1.
  • Page 678 EX355 W3-6-3 UPPER AND LOWER ROLLER 3. Supply grease to valve (1) to adjust tracks ten- sion. Check the track tension measuring the track sag (A) as indicated in the TRACKS section. Grease Outlet SM0100 Track sag specifications (A): 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...

  • Page 679: Remove And Install Lower Roller

    W3-6-4 EX355 UPPER AND LOWER ROLLER REMOVE AND INSTALL LOWER ROLLER Removal 1. Remove the roller guard and loosen bolts (5). : 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).
  • Page 680 EX355 W3-6-5 UPPER AND LOWER ROLLER WARNING Lower roller weight: 56 kg (124 lb) 4. Securely hold the lower roller using a fork lift. Remove lower roller (1). SM1238 Installation 1. Securely hold the lower roller using a fork lift. Put lower rollers (1) on the tracks as illustration.
  • Page 681 W3-6-6 EX355 UPPER AND LOWER ROLLER 4. Supply grease to valve (3) to adjust tracks ten- sion. Check the track tension measuring the track sag (A) as indicated in the TRACKS section. Grease Outlet SM0100 Track sag specifications (A): 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...

  • Page 682: Disassemble Upper Roller

    EX355 W3-6-7 UPPER AND LOWER ROLLER DISASSEMBLE UPPER ROLLER NOTE - Replace the upper roller as an assembly. SM1241...

  • Page 683: Disassemble Lower Roller

    W3-6-8 EX355 UPPER AND LOWER ROLLER DISASSEMBLE LOWER ROLLER SM1242 4 - O-ring (2 Used) 7 - Roller 1 - Plug (2 Used) 5 - Floating Seal (2 Used) 8 - Axle 2 - Collar ( 2 Used) 6 - Bushing (2 Used) 3 - Elastic pin (2 Used)
  • Page 684 EX355 W3-6-9 UPPER AND LOWER ROLLER Disassemble Lower Roller • Be sure to thoroughly read “Precautions for Disas- sembly and Assembly” on page W1-1-1 before starting the disassembly work. 1. Remove plug (1) and elastic pins (3) from collars (2), and drain oil. : 6 mm : 14 mm SM1243...

  • Page 685: Assemble Lower Roller

    W3-6-10 EX355 UPPER AND LOWER ROLLER ASSEMBLE LOWER ROLLER SM1246 4 - O-ring (2 Used) 7 - Roller 1 - Plug (2 Used) 5 - Floating Seal (2 Used) 8 - Axle 2 - Collar ( 2 Used) 6 - Bushing (2 Used) 3 - Elastic pin (2 Used)
  • Page 686 EX355 W3-6-11 UPPER AND LOWER ROLLER Assemble Lower Roller 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).

  • Page 687: Maintenance Standard

    110 (4.33) Lower Roller SM1252 Unit: mm (in) Standard Allowable Limit Remedy 203 (7.99) 213 (8.39) Buildup weld 256 (10.08) 26.5 (1.04) 18.5 (0.73) finishing 175 (6.89) 165 (6.50) IMPORTANT - Consult FIAT KOBELCO for any inqueries concerning welding procedure.
  • Page 688 EX355 W3-6-13 UPPER AND LOWER ROLLER Axle and Bushing Unit: mm (in) Standard Allowable Limit Remedy Axle Outside Dia. 75 (2.95) 74.2 (2.92) Bushing Inside Dia. 75 (2.95) 76 (2.99) Replace Bushing Flange Thickness 2 (0.0079) 1.2 (0.047)
  • Page 689 W3-6-14 EX355 UPPER AND LOWER ROLLER NOTES:...

  • Page 690: Remove And Install Tracks

    EX355 W3-7-1 TRACKS REMOVE AND INSTALL TRACKS Removal 1. Move the tracks so that master pin (3) is posi- tioned over front idler (4). Put a wooden block under track shoes (5), as shown. SM1254 WARNING Do not loosen valve (1) quickly on loosen too much since high-pressure grease in the adjusting cylin- der may spout out.
  • Page 691 W3-7-2 EX355 TRACKS WARNING The front idler may jump out of position due to strong spring force when the tracks is discon- nected. Especially, the strong spring force is al- ways 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.
  • Page 692 EX355 W3-7-3 TRACKS Installation 1. Jack up the machine and put the track under the lower roller. Sprocket Be sure to position the track in correct direction, as side illustrated. Idler side SM1261 2. Lift the track, and place it on sprocket (1). SM1262 3.
  • Page 693 W3-7-4 EX355 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. A: 75294946 SM1257 B: 75295630 C: 75298429 D: 75298430 E: 75298428 G: 75297580...
  • Page 694 EX355 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 ground.
  • Page 695 W3-7-6 EX355 TRACKS Loosening the track WARNING - Do not loosen the valve (1) quickly or too much as grease pressure inside the cylinder might dangerously eject it off its seat. - Loosen the valve with care, keeping the body parts and face away from the valve (1).

  • Page 696: Maintenance Standard

    Do not measure the master-pin included part of the track. SM1266 Unit: mm (in) Standard Allowable Remedy Limit 864 (34) 882 (34.7) IMPORTANT - Consult FIAT KOBELCO for any inqueries concerning welding procedures. Master Pin SM1269 Unit: mm (in) Standard Allowable Remedy Limit 242 (9.53) Replace 44.4 (1.75)
  • Page 697 W3-7-8 EX355 TRACKS Master Bushing SM1267 Unit: mm (in) Standard Allowable Remedy Limit 148.3 (5.84) 44.6 (1.76) 47.5 (1.87) Replace 66.5 (2.62) 63 (2.48) Grouser Shoe SM1268 Unit: mm (in) Standard Allowable Remedy Limit 247 (9.72) 11 (0.43) Replace 36 (1.42) 30 (1.18)
  • Page 698 SECTION 4 EX355 FRONT ATTACHMENT CONTENTS Group 2 - Cylinders Group 1 - Front attachment Remove and install cylinders ....W4-2-1 Remove and install front attachment (standard and BEH monobloc version) . W4-1-1 Hydraulic circuit pressure release procedure ......W4-2-12 Maintenance Standard (standard and BEH monobloc version) .

  • Page 699: Remove And Install Front Attachment

    EX355 W4-1-1 FRONT ATTACHMENT REMOVE AND INSTALL FRONT ATTACHMENT (standard and BEH 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.
  • Page 700 W4-1-2 EX355 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.
  • Page 701 EX355 W4-1-3 FRONT ATTACHMENT WARNING Approx. weight of front attachment assembly: • standard version: 6 800 kg (14 990 lb) • BEH version: 6 100 kg (13 451 lb) 8. Attach the boom to a crane. Slighty hoist the boom to take out any wire rope slack.
  • Page 702 W4-1-4 EX355 FRONT ATTACHMENT Installation WARNING Approx. weight of front attachment assembly: • standard version: 6 800 kg (14 990 lb) • BEH version: 6 100 kg (13 451 lb) 1. Install the front attachment Install dust seals to boom foot. Align the boom foot boss with the main frame SM1325 boss.
  • Page 703 EX355 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.

  • Page 704: Maintenance Standard

    W4-1-6 EX355 FRONT ATTACHMENT MAINTENANCE STANDARD (standard and BEH monobloc version) SM1328 Unit: mm (in) Parts Name Standard Allowable Limit Remedy 110 (4.33) 109.0 (4.31) Bushing 110 (4.33) 111.5 (4.39) 110 (4.33) 109.0 (4.31) Boss (Main Frame) 110 (4.33) 111.5 (4.39) Bushing (Boom Cylinder) 110 (4.33) 111.5 (4.39)
  • Page 705 EX355 W4-1-7 FRONT ATTACHMENT Unit: mm (in) Parts Name Allowable Standard Remedy Limit 90 (3.54)/110 (4.33)* 89.0 (3.50)/109.0 (4.29)* Boss (Arm) 90 (3.54)/110 (4.33)* 91.5 (3.60)/111.5 (4.39)* Bushing (Bucket Cylinder) 90 (3.54)/110 (4.33)* 91.5 (3.60)/111.5 (4.39)* 100 (3.94)/110 (4.33)* 99.0 (3.90)/109.0 (4.29)* Bushing 100 (3.94)/110 (4.33)* 101.5 (4.00)/111.5 (4.39)*...

  • Page 706: Bucket Teeth

    W4-1-8 EX355 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. •...

  • Page 707: Standard Dimensions For Arm And Bucket Connection

    EX355 W4-1-9 FRONT ATTACHMENT STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION Sezione A Sezione B Unit: mm (in) EX355 FH330.3 a (*) b (*) ← ← ← ← 1653 ← ← ← ← ← ← ← ← 5° ← 45° (*) Arm: 3 190 mm for standard version, 2 076 mm for BEH version...
  • Page 708 W4-1-10 EX355 FRONT ATTACHMENT NOTES:...

  • Page 709: Remove And Install Front Attachment (Triple Articulation Version)

    EX355 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.
  • Page 710 W4-1-12 EX355 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.
  • Page 711 EX355 W4-1-13 FRONT ATTACHMENT WARNING Front assembly weight: 7 500 kg (16 530 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.
  • Page 712 W4-1-14 EX355 FRONT ATTACHMENT Installation WARNING Front assembly weight: 7 500 kg (16 530 lb) WARNING To secure the top arm with an other crane, when remove the front attachment. SM1325 1. Install the front attachment. Install dust seals to boom foot. Align the boom foot boss with the main frame boss.
  • Page 713 EX355 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.
  • Page 714 W4-1-16 EX355 FRONT ATTACHMENT MAINTENANCE STANDARD (triple articulation version) SM1357 Unit: mm (in) Parts Name Standard Allowable Limit Remedy 110 (4.33) 109.0 (4.31) Bushing 110 (4.33) 111.5 (4.39) 110 (4.33) 109.0 (4.31) Boss (Main Frame) 110 (4.33) 111.5 (4.39) Bushing (Boom Cylinder) 110 (4.33) 111.5 (4.39) 110 (4.33)
  • Page 715 EX355 W4-1-17 FRONT ATTACHMENT Unit: mm (in) Parts Name Standard Allowable Limit Remedy 90 (3.54) 89.0 (3.50) Boss (Arm) 90 (3.54) 91.5 (3.60) Bushing (Bucket Cylinder) 90 (3.54) 91.5 (3.60) 100 (3.94) 99.0 (3.90) Bushing 100 (3.94) 101.5 (4.00) Bushing (Bucket Cylinder) 100 (3.94) 101.5 (4.00) 90 (3.54)
  • Page 716 W4-1-18 EX355 FRONT ATTACHMENT NOTES:...

  • Page 717: Remove And Install Cylinders

    EX355 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.
  • Page 718 W4-2-2 EX355 CYLINDERS 4. Use wire (14) to secure cylinder rod (13) as illustrated. 5. Disconnected hoses (9) (2 Used) from bucket cylinder (1). Put plugs on cylinder pipes and hoses. : 10 mm : 36 mm SM1333 WARNING Bucket cylinder weight: •...
  • Page 719 EX355 W4-2-3 CYLINDERS Install Bucket Cylinder WARNING Bucket cylinder weight: • standard version: 240 kg (529 lb) • BEH version: 294 kg (648 lb) 1. Connect bucket cylinder (1) to a crane using a sling belt. Align the hole on the bucket cylinder tube with the pin hole on the arm-tip bracket.
  • Page 720 W4-2-4 EX355 CYLINDERS Remove Arm Cylinder 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”.
  • Page 721 EX355 W4-2-5 CYLINDERS WARNING Arm cylinder weight: 470 kg (1036 lb) 8. Use a crane to slightly hoist arm cylinder (1). SM1335 9. Loosen lock nuts (4). Remove bolt (5) and pin (3). Then remove thrust plate (15) from arm cylinder (1).
  • Page 722 W4-2-6 EX355 CYLINDERS Install Arm Cylinder WARNING Arm cylinder weight: 470 kg (1036 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 (18).
  • Page 723 EX355 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 WARNING Boom cylinder weight: 294 kg (648 lb)
  • Page 724 W4-2-8 EX355 CYLINDERS Install Boom Cylinder WARNING Boom cylinder weight: 294 kg (648 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 (8) and lock nuts (7). Tighten lock nuts (7). SM1342 : 30 mm : 540 N m (55 kgf m, 400 lbf ft)
  • Page 725 EX355 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.
  • Page 726 W4-2-10 EX355 CYLINDERS WARNING Positioning cylinder weight: 349 kg (769 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 9. Remove positioning cylinder (1). SM1362...
  • Page 727 EX355 W4-2-11 CYLINDERS Install positioning cylinder WARNING Positioning cylinder weight: 349 kg (769 lb) 1. Connect positioning cylinder (1) to a crane using a sling belt. Align the hole on the positioning cylinder tube with the pin hole on the boom-tip bracket. SM1362 2.

  • Page 728: Hydraulic Circuit Pressure Release Procedure

    W4-2-12 EX355 CYLINDERS HYDRAULIC CIRCUIT PRESSURE RE- Machine Front LEASE PROCEDURE WARNING 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 loos- ening the overload relief valve(s) for the line(s) or hose(s) to be disconnected.

  • Page 729: Cylinder Air Bleeding Procedure

    EX355 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 Extend and retract slowly 5 times.

  • Page 730: Disassemble Cylinders

    W4-2-14 EX355 CYLINDERS DISASSEMBLE CYLINDERS Boom Cylinder 1 2 3 4 6 9 10 13 20 21 23 SM1350A 14 19 16 17 18 20 19 Bucket Cylinder 1 2 3 4 6 9 10 13 20 16 20 21 19 16 17 18 19 SM1351 7 - Cylinder Head...
  • Page 731 EX355 W4-2-15 CYLINDERS Disassemble Boom and Bucket Cylinders Be sure to thoroughly read all the “Precautions for 5. Remove set screw (22) and steel ball (23). Disassembly and Assembly” on page W1-1-1 before NOTE - Cut away its mushroomed portion using a drill starting the disassembly procedure.
  • Page 732 W4-2-16 EX355 CYLINDERS Arm Cylinder 1 2 3 4 6 9 10 13 20 25 26 28 24 22 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...
  • Page 733 EX355 W4-2-17 CYLINDERS Disassemble Arm Cylinder Be sure to thoroughly read all the “Precautions for 5. Remove set screw (22) and steel ball (23). Disassembly and Dissembly” on page W1-1-1 before starting the disassembly procedure. NOTE - Cut away its mushroomed portion using a drill first, as set screw (22) was mushroomed with a punch The disassembly procedure below starts on the and hammer at two places after it had been screwed...
  • Page 734 W4-2-18 EX355 CYLINDERS Positioning Cylinder (triple articulation version) 1 2 3 4 6 9 10 21 23 19 16 17 18 20 19 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...
  • Page 735 EX355 W4-2-19 CYLINDERS Disassemble Positioning Cylinder Be sure to thoroughly read all the “Precautions for 5. Remove set screw (22) and steel ball (23). Disassembly and Assembly” on page W1-1-1 before starting the disassembly procedure. NOTE - Cut away its mushroomed portion using a drill first, as set screw (22) was mushroomed with a punch The disassembly procedure below starts on the and hammer at two places after it had been screwed...

  • Page 736: Assemble Cylinders

    W4-2-20 EX355 CYLINDERS ASSEMBLE CYLINDERS Boom Cylinder Face the slit toward the piston Slit Green Black 3 4 5 6 7 8 9-10 11 12 13 14 15 16 17 19 20 21 22-23 SM1353 Be sure that oil groove faces the correct direction when assembling Bucket Cylinder Slit...
  • Page 737 EX355 W4-2-21 CYLINDERS Assemble Bucket and Boom Cylinder 1. Install bushing (5) to cylinder head (7) using a 7. Install cushion bearing (13) to cylinder rod (11). press. (For boom cylinder only, install cushion seal (14).) Special tools for bushing installation: Install piston (15) to cylinder rod (11).
  • Page 738 W4-2-22 EX355 CYLINDERS Arm Cylinder Face the slit toward the piston Slit Green Black 3 4 5 6 7 8 9-10 11 12 13 14 15 16 17 19 20 21 22-23 Be sure that oil groove faces the correct direction when assembling SM5525 11 - Cylinder Rod 1 - Wiper Ring...
  • Page 739 EX355 W4-2-23 CYLINDERS Assemble Arm Cylinder 1. Install bushing (5) to cylinder head (7) using a 8. Install shim (21) to cylinder rod (11). Tighten nut press. (24) using special tool (75298624). Special tools for bushing installation: Ø 115 mm (75301683) 75298624 IMPORTANT- Be sure that the rings are installed correctly.
  • Page 740 W4-2-24 EX355 CYLINDERS Positioning Cylinder (triple articulation version) Slit Green Black 3 4 5 6 7 8 9-10 11 12 15 16 17 19 20 21 22-23 SM1368 15 - Piston 21 - Shim 1 - Wiper Ring 7 - Cylinder Head 16 - Backup Ring 22 - Set Screw 2 - Backup Ring...
  • Page 741 EX355 W4-2-25 CYLINDERS Assemble Positioning Cylinder (triple articulation version) 8. Install shim (21) to cylinder rod (11). Tighten nut 1. Install bushing (5) to cylinder head (7) using a (24) using special tool (75298623). press. Special tools for bushing installation: Ø 105 mm (75301655) 75298623 IMPORTANT- Be sure that the rings are installed...

  • Page 742: Maintenance Standard

    W4-2-26 EX355 CYLINDERS MAINTENANCE STANDARD Unit: mm (in) Cylinders STANDARD (A) Remedy BEH bucket and boom 105 ± 0.025 (4.13 ± 0.001) Replace or 115 ± 0.025 (4.53 ± 0.001) plate with Standard bucket 95 ± 0.03 (3.74 ± 0.001) chromium Positioning (*) 105 ±...

  • Page 743: Special Tools

    EX355 W4-2-27 CYLINDERS SPECIAL TOOLS Piston nut socket wrench: 75297549 for BEH bucket and boom cylinders (115 mm) 75298684 for standard bucket cylinder (110 mm) 75301638 for arm cylinder (130 mm) 75298552 for positioning cylinder (120 mm) (triple articulation version) SM1366 Use nut loosening/tightening workbench: 75298623 75298624 (arm cylinder)
  • Page 744 W4-2-28 EX355 CYLINDERS NOTES:...
  • Page 745 SECTION 5 EX355 ENGINE AND ACCESSORY CONTENTS Group 1 - General Information Injection Pump ........W5-3-13 Bearing Case ........W5-3-17 General Repair instructions ....W5-1-1 Oil Cooler ..........W5-3-19 External View ......... W5-1-3 Rocker Arm and Shaft Assembly ..W5-3-22 Main Data and Specifications ....
  • Page 746 SECTION 5 EX355 Group 7 - Engine Induction Service Precautions ....... W5-7-1 Turbocharger .......... W5-7-1 Group 8 - Starting and Charging Service Precautions ....... W5-8-1 Alternator ..........W5-8-1 Starter Motor ........W5-8-10 Group 9 - Troubleshooting Hard Starting ......... W5-9-1 Unstable Idling ........

  • Page 747: General Information

    2. The use of proper tools and special tools, where specified, is important for efficient and reliable performance of service repairs. 3. When replacement parts are required, consult the appropriate FIAT KOBELCO PARTS CATALOG. 4. Used cotter pins, plastic clips, gaskets, O-rings oil seals, lock washers, and self-locking nuts should be discarded and new ones should be installed.
  • Page 748 W5-1-2 EX355 GENERAL INFORMATION 18. Test fluid from the injection nozzle tester will spray out of the injection nozzle under great pressure. It can easily puncture a person's skin. Keep your hands away from the injection nozzle at all times. 19.

  • Page 749: External View

    EX355 W5-1-3 GENERAL INFORMATION ENGINE EXTERNAL VIEW Cooling fan Cylinder head Cylinder head cover Oil filler cap Flywheel Oil dipstick Exhaust manifold Turbocharger Alternator Water pump Starter motor Crank pulley Oil pan Flywheel housing Oil drain plug Fuel filter Inlet pipe Intake duct NOTE: Engine details may vary depending on the specifications.

  • Page 750: Main Data And Specifications

    W5-1-4 EX355 GENERAL INFORMATION MAIN DATA AND SPECIFICATIONS ITEMS 6HK1 Engine type Four cycle, water cooled, in-line, overhead camshaft direct injection Combustion chamber Open type in piston crown Cylinder liner Timing drive system Gear drive No. of cylinders - bore x stroke mm (in) 6 -115 x 125 (4.53 x 4.92) No.
  • Page 751 EX355 W5-1-5 GENERAL INFORMATION ITEMS 6HK1 Relief valve opening pressure kPa (kg/cm /psi) 780 (8.0/114) Oil pressure switch operating pressure* kPa (kg/cm /psi) 29 (0.3/4) Main oil filter Paper element Bypass valve opening pressure kPa (kg/cm /psi) 200 (2.0/28.4) Oil volume* L (qts) 36 (38) with combined main and partial oil filter Oil cooler...

  • Page 752: Service Standards

    W5-1-6 EX355 GENERAL INFORMATION SERVICE STANDARDS ITEMS SERVICE STANDARD SERVICE LIMIT Cylinder Head Lower Face Warpage mm (in) 0.05 (0.002) or less 0.20 (0.008) Do not regrind the lower face. Valve Guide Valve Stem Clearance Intake 0.04 - 0.06 0.20 (in) (0.0016 - 0.0024) (0.008)
  • Page 753 EX355 W5-1-7 GENERAL INFORMATION ITEMS SERVICE STANDARD SERVICE LIMIT Rocker Arm Shaft and Rocker Arm Rocker Arm Shaft Run-Out mm (in) 0.30 (0.012) Rocker Arm Shaft Outside Diameter 21.979 - 22.000 21.85 (in) (0.865 - 0.866) (0.860) Rocker Arm Inside Diameter 22.010 - 22.035 (in) (0.867 - 0.868)
  • Page 754 W5-1-8 EX355 GENERAL INFORMATION ITEMS SERVICE STANDARD SERVICE LIMIT Piston and Piston Ring Piston Grade Cylinder Liner and Piston Clearance 0.122 - 0.156 – (in) (0.0048 - 0.0061) Piston Ring and Piston Ring Groove Clearance Compression Ring 0.057 - 0.097 0.20 (in) (0.0022 - 0.0038)
  • Page 755 EX355 W5-1-9 GENERAL INFORMATION ITEMS SERVICE STANDARD SERVICE LIMIT Connecting Rod Connecting Rod Alignment mm (in) 0.05 (0.002) or less 0.20 (0.008) Connecting Rod Small End Bushing Diameter 36.012 - 36.022 (in) (1.4178 -1.4182) Piston Pin and Connecting Rod Small End Bushing Clearance 0.012 - 0.027 0.05 (in)
  • Page 756 W5-1-10 EX355 GENERAL INFORMATION ITEMS SERVICE STANDARD SERVICE LIMIT Idler Gear Idler Gear Shaft A Outside Diameter 49.950 - 49.975 (in) (1.9665 - 1.9675) Idler Gear Shaft B and C Outside Diameter 29.959 - 29.980 29.9 (in) (1.1795 - 1.1803) (1.1772) Idler Gear Shaft A and Idler Gear Clearance...

  • Page 757: Nut And Bolt Angular Tightening Method

    EX355 W5-1-11 GENERAL INFORMATION NUT AND BOLT ANGULAR TIGHTENING METHOD Line The angular tightening method uses the plastic region of high tensile steel nuts and bolts to precision tighten important engine fasteners. Because of the method’s nature, there is a limit to the number of times a particular fastener may be reused.
  • Page 758 W5-1-12 EX355 GENERAL INFORMATION 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 SM7004 Example: Specified Angle and Tightening Rotation 30°...

  • Page 759: Torque Specifications

    EX355 W5-1-13 GENERAL INFORMATION TORQUE SPECIFICATIONS Auxiliary Parts N•m (kgf•m/Ib ft) 39(4.0/29) Cooling fan 83(8.5/61) Starter SM7006...
  • Page 760 W5-1-14 EX355 GENERAL INFORMATION Engine External Parts N•m (kgf•m/Ib ft) 39(4.0/29) 19(1.9/14) Fuel filter Oil cooler 88(9.0/65) Coupling 39(4.0/29) Oil port cover 44(4.5/32) Injection pump 52(5.3/38) Turbocharger SM7007...
  • Page 761 EX355 W5-1-15 GENERAL INFORMATION Cylinder Head N•m (kgf•m/Ib ft) Apply engine oil M14: 98 (10/72) → 147 (15.0/108) → 30°~60° Apply molybdenum M10: 38 (3.9/28) disulfide grease M14: Apply molybdenum disulfide grease M10: Apply engine oil Apply engine oil Apply ThreeBond No1207B Apply ThreeBond No1207C...
  • Page 762 W5-1-16 EX355 GENERAL INFORMATION Cylinder Head N•m (kgf•m/Ib ft) Apply engine oil Apply engine oil 19 (1.9/14) Apply engine oil SM7009...
  • Page 763 EX355 W5-1-17 GENERAL INFORMATION Oil Pan N•m (kgf•m/Ib ft) SM7010...
  • Page 764 W5-1-18 EX355 GENERAL INFORMATION Timing Gears N•m (kgf•m/Ib ft) Apply engine oil Apply engine oil Apply molybdenum Apply engine oil disulfide grease Apply engine oil Apply ThreeBond No.TB1201 Apply ThreeBond No TB 1201 3(3.2/23) Apply engine oil Apply molybdenum disulfide grease SM7011...
  • Page 765 EX355 W5-1-19 GENERAL INFORMATION Water Pump N•m (kgf•m/Ib ft) SM7012...
  • Page 766 W5-1-20 EX355 GENERAL INFORMATION Piston, Connecting Rod and Crankshaft N•m (kgf•m/Ib ft) Apply ThreeBond No1207C Apply molybdenum disulfide grease Apply engine oil Apply molybdenum disulfide grease Apply engine oil Apply engine oil Apply ThreeBond No 1207C or No 1216C M14: Apply molybdenum disulfide grease SM7013...

  • Page 767: Standard Bolt Torque Specifications

    EX355 W5-1-21 GENERAL INFORMATION STANDARD BOLT TORQUE SPECIFICATIONS The tightening torque values given in the table below are applicable to all bolts unless otherwise specified. Standard bolt N•m (kgf•m/lb•ft) Bolt Identif. Bolt Diameter x pitch (mm) M6 x 1.0 4-8 (0.4-0.8/3-6) 5-10 (0.5-1.0/4-7) –––––––...
  • Page 768 W5-1-22 EX355 GENERAL INFORMATION The tightening torque values given in the table below are applicable to all bolts unless otherwise specified. Flanged head bolt N•m (kgf•m/lb•ft) Bolt Identif. Bolt Diameter pitch (mm) M6 x 1.0 5-9 (0.5-0.9/4-7) 6-12 (0.6-1.2/4-9) ––––––– M8 x 1.25 11 -20 (1.1 -2.0/8-15) 15-28 (1.6-2.9/12-21)

  • Page 769: Recommended Thread Locking Agents

    EX355 W5-1-23 GENERAL INFORMATION RECOMMENDED THREAD LOCKING AGENTS LOCTITE Type LOCTITE Color LOCTITE 242 Blue LOCTITE 262 LOCTITE 271 Application Steps 1. Completely remove all lubricant and moisture from the bolts and the female-threaded surfaces of the parts to be joined. The surfaces must be perfectly dry.

  • Page 770: Special Tools

    W5-1-24 EX355 GENERAL INFORMATION SPECIAL TOOLS TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME 8-94396-819-0 8-94396-858-0 Replacer; Slinger Installer; Crankshaft gear 5-88402-627-0 8-94396-856-0 Installer; Oil seal cylinder head Setting tool; Oil seal 5-8840-2623-0 5-8840-2621-0 Remover; Nozzle Remover; Valve spring sleeve 5-8840-2628-0 Remover/Installer;...

  • Page 771: Lubricant Applications

    EX355 W5-1-25 GENERAL INFORMATION LUBRICANT APPLICATION Name of Lubricant Lubrication area Engine Oil Turbocharger bearings Cylinder head bolts (M10 bolt) Rocker arm rollers Camshaft cam nose and journal Camshaft fixing bolts and stud bolts Valve ends Oil seal lips Idle gear shaft & fixing bolts Cylinder liner bores Connecting rod bearing sliding surfaces Crank bearing sliding surfaces...

  • Page 772: Identification (Engine Serial Number)

    W5-1-26 EX355 GENERAL INFORMATION IDENTIFICATION Engine Serial Number The engine serial number is stamped on the front of the cylinder block. Engine model & serial No. Engine model Serial number 6HK1 000000 SM7015...

  • Page 773: Maintenance

    EX355 W5-2-1 MAINTENANCE LUBRICATION SYSTEM 2. Before installing a new fuel filter, apply fuel to the gasket of the cartridge. 3. Turn the fuel filter until the filter gasket comes in Oil filter replacement contact with the sealed face. 4. Use the filter wrench to turn in the fuel filter an 1.

  • Page 774: Injection Nozzle

    W5-2-2 EX355 MAINTENANCE INJECTION NOZZLE Opening Pressure and Spray Condition Check 2. Check the spray condition. 1. Use an injection nozzle tester to check the nozzle opening pressure. If the spray condition is bad, the injection nozzle must be replaced or reconditioned. If the opening pressure is above or below the (1) Correct specified value, the injection nozzle must be re-...

  • Page 775: Air Bleeding

    EX355 W5-2-3 MAINTENANCE AIR BLEEDING FEED PUMP STRAINER • Make sure that draining plug (3) and air bleeding • Remove connection (2) from fuel pump body (1). plug (4) on water separator (5) are tightened. If air bleeding plug (4) is not tightened, air is not expelled •...

  • Page 776: Injection Timing Adjustment

    W5-2-4 EX355 MAINTENANCE INJECTION TIMING ADJUSTMENT Injection Timing inspection 1. Disconnect the negative battery cable. Pointer 2. Rotate the crankshaft in the normal direction of engine rotation to align the injection timing mark on the damper with the timing pointer on the front cover.

  • Page 777: Cooling System

    EX355 W5-2-5 MAINTENANCE COOLING SYSTEM VALVE CLEARANCE ADJUSTMENT Fan Belt Inspection The following instructions assume that valve clear- ance is adjusted beginning with the No. 1 piston at top Check the drive belt tension. Depress the drive belt dead center (TDC) on the compression stroke. mid-portion with a 100 N (10kg/22 lb) force.
  • Page 778 W5-2-6 EX355 MAINTENANCE Valve Clearance: 0.4 mm (0.0016 in) d. In this condition, the opposite end of the bridge is raised. Readjust by loosening the adjusting b. Insert a feeler gauge between the rocker arm screw on the bridge until there is a slight drag and the bridge and adjust the valve clearance on the feeler gauge.

  • Page 779: Compression Pressure Measure

    EX355 W5-2-7 MAINTENANCE Intake and Exhaust Valve Arrangement Cylinder No. Valve Names No. 1 cyl. at TDC on compression No. 6 cyl. at TDC on compression I : Intake valve. E: Exhaust valve COMPRESSION PRESSURE MEASURE To measure the compression pressure, the engine must be cold.

  • Page 780: Recommended Lubricants

    W5-2-8 EX355 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 (59ºF) (77ºF) (86ºF) (5ºF) [Multi-grade] SM7033...

  • Page 781: Engine Overhaul

    EX355 W5-3-1 ENGINE OVERHAUL SERVICE PRECAUTIONS • After removing the intake air duct or air cleaner, • Be sure to use the correct fastener in the proper immediately cover the intake opening with a clean location. If a used fastener is replaced with a new cloth.
  • Page 782 W5-3-2 EX355 ENGINE OVERHAUL Combustion Chambers Isuzu’s unique combustion chamber design provides easy starting, maximum power output, and operating economy. Direct fuel injection is used. Each cylinder has an injection nozzle placed precisely at the center of the cylinder. Intake ports generate maximum swirl effect for the airfuel mixture.

  • Page 783: Turbocharger

    EX355 W5-3-3 ENGINE OVERHAUL TURBOCHARGER Removal 1. Remove the oil feed pipe. • Discard the gaskets. 2. Remove the oil drain pipe. • Discard the gaskets. 3. Remove the turbocharger. NOTE: Plug the turbocharger body oil ports and openings to prevent the entry of foreign material. Installation SM7035 1.

  • Page 784: Exhaust Manifold

    W5-3-4 EX355 ENGINE OVERHAUL EXHAUST MANIFOLD Tighten the nuts to the specified torque in the order shown in the illustration below. Removal Torque: 34 N•m (3.5 kgm/25 Ibft) 1. Remove the turbocharger oil feed pipe. 2. Remove the turbocharger oil drain pipe. 3.
  • Page 785 EX355 W5-3-5 ENGINE OVERHAUL 3. Install the oil drain pipe to the turbocharger. 4. Install the oil feed pipe to the turbocharger. SM7035...

  • Page 786: Intake Cover

    W5-3-6 EX355 ENGINE OVERHAUL INTAKE COVER Removal 1. Remove the fuel pipes. 2. Remove the booster air pipe. 3. Remove the injection pipes. 4. Remove the fuel filter and bracket. 5. Remove the intake pipe. 6. Remove the intake cover. 7.
  • Page 787 EX355 W5-3-7 ENGINE OVERHAUL 4. Install the injection pipes and tighten the sleeve 6. Install the fuel leak off pipe (1) with new gasket. nuts to the specified torque. Tighten the eye bolts to the specified torque. Torque: 29 N•m (3.0 kgm/22 Ibft) Torque: Cylinder head side: 29 N•m (3.0 kgm/22 Ibft) Fuel filter side:...

  • Page 788: Water Pump

    W5-3-8 EX355 ENGINE OVERHAUL WATER PUMP Removal 1. Loosen the fan fixing nuts to remove the cooling fan. SM7046 2. Loosen the fan pulley fixing bolts. 3. Remove the fan belt. • Loosen the mounting bolt (2) and the sliding piece nut (1).
  • Page 789 EX355 W5-3-9 ENGINE OVERHAUL 4. Remove the adapter and fan pulley. SM7050 Adapter Bypass hose Fan pulley Water duct Water pump Water duct 5. Disconnect the bypass hose. 6. Loosen the fixing nuts and bolts from the water pump. 7. Remove the water pump from the front plate. 8.
  • Page 790 W5-3-10 EX355 ENGINE OVERHAUL Installation 4. Install the water duct with new gasket to the oil cooler and water pump. 1. Install the water pump with new gaskets to the Tighten the bolts to the specified torque. front plate. Use the locating pin. Torque: 20 N•m (2.0 kgm/14 Ibft) 2.
  • Page 791 EX355 W5-3-11 ENGINE OVERHAUL 10. Install the cooling fan. Tighten the fixing nuts to the specified torque. Torque: 39 N•m (4.0 kgm/29 Ibft) SM7046 11. Adjust the fan tip clearance. Clearance: 7 - 13 mm (0.28 - 0.51 in)

  • Page 792: Alternator

    W5-3-12 EX355 ENGINE OVERHAUL ALTERNATOR Removal 1. Remove the sliding piece nut (1). 2. Remove the alternator mounting bolt (2). 3. Remove the fan belt. 4. Remove the alternator. SM7049 Water pump Alternator SM7049 Installation 1. Install the alternator. 2. Install the adjusting plate. Crankshaft 3.

  • Page 793: Injection Pump

    EX355 W5-3-13 ENGINE OVERHAUL INJECTION PUMP Removal 1. Remove the leak off pipe (1). 3. Remove the injection pipe. SM7045 SM7043 2. Remove the fuel pipes (1), (2) and (3). NOTE: Protect the joint openings of the injection pipe to prevent the entry of foreign material. 4.
  • Page 794 W5-3-14 EX355 ENGINE OVERHAUL Remove the oil feed pipe (1) from the injection Loosen the injection pump fixing bolts (1). pump. Remove the oil return pipe (2). SM7057 SM7055 10. Remove the injection pump. 11. Remove the injection pump bracket. Loosen the coupling bolts (1).
  • Page 795 EX355 W5-3-15 ENGINE OVERHAUL Installation • Install the injection pump to the injection pump bracket. Use the locating dowel pin. 1. Install the injection pump bracket to the cylinder • Tighten the injection pump fixing bolts to the block. Use the locating pin. specified torque.
  • Page 796 W5-3-16 EX355 ENGINE OVERHAUL Install the oil feed pipe (1) to the injection pump. 10. Install the fuel return pipe. Torque: 27 N•m (2.8 kgm/20 Ibft) • Tighten the bolts to the specified torque. Install the oil return pipe (2). Torque: 37 N•m (3.8 kgm/27 Ibft) Torque: 34 N•m (3.5 kgm/25 Ibft) 11.

  • Page 797: Bearing Case

    EX355 W5-3-17 ENGINE OVERHAUL BEARING CASE Installation 1. Bring No. 1 piston to top dead center on the Removal compression stroke. 1. Remove the injection pump. Refer to “Injection Pump Removal” in this manual. 2. Remove the coupling. • Loosen the bolt (1). Pointer SM7023 2.
  • Page 798 W5-3-18 EX355 ENGINE OVERHAUL • Tighten the fixing nuts and bolts to the specified torque: Torque: Bolt (1): 73 N•m (7.4 kgm/54 Ibft) Nut (2): 73 N•m (7.4 kgm/54 Ibft) Nut (3), (4) : 40 N•m (4.1 kgm/30 Ibft) POINTER SM7063 3.

  • Page 799: Oil Cooler

    EX355 W5-3-19 ENGINE OVERHAUL OIL COOLER Installation Install the oil cooler assembly with new gaskets Removal to the cylinder block. • Clean the sealing surface of the oil cooler. 1. Remove the fuel leak off pipe. • Apply ThreeBond No. 1207C/1216C or 2.
  • Page 800 W5-3-20 EX355 ENGINE OVERHAUL Install the injection pump. Install the injection pipes. Refer to “Injection Pump Installation” in this • Tighten the sleeve nuts to the specified torque. manual. Torque: 29 N•m (3.0 kgm/22 Ibft) Install the oil feed pipe (1) to the injection pump. Torque: 27 N•m (2.8 kgm/20 Ibft) Install the oil return pipe (2).
  • Page 801 EX355 W5-3-21 ENGINE OVERHAUL 12. Install the fuel leak off pipe (1). • Tighten the bolts to the specified torque. Torque: Cylinder head side: 29 N•m (3.0 kgm/22 Ibft) Filter side: 25 N•m (2.5 kgm/18 Ibft) SM7045...

  • Page 802: Rocker Arm And Shaft Assembly

    W5-3-22 EX355 ENGINE OVERHAUL ROCKER ARM AND SHAFT ASSEMBLY Removal SM7067 Cylinder head cover Bearing Gasket Camshaft Rocker arm assembly Rubber plug Cam bearing cap Cylinder head...
  • Page 803 EX355 W5-3-23 ENGINE OVERHAUL 1. Remove the head cover. NOTE: Do not remove the rocker arm fixing bolts (indicated by an arrow). 2. Remove the cylinder head cover gasket. Discard the gasket. NOTE: Be careful not to lose the collars inserted into the cylinder head cover assembly.
  • Page 804 W5-3-24 EX355 ENGINE OVERHAUL 2. Install the rocker arm assembly. 3. Adjust the valve clearance. Refer to “Valve Clear- 1. Apply engine oil to the front and rear camshaft ance Adjustment” in this manual. bracket sliding surfaces. 4. Apply ThreeBond 1207B or equivalent to the rub- 2.
  • Page 805 EX355 W5-3-25 ENGINE OVERHAUL 4. Tighten the cylinder head cover bolts to the specified torque a little at a time in the numeri- cal order shown in the illustration. Torque: 13 N•m (1.3 kgm/9.4 Ibft) SM7075...
  • Page 806 W5-3-26 EX355 ENGINE OVERHAUL Disassembly SM7076 Camshaft bracket Bracket Rocker arm Rocker arm shaft Spring washer...
  • Page 807 EX355 W5-3-27 ENGINE OVERHAUL 1. Disassemble the rocker arm and shaft assembly. • Loosen the rocker arm shaft fixing bolts (1). • Disassemble the bracket, rocker arm, washer and rocker arm shaft. NOTE: Keep each rocker arm and bracket in order so that they can be reinstalled to their original positions.
  • Page 808 W5-3-28 EX355 ENGINE OVERHAUL ROCKER ARM BUSHING INSIDE DIAMETER Use either a vernier caliper or a dial indicator to measure the rocker arm bushing inside diameter. Rocker arm bushing inside diameter Standard: 22.010 - 22.035 mm (0.867 - 0.868 in.) Rocker arm and rocker arm shaft clearance Standard: 0.01 - 0.056 mm (0.0004 - 0.0022 in.) Limit: 0.2 mm (0.0079 in.)
  • Page 809 EX355 W5-3-29 ENGINE OVERHAUL ROCKER ARM ROLLER AND ROCKER ARM PIN 7. Check the rocker arm roller and camshaft contact surfaces for excessive wear and damage. 1. Pass a piece of string between the rocker arm and the rocker arm roller. 2.
  • Page 810 W5-3-30 EX355 ENGINE OVERHAUL BRIDGE GAP 4. Install the rocker arm shaft bracket as shown in the installation. Check the valve cap and rocker arm contact surfaces for excessive wear and damage. If the wear exceeds the limit, the valve cap must be replaced. Valve cap wear Limit: 0.1 mm (0.004 in) Front...

  • Page 811: Camshaft

    EX355 W5-3-31 ENGINE OVERHAUL CAMSHAFT Removal SM7067 Cylinder head cover Bearing Gasket Camshaft Rocker arm assembly Rubber plug Cam bearing cap Cylinder head...
  • Page 812 W5-3-32 EX355 ENGINE OVERHAUL 1. Remove the head cover. Installation 2. Remove the cylinder head cover gasket. Discard the gasket. 1. Install the camshaft with camshaft gear to the cylinder head. 1. Align the crankshaft damper pulley TDC mark NOTE: Be careful not to lose the collars inserted into with the pointer by rotating the crankshaft in the the cylinder head cover assembly.
  • Page 813 EX355 W5-3-33 ENGINE OVERHAUL 6. If the “B” mark and upper cylinder head face 6. Install the rubber plug to the cylinder head. are not aligned, No. 1 piston is not on the 1. Apply ThreeBond 12078 or equivalent to the compression stroke.
  • Page 814 W5-3-34 EX355 ENGINE OVERHAUL 7. Install the cylinder head cover with new gasket. 1. Clean the head cover gasket groove and the head cover gasket. 2. Install the new head cover gasket and collar to the head cover. 3. Install the cylinder head cover to the cylinder head.
  • Page 815 EX355 W5-3-35 ENGINE OVERHAUL Disassembly SM7093 Camshaft gear Knock pin Camshaft...
  • Page 816 W5-3-36 EX355 ENGINE OVERHAUL 1. Remove the camshaft gear. 2. Use a micrometer to measure each camshaft • Check the gear for excessive wear or damage. journal diameter in two directions (1) and (2). If • Use an universal puller to pull out the camshaft the measured value is less than the specified gear.
  • Page 817 EX355 W5-3-37 ENGINE OVERHAUL 4. Mount the camshaft on V-blocks. Measure the Reassembly run-out with a dial indicator at the No: 4 camshaft journal. If the measured value exceeds the speci- 1. Install the gear alignment pin to the camshaft. fied limit, the camshaft must be replaced.

  • Page 818: Cylinder Head

    W5-3-38 EX355 ENGINE OVERHAUL CYLINDER HEAD Removal SM7101 Cylinder head cover 9. Glow plug Gasket 10. Rocker arm assembly Rubber plug 11. Bridge cap Leak off pipe 12. Bridge Injection nozzle bracket 13. Camshaft Injection nozzle 14. Cylinder head Gasket 15.
  • Page 819 EX355 W5-3-39 ENGINE OVERHAUL Remove the head cover. 10. Remove the bridge. Remove the cylinder head cover gasket. Discard the gasket. NOTE: Keep the bridges in order for reassembly to their original positions. NOTE: Be careful not to lose the collars inserted into the cylinder head cover assembly.
  • Page 820 W5-3-40 EX355 ENGINE OVERHAUL Installation • Apply molybdeum disulfide grease to the cylin- der head bolts (M14) threads and setting faces. 1. Install the new cylinder head gasket. • Apply engine oil to the cylinder head bolts (M10) • Clean the cylinder block surface and remove threads and setting faces.
  • Page 821 EX355 W5-3-41 ENGINE OVERHAUL 3. Install the camshaft with gear to the cylinder head. 5. Install the bridge caps. Refer to “Camshaft Installation” in this manual. 1. Apply engine oil to the bridge cap. 2. Install the bridge cap to the bridge. SM7091 SM7108 4.
  • Page 822 W5-3-42 EX355 ENGINE OVERHAUL 7. Install the glow plugs to the cylinder head. 10.Adjust the valve clearance. Tighten the glow plugs to the specified torque. Refer to “Valve Clearance Adjustment” in this manual. Torque: 20 N•m (2.0 kgm/14 Ibft) 11.Install the rubber plugs. 8.
  • Page 823 EX355 W5-3-43 ENGINE OVERHAUL 12. Install the cylinder head cover and gasket. 1. Clean the head cover gasket groove and the head cover gasket. 2. Install the new head cover gasket and collar to the head cover. 3. Install the cylinder head cover to the cylinder head.
  • Page 824 W5-3-44 EX355 ENGINE OVERHAUL Disassembly SM7111 1. Cylinder head 14. Idler gear cover 2. Oil seal 15. Gasket 3. Bridge guide 16. Thermostat 4. Nozzle sleeve 17. Water outlet pipe 5. Valve seat insert 18. Overheat warning switch 6. Valve guide 19.
  • Page 825 EX355 W5-3-45 ENGINE OVERHAUL 1. Remove the bridge cap and bridge. 9. Remove the split collar. 1. Place the cylinder head on a flat wooden surface. NOTE: Keep the bridges and caps in order for 2. Use the valve spring compressor 5-8840- reassembly to their original positions.
  • Page 826 W5-3-46 EX355 ENGINE OVERHAUL 11. Remove the valve guide. 13. Remove the injection nozzle sleeve. Use the • Use the valve guide remover 5-8840-2628-0 nozzle sleeve remover 5-8840-2623-0 to drive to remove the valve guide. the nozzle sleeve from the lower side cylinder head.
  • Page 827 EX355 W5-3-47 ENGINE OVERHAUL 15. Remove the injection pipe oil seal. SM7120 SM7119 Inspection and Repair Make the necessary adjustments, repairs, and part replacements if excessive wear, or damage is discov- ered during inspection. CYLINDER HEAD Cylinder Head Lower Face Warpage Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower face.
  • Page 828 W5-3-48 EX355 ENGINE OVERHAUL Valve Stem Clearance Valve Stem Outside Diameter Intake Valve Measure the valve stem diameter at three points. If Standard: 0.04 - 0.06 mm (0.0016 - 0.0024 in) the measured value is less than the specified limit, the Limit: 0.20 (0.008 in) valve and the valve guide must be replaced as a set.
  • Page 829 EX355 W5-3-49 ENGINE OVERHAUL • Installation VALVE AND VALVE SEAT INSERT 1. Apply engine oil to the valve guide outer circumfer- Valve Thickness ence. 2. Set the ring to the valve guide replacer 5-8840- Measure the valve thickness. If the measured value is 2628-0.
  • Page 830 W5-3-50 EX355 ENGINE OVERHAUL Valve Contact Width 3. Use a screwdriver (3) to pry the valve seat insert free. 1. Check the valve contact faces for roughness and Take care not to damage the cylinder head (4). unevenness. Make smooth the valve contact sur- faces.
  • Page 831 EX355 W5-3-51 ENGINE OVERHAUL • Correction NOTE: Use an adjustable valve cutter pilot. Do not allow the valve cutter pilot to wobble inside the valve 1. Remove the carbon from the valve seat insert guide. Check that valve depression is within the surface.
  • Page 832 W5-3-52 EX355 ENGINE OVERHAUL VALVE SPRING Valve Spring Free Height Use a vernier caliper to measure the valve spring free height. If the measured value is less than the specified limit, the valve spring must be replaced. Spring Free Height mm (in) Standard Limit...
  • Page 833 EX355 W5-3-53 ENGINE OVERHAUL Reassembly SM7111 1. Cylinder head 14. Idler gear cover 2. Oil seal 15. Gasket 3. Bridge guide 16. Thermostat 4. Nozzle sleeve 17. Water outlet pipe 5. Valve seat insert 18. Overheat warning switch 6. Valve guide 19.
  • Page 834 W5-3-54 EX355 ENGINE OVERHAUL 1. Use the oil seal installer 5-8840-2627-0 to install 2. Tighten the engine hangers to the specified the oil seals to the cylinder head. torque. Torque: 48 N•m (4.9 kgm/35 Ibft) SM7119 SM7140 3. Install the bridge guides to the cylinder head. 1.
  • Page 835 EX355 W5-3-55 ENGINE OVERHAUL 4. install the injection nozzle sleeves to the cylinder head. 1. Install the gasket (2) to the nozzle sleeve and apply engine oil. 2. Apply sealer to the tapered part (1) of the nozzle sleeve. LOCKTITE No. TL290 SM7143 5.
  • Page 836 W5-3-56 EX355 ENGINE OVERHAUL 2. Attach the valve guide replacer 5-8840-2628- 2. Install the valve springs with their fine pitched 0 to the valve guide. end (painted) facing down. 3. Use a hammer to drive the valve guide into Colored position from the cylinder head upper face.
  • Page 837 EX355 W5-3-57 ENGINE OVERHAUL 13. Install the idler gear C. 15. Install the thermostats to the cylinder head. 1. Apply engine oil to the idler gear shaft and 1. Install the thermostat gaskets (1) to the flange idler gear C bushing before installation. of thermostats.
  • Page 838 W5-3-58 EX355 ENGINE OVERHAUL 17. Install the exhaust manifold gaskets. Install the 18. Install the exhaust manifold to the cylinder head. gasket with the protruding part of the gasket 1. Install the three gas seal rings to the rear facing down. exhaust manifold.
  • Page 839 EX355 W5-3-59 ENGINE OVERHAUL 4. Install the distance tube (1) and washer (2) to 19. Install the intake cover with new gasket to the the stud bolts. cylinder head. 5. Install the distance tube (1), washer (2), and 1. Install the intake cover bolts with the distance distance nut to the stud bolt at the front side pipe and the mounting rubber.
  • Page 840 W5-3-60 EX355 ENGINE OVERHAUL 21. Install the bridge to the bridge guide. • Apply engine oil to the bridge. 22. Install the bridge cap to the bridge. • Apply engine oil to the bridge cap. SM7152...

  • Page 841: Crank Pulley And Flywheel

    EX355 W5-3-61 ENGINE OVERHAUL CRANK PULLEY AND FLYWHEEL Removal SM7153 Crank pulley Ring gear Damper Flywheel Crankshaft Washer...
  • Page 842 W5-3-62 EX355 ENGINE OVERHAUL 1. Remove the cooling fan. 2. Remove the fan belts. 3. Remove the crankshaft damper pulley from the crankshaft. • Block the crankshaft with a piece of hard wood to prevent the damper pulley from turning. •...
  • Page 843 EX355 W5-3-63 ENGINE OVERHAUL 3. Install the fan belts. 2. Inspect the crankshaft damper for cracking or 4. Adjust the fan belt tension. Refer to “Fan Belt separation. If any abnormality on the crankshaft inspection” in this manual. damper is found, inspect the crankshaft and the flywheel fixing bolts.
  • Page 844 W5-3-64 EX355 ENGINE OVERHAUL 3. Install the damper to the crankshaft pulley. SM7161 Diagonally tighten the damper fixing bolts to the specified torque. Torque: 48 N•m (4.9 kgm/35 Ibft)

  • Page 845: Timing Gears

    EX355 W5-3-65 ENGINE OVERHAUL TIMING GEARS Removal SM7162 Washer 8. Slinger Flywheel 9. Idler gear shaft A Cover 10. Idler gear A Idler gear D 11. Thrust collar Idler gear shaft D 12. Oil pump Flywheel housing 13. Idler gear B Oil seal 14.
  • Page 846 W5-3-66 EX355 ENGINE OVERHAUL 1. Remove the flywheel housing. Refer to “Flywheel Housing Removal” in this manual. 2. Measure the idler gear backlash. 1. Set a dial indicator to the idler gear. Hold both the gear to be checked and the adjoining gear stationary.
  • Page 847 EX355 W5-3-67 ENGINE OVERHAUL Inspection and Repair Installation Make the necessary adjustments, repairs, and part 1. Install the idler gear B shaft. replacements if excessive wear or damage is discov- 1. Install the idler gear B shaft to the cylinder ered during inspection.
  • Page 848 W5-3-68 EX355 ENGINE OVERHAUL 3. Install the oil pump to the cylinder block. 4. Install the oil pump to the cylinder body within 1. Carefully wipe any foreign material from the 15 minutes of sealant application. cylinder body rear surface. 5.
  • Page 849 EX355 W5-3-69 ENGINE OVERHAUL 3. Install the idler gear A (1) to the idler gear shaft. 2. Install the flywheel housing to the cylinder 4. Align the crankshaft gear (2) L mark and the block. Refer to “Flywheel Housing Installation” idler gear (1) 0 marks.

  • Page 850: Flywheel Housing

    W5-3-70 EX355 ENGINE OVERHAUL FLYWHEEL HOUSING Removal SM7177 Washer Idler gear shaft D Flywheel Flywheel housing Cover Oil seal Idler gear D Oil slinger...
  • Page 851 EX355 W5-3-71 ENGINE OVERHAUL 1. Remove the oil pan. 9. Use the slinger remover 894396-8580 to remove Refer to “Oil Pan Removal” in this manual. the slinger. 2. Loosen the flywheel fixing bolts to remove the Take care not to damage the crankshaft. flywheel.
  • Page 852 W5-3-72 EX355 ENGINE OVERHAUL Installation 2. Install the idler gear shaft to the cylinder block. 1. Apply engine oil to the idler gear shaft D. 2. Apply engine oil to the inside diameter and 1 Install the flywheel housing to the cylinder block. 1.
  • Page 853 EX355 W5-3-73 ENGINE OVERHAUL 4. Install the rear stinger using the oil seal installer 5. Use the oil seal installer 894396-8560 to install the 894396-8560. oil seal. 1. Install the stinger (1) to the end of adapter (2). Install the adapter to the crankshaft (3). NOTE: The rear stinger is gray and the front stinger is black.
  • Page 854 W5-3-74 EX355 ENGINE OVERHAUL 6. Install the flywheel and washer to the crankshaft. 7. Install the oil pan with new gasket to the cylinder block. 1. Block the crankshaft with a piece of hard wood Refer to “Oil Pan Installation” in this manual. to prevent the flywheel from turning.

  • Page 855: Oil Pan

    EX355 W5-3-75 ENGINE OVERHAUL OIL PAN Removal SM7187 Clip Oil strainer Oil pan Gasket Gasket...
  • Page 856 W5-3-76 EX355 ENGINE OVERHAUL 1. Remove the breather hose clip. 2. Apply a 3 mm bead of sealant (Three Bond 2. Loosen the fixing nuts and bolts to remove the oil No.1207C or equivalent) to the cylinder block and pan and gasket. flywheel housing fitting faces (1) and the crank- •...

  • Page 857: Front Cover

    EX355 W5-3-77 ENGINE OVERHAUL FRONT COVER Removal SM7191 Damper pulley Gasket Oil seal Slinger Adjusting plate Crankshaft Front plate Crankcase...
  • Page 858 W5-3-78 EX355 ENGINE OVERHAUL 1. Remove the water pump. 7. Use the slinger remover 8-94396-858-0 to remove Refer to “Water Pump Removal” in this manual. the slinger. 2. Remove the alternator. • Discard the removed oil seal and slinger. Refer to “Alternator Removal” to this manual. 3.
  • Page 859 EX355 W5-3-79 ENGINE OVERHAUL 4. Tighten the front cover bolts to the specified 3. After pressing in the slinger, make sure that the torque. distance between the crankshaft end surface and the slinger is the specified value.” Torque: 19 N•m (1.9 kgm/14 Ibft) Distance (A): 17.7 - 18.3 mm (0.70 - 18.3 in) NOTE: Be sure to replace the slinger and oil seal as a set.
  • Page 860 W5-3-80 EX355 ENGINE OVERHAUL 6. Install the water pump to the front plate. 5. Install the crankshaft damper pulley to the crank- shaft. Refer to “Water Pump Installation” in this manual. 1. Apply engine oil to the threads and setting 7.

  • Page 861: Piston

    EX355 W5-3-81 ENGINE OVERHAUL PISTON Removal SM7199 Bearing cap Bearings Bolt Piston with connecting rod...
  • Page 862 W5-3-82 EX355 ENGINE OVERHAUL 1. Remove the cylinder head assembly. Installation Refer to “Cylinder Head Removal” in this manual. 2. Remove the oil pan. 1. Install the piston with connecting rod. Refer to “Oil Pan Removal” in this manual. 1. Clean the piston in solvent to remove all 3.
  • Page 863 EX355 W5-3-83 ENGINE OVERHAUL 7. Position the piston head front mark (1) so that it 11. Apply molybdenum disulfide grease to the is facing the front of the engine. threads and setting faces of each connecting rod bolt. 12. Install the connecting rod bearing cap. NOTE: The connecting rod forging mark (projecting) 13.
  • Page 864 W5-3-84 EX355 ENGINE OVERHAUL Disassembly SM7207 Piston rings Connecting rod Snap ring Connecting rod cap Piston pin Bearings Piston...
  • Page 865 EX355 W5-3-85 ENGINE OVERHAUL 4. Remove the snap ring (1). Use a pair of snap ring pliers to remove the snap CAUTION rings. Do not bend or damage the oil jet. NOTE: When removing the piston and connection rod assembly, pull the connecting rod parallel to the cylinder bore.
  • Page 866 W5-3-86 EX355 ENGINE OVERHAUL PISTON RING AND PISTON RING GROOVE CLEARANCE 1. Visually inspect the piston ring grooves. If a piston ring groove is damaged or distorted, the piston must be replaced. 2. Use a feeler gauge (1) to measure the clearance between the piston ring and the piston ring groove at several points around the piston.
  • Page 867 EX355 W5-3-87 ENGINE OVERHAUL PISTON RING EXPANSION FORCE PISTON PIN HOLE AND PISTON PIN CLEAR- ANCE Use an expansion force gauge to measure the piston ring expansion force. Use a inside dial indicator to measure the piston pin hole (in the piston). Piston ring expansion force Piston pin hole and piston pin clearance ring:...
  • Page 868 W5-3-88 EX355 ENGINE OVERHAUL CONNECTING ROD ALIGNMENT CRANKSHAFT AND CONNECTING ROD BEAR- ING CLEARANCE Use a connecting rod aligner to measure the distor- tion and the parallelism between the connecting rod 1. Clean the crankshaft, connecting rod, bearing big end hole and the connecting rod small end hole. If cap, and bearings.
  • Page 869 EX355 W5-3-89 ENGINE OVERHAUL 7. If the clearance between the measured bearing PISTON AND LINER BORE CLEARANCE inside diameter and the crankpin exceeds the If the cylinder liner has been replaced, install the specified limit, the bearing and/or crankshaft must piston using service parts.
  • Page 870 W5-3-90 EX355 ENGINE OVERHAUL The grade mark is stamped on the top of the piston • Apply engine oil to the piston pin. installed at the factory, but service part pistons do not • Insert the piston pin to the connecting rod have any grade (single grade).
  • Page 871 EX355 W5-3-91 ENGINE OVERHAUL • Apply molybdenum disulfide grease to the two 4. Install the connecting rod bearing. piston skirts. This will facilitate smooth break-in Carefully wipe any oil or other foreign material when the engine is first started after reassembly. from the connecting rod bearing back faces and •...
  • Page 872 W5-3-92 EX355 ENGINE OVERHAUL • Align the connecting rod cap cylinder number marks and the connecting rod cylinder number marks. SM7206 • Install the connecting rod caps. • Apply molybdenum disulfide grease to the threads and setting faces of each connecting rod bolt.

  • Page 873: Crankshaft

    EX355 W5-3-93 ENGINE OVERHAUL CRANKSHAFT Removal SM7223 Crank pulley 8. Thrust bearings Oil seal 9. Thrust bearings Adjusting plate 10. Crank bearings Front cover 11. Crankshaft Gasket 12. Slinger Piston with connecting rod 13. Crankcase Connecting rod bearing...
  • Page 874 W5-3-94 EX355 ENGINE OVERHAUL Remove the cylinder head assembly. Refer to “Cylinder Head Removal” in this manual. Remove the oil pan. Refer to “Oil Pan Removal” in this manual. Remove the flywheel housing . Refer to “Flywheel Housing Removal” in this manual.
  • Page 875 EX355 W5-3-95 ENGINE OVERHAUL 3. Install the upper bearings to their original posi- tion, if they are reused. WARNING Compressed air can cause personal injury when used for cleaning. Wear safety glasses and protec- tive clothing. CAUTION Do not apply engine oil to the bearing back faces Installation and cylinder block bearing surfaces.
  • Page 876 W5-3-96 EX355 ENGINE OVERHAUL 3. Install the crankshaft to the cylinder block. 5. Install the lower side crankshaft thrust bearings. • Carefully wipe any foreign material from the 1. Apply engine oil to the thrust bearing oil crankshaft. grooves before installation. •...
  • Page 877 EX355 W5-3-97 ENGINE OVERHAUL 3. Apply engine oil to the lower bearing sliding 6. Tighten the crankcase M14 bolts in three steps surfaces. using the angular tightening method. 4. Apply unbroken strips of ThreeBond 1207C or Torque: equivalent to the lower face of the cylinder Step: 98 N•m (10 kgm/72 Ibft) block as shown in the illustration.
  • Page 878 W5-3-98 EX355 ENGINE OVERHAUL 7. Install the piston with the connecting rod. Refer to “Piston Installation” in this manual. 8. Install the timing gears to the cylinder block. Refer to “Timing Gear installation” in this manual. 9. Install the flywheel housing to the cylinder block. Refer to “Flywheel Housing Installation”...
  • Page 879 EX355 W5-3-99 ENGINE OVERHAUL Disassembly SM7239 Crankshaft Crankshaft gear 1. Use the crankshaft gear remover 8-94396-818-0 to remove the crankshaft gear. NOTE: Do not remove the crankshaft gear from the crankshaft unless the gear is damaged. SM7240...
  • Page 880 W5-3-100 EX355 ENGINE OVERHAUL Inspection and Repair CRANKSHAFT RUN-OUT 1. Set a dial indicator to the center of the No.4 Make the necessary adjustments, repairs, and part crankshaft journal. replacements if excessive wear or damage is discov- 2. Gently turn the crankshaft in the normal direction ered during inspection.
  • Page 881 EX355 W5-3-101 ENGINE OVERHAUL CRANKSHAFT JOURNAL AND CRANKPIN DIAM- 4. Tighten the lower crankcase M14 bolts in three ETER steps using the angular tightening method. 1. Use a micrometer to measure the crankshaft Torque: journal diameter across points (1) - (1) and (2) - (2). step: 98 N•m (10 kgm/72 Ibft) 2.
  • Page 882 W5-3-102 EX355 ENGINE OVERHAUL CRANKSHAFT JOURNAL AND BEARING CLEAR- CRANKSHAFT TUFFTRIDING INSPECTION ANCE • Use an organic cleaner to thoroughly clean the If the clearance between the measured bearing inside crankshaft. There must be no oil on the crankshaft. diameter and the crankshaft journal diameter ex- •...
  • Page 883 EX355 W5-3-103 ENGINE OVERHAUL Reassembly SM7239 Crankshaft Crankshaft gear...
  • Page 884 W5-3-104 EX355 ENGINE OVERHAUL 1. Install the crankshaft gear to the crankshaft (if necessary). 1. Install the crankshaft timing gear alignment pin. 2. Heat the crankshaft gear evenly with a gas burner to invite thermal expansion. Do not allow the temperature of the gas burner to exceed 180 °C (356 °F).

  • Page 885: Cylinder Block

    EX355 W5-3-105 ENGINE OVERHAUL CYLINDER BLOCK Removal SM7248 Oil pressure switch Cylinder liner Crankcase Cylinder block Oil jet...
  • Page 886 W5-3-106 EX355 ENGINE OVERHAUL 1. Remove the turbocharger. 6. Install the flywheel to the crankshaft. Refer to “Turbocharger Removal” in this manual. Refer to “Crank Pulley and Flywheel Installation” 2. Remove the water pump. in this manual. Refer to “Water Pump Removal” in this manual. 7.
  • Page 887 EX355 W5-3-107 ENGINE OVERHAUL Disassembly SM7248 Oil pressure switch Cylinder liner Crankcase Cylinder block Oil jet...
  • Page 888 W5-3-108 EX355 ENGINE OVERHAUL 1. Remove the lower crankcase. Inspection and Repair • Loosen the fixing bolts to disassemble the lower Make the necessary adjustment, repairs, and part crankcase. replacements if excessive wear or damage is discov- • Place the crankcase on a flat piece of wool. ered during inspection.
  • Page 889 EX355 W5-3-109 ENGINE OVERHAUL • Apply water under pressure to the cylinder body water jacket to check for leakages. Water Pressure: 490 kPa (5 kg/cm /70 psi) If water leakage is found, the cylinder block must be replaced. CYLINDER LINER GRADE SELECTION AND STANDARD FITTING INTERFERENCE Accurately measured fitting interference and proper cylinder liner grade selection are extremely impor-...
  • Page 890 W5-3-110 EX355 ENGINE OVERHAUL CYLINDER BORE MEASUREMENT OIL JET If the marking is not clear, measure the cylinder bore Check the oil port on the oil jet for clogging. inside diameter. • Use a cylinder bore dial indicator to measure the cylinder bore in the thrust and axial direction of the crankshaft.
  • Page 891 EX355 W5-3-111 ENGINE OVERHAUL Reassembly SM7248 Oil pressure switch Cylinder liner Crankcase Cylinder block Oil jet...
  • Page 892 W5-3-112 EX355 ENGINE OVERHAUL 1. Install the cylinder liner to the cylinder block. • Use new kerosene or diesel fuel to thoroughly clean the cylinder liner and bore • Use compressed air to blow-dry the cylinder liner and bore surface. WARNING Compressed air can cause personal injury when used for cleaning.
  • Page 893 EX355 W5-3-113 ENGINE OVERHAUL 5. Install the oil pressure switch. • Install the adapter (1) to the cylinder block and tighten to the specified torque. • Install the oil pressure switch (2). Torque: Adapter: 118 N•m (12.0 kgm/87 Ibft) Oil pressure switch: 18 N•m (1.8 kgm/13 Ibft) Sealant SM7259...
  • Page 894 W5-3-114 EX355 ENGINE OVERHAUL NOTE...

  • Page 895: Engine Lubrication

    EX355 W5-4-1 ENGINE LUBRICATION SERVICE PRECAUTION GENERAL DESCRIPTION • Be sure to use the correct fastener in the proper Lubricating Oil Flow location. If a used fastener is replaced with a new one, the new fastener must be identical to The engine uses a pressure-feed lubrication system.
  • Page 896 W5-4-2 EX355 ENGINE LUBRICATION Lubricating Oil Flow Oil Filter Starter Battery Switch Oil Pressure Indicator Light Oil Cooler Main Oil Sub Oil Gallery Main Oil Gallery Filter Combined Type Camshaft Crank Check Idler Idler Idler Partial Bearing Shaft Valve Gear A Gear B Gear C Oil Filter...

  • Page 897: Oil Pump

    EX355 W5-4-3 ENGINE LUBRICATION OIL PUMP SM7261 Oil pump drive gear Cotter pin Oil pump body Drive gear Oil relief valve Driven gear and shaft...
  • Page 898 W5-4-4 EX355 ENGINE LUBRICATION Disassembly 4. Remove the oil pump drive gear. Use a gear puller to remove the oil pump drive 1. Remove the driven gear and shaft. gear. SM7262 SM7264 2. Remove the cotter pin. Inspection and Repair 3.
  • Page 899 EX355 W5-4-5 ENGINE LUBRICATION 2. Use a feeler gauge to measure the clearance 4. Use an inside dial indicator or inside micrometer to between the body and the gear side surfaces. measure the pump body inside diameter and the If the clearance between the gears and the body cylinder block bushing inside diameter.
  • Page 900 W5-4-6 EX355 ENGINE LUBRICATION 6. Use an inside and outside micrometer to measure Reassembly the interference between the oil pump drive gear inside diameter and drive gear shaft outside diam- 1. Install the drive gear and oil pump drive gear. eter.

  • Page 901: Oil Cooler

    EX355 W5-4-7 ENGINE LUBRICATION OIL COOLER Disassembly SM7273 Oil cooler element Plug Gasket Oil thermostat Gasket Bypass pipe Body...
  • Page 902 W5-4-8 EX355 ENGINE LUBRICATION 1. Loosen the fixing nuts to remove the element. Inspection and Repair Discard the gaskets. 2. Remove the bypass pipe. 1. Use the dye penetrant detector procedure to in- 3. Remove the oil thermostat. spect the element for cracking. 4.
  • Page 903 EX355 W5-4-9 ENGINE LUBRICATION 4. Install the oil cooler element with new gasket to the body. 5. Tighten the element fixing nuts to the specified torque. Torque: 20 N•m (2.0 kgm/14 Ibft) SM7277...

  • Page 904: Oil Filter

    W5-4-10 EX355 ENGINE LUBRICATION OIL FILTER SM7280 Oil filter Oil filter body By-pass valve Gaskets Gasket Gasket...
  • Page 905 EX355 W5-4-11 ENGINE LUBRICATION Disassembly 2. Inspect the oil filter. • Inspect the orifice of the partial oil filter for 1. Use the filter wrench 1-85221-097-0 to remove the restriction. oil filter. • Supply compression air to the orifice (indicated by a arrow).
  • Page 906 W5-4-12 EX355 ENGINE LUBRICATION 2. Install the by-pass valve with new gasket to the filter body. • Tighten the valve to the specified torque. Torque: 37 N•m (3.8 kgm/27 Ibft) SM7285 3. Install the oil filter to the oil filter body. •...

  • Page 907: Engine Cooling

    EX355 W5-5-1 ENGINE COOLING SERVICE PRECAUTION GENERAL DESCRIPTION • Be sure to use the correct fastener in the proper location. If a used fastener is replaced with a new Coolant Flow one, the new fastener must be identical to the previous one.

  • Page 908: Thermostat

    W5-5-2 EX355 ENGINE COOLING THERMOSTAT Disassembly SM7287 Water outlet pipe Gaskets Thermostats...
  • Page 909 EX355 W5-5-3 ENGINE COOLING 1. Loosen the fixing bolts to remove the water outlet pipe. Discard the gaskets. Stirring rod 2. Remove the thermostats. Inspection and Repair Make necessary adjustment, repairs, and part re- placements if excessive wear or damage is discov- ered during inspection.
  • Page 910 W5-5-4 EX355 ENGINE COOLING 2. Install new gaskets. 3. Install the water outlet pipe. 4. Tighten the fixing bolts to the specified torque. Torque: 19 N•m (1.9 kg/14 Ibft) SM7291...

  • Page 911: Water Pump

    EX355 W5-5-5 ENGINE COOLING WATER PUMP Disassembly SM7292 Center 9. Shaft Dust cover 10. Water pump body Snap ring 11. Dowel pin Bearing 12. Seal unit Bearing 13. Impeller Spacer 14. Gasket Bearing 15. Cover Washer 16. Bolt...
  • Page 912 W5-5-6 EX355 ENGINE COOLING 1. Remove the rear cover from the water pump body. Inspection and Repair 2. Use a remover to remove the impeller from the water pump. Make the necessary adjustments, repairs and part 3. Use a puller to remove the water pump center. replacements if excessive wear or damage is discov- 4.
  • Page 913 EX355 W5-5-7 ENGINE COOLING 2. Carefully wipe away any bearing grease. 4. Use a bench press to gradually press the water 3. Listen for excessive bearing operating noise. pump shaft down until the bearings are seated correctly. SM7297 SM7294 Excessive bearing operating noise indicates se- 2.
  • Page 914 W5-5-8 EX355 ENGINE COOLING 3. Position the pump shaft with bearings to the 4. Install the seal unit to the water pump body. water pump body. • Press in the seal unit to the specified position 4. Use a bench press to gradually press the water using bench press...

  • Page 915: Engine Fuel

    EX355 W5-6-1 ENGINE FUEL SERVICE PRECAUTION GENERAL DESCRIPTION • Be sure to use the correct fastener in the proper Fuel System Operation location. If a used fastener is replaced with a new one, the new fastener must be identical to The fuel injection pump is driven by the crankshaft.
  • Page 916 W5-6-2 EX355 ENGINE FUEL Fuel Flow SM7304 Fuel system components The fuel system consists of the fuel tank, the fuel feed Open the drain plug at the bottom of the sedimentor pump, the water sedimentor, the fuel filter, the injec- to drain the water.
  • Page 917 EX355 W5-6-3 ENGINE FUEL INJECTION PUMP Major injection pump components are the pump body, the plungers, the governor, and the timing advancer. The injection pump is the nucleus of the diesel engine fuel system. It pressurizes and delivers precisely timed and measured fuel charges to the engine cylin- ders.

  • Page 918: Fuel Filter

    W5-6-4 EX355 ENGINE FUEL FUEL FILTER Disassembly SM7305 Fuel filter Fuel filter body Overflow valve...
  • Page 919 EX355 W5-6-5 ENGINE FUEL Reassembly 1. Remove the fuel filter with a filter wrench. 1. Install the overflow valve to the fuel filter body. 2. Install the fuel filter. CAUTION • Before installating a new fuel filter, apply fuel to Be careful not to spill the fuel remaining in the fuel the gasket.
  • Page 920 W5-6-6 EX355 ENGINE FUEL INJECTION NOZZLE SM7308 Retaining nut 9. Adjusting shim Nozzle 10. 2 spring 11. Collar Spacer 12. Spring seat 13. 1 spring Lift piece 14. Adjusting shim Spring seat 15. Nozzle holder body Push rod...
  • Page 921 EX355 W5-6-7 ENGINE FUEL Disassembly Reassembly The 2-spring nozzle reduces nitrogen oxide NOx and 1. Place the nozzle holder in a vise. particulate exhaust gas emissions. 2. Install the adjusting shim (1), 1 spring (2), and 1. Use a wire brush to remove carbon deposits from spring seat (3).
  • Page 922 W5-6-8 EX355 ENGINE FUEL 4. Install the pins (1), lift piece (2), and spacer (3). 7. Hand-tighten the adjustment retaining nut to- gether with the gasket to the nozzle holder. Retaining nut: 157892-4000 (ZEXEL) Gasket: 157892-1500 (ZEXEL) Retaining nut Nozzle (Special tool) Gasket SM7312...
  • Page 923 EX355 W5-6-9 ENGINE FUEL 9. Set the nozzle holder to the nozzle tester. FULL NEEDLE VALVE LIFT CONFIRMATION 10. Operate the nozzle tester. Measure the first 1. Install the gasket (1) and plug (2) to the adjustment nozzle opening pressure. retaining nut.
  • Page 924 W5-6-10 EX355 ENGINE FUEL 3. Install the nut (1) to the dial gauge holder (2). Nut: 1578921000 (ZEXEL) SM7320 4. Install the pin to the dial gauge. NOTE: Pin lengths of the pins do not include the threaded portions. Pin ( l = 60 mm): 157892-5300 (ZEXEL) Dial gauge: 157892-3800 (ZEXEL) SM7322...
  • Page 925 EX355 W5-6-11 ENGINE FUEL 6. Set the nozzle holder to the nozzle tester and zero PRE-LIFT CONFIRMATION the dial gauge. 1. With the needle valve at full lift, release the nozzle 7. Operate the nozzle tester to bleed any air from tester handle.
  • Page 926 W5-6-12 EX355 ENGINE FUEL PRE-LIFT MEASURING POINT 3. Confirm that pre-lift ‘L’ is as specified. Read the dial gauge at first nozzle opening pressure Pre-lift: 0.05 mm (0.0020 in) (approx 1 MPa (10 kg/cm /140 psi). 4. If pre-lift is not as specified, replace the pin, lift piece, spacer, and nozzle assembly as a set with the service kit.
  • Page 927 EX355 W5-6-13 ENGINE FUEL 34.3~44.1MPa nozzle {350~450 kgf/cm opening pressure Pressure gauge In-line pressure SM7329 SM7331 2. Release the nozzle tester handle so that in-line SECOND NOZZLE OPENING PRESSURE AD- pressure decreases. JUSTMENT If the second nozzle opening pressure is not as specified, disassemble the nozzle holder and remove NOTE: The in-line pressure will decrease and needle the shim.
  • Page 928 W5-6-14 EX355 ENGINE FUEL FINAL INSPECTION Remove the dial gauge, nut, and dial gauge holder. Dial gauge Dial gauge holder SM7311 1. Collar 2. 2 spring SM7333 3. Adjusting shim 4. Spring seat 5. Push rod Remove the retaining nut and gasket. SM7315 SM7332 Install but do not tighten the original retaining nut.
  • Page 929 EX355 W5-6-15 ENGINE FUEL 7. Set the nozzle holder to the nozzle tester. 8. Check the 1 nozzle opening pressure. 9. Check the spray condition. 10. Check for oil leakage. CAUTION The nozzle, lift piece, pins, and spacers must be replaced as a set (nozzle service kit).

  • Page 930: Injection Nozzle Holder

    W5-6-16 EX355 ENGINE FUEL INJECTION PUMP Identification Use the injection pump assembly number (stamped on the plate at the side of the pump) to determine the applicable injection pump calibration data (refer to the following page). If the applicable calibration data is not listed in this Manual, contact the manufacturer’s nearest author- ized service facility (Bosch Automotive System Cor- poration or Robert Bosch GMBH).
  • Page 931 EX355 W5-6-17 ENGINE FUEL INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM Injection Pump Assembly Number ISUZU No. ZEXEL No. Remarks ISUZU No. ZEXEL No. Remarks 1-15603-334-1 106671-6451 Injection Volume Control rack Pump speed Injection volume Variance Boost pressure Remarks position (mm) (min /1,000 strokes) (kPa)
  • Page 932 W5-6-18 EX355 ENGINE FUEL GOVERNOR PERFORMANCE RACK LIMIT IDLING SUB SPRING SET BOOST COMPENSATOR STROKE; 0.7±0.1 mm GOVERNOR SPRING SET BOOST COMPENSATOR ADJUSTING SPEED 550min 360mmHg 1102,5mmHg BOOST PRESSURE (kPa) SM7335 SPEED CONTROL LEVER AND STOP LEVER SPEED LEVER STOP LEVER FULL SPEED STOP STOP...
  • Page 933 EX355 W5-7-1 ENGINE INDUCTION SERVICE PRECAUTION TURBOCHARGER • Be sure to use the correct fastener in the proper General Description location. If a used fastener is replaced with a new one, the new fastener must be identical to Major turbocharger components are the center hous- the previous one.
  • Page 934 W5-7-2 EX355 ENGINE INDUCTION Identification Turbocharger Servicing The turbocharger name plate gives the date of manu- 1. Refer to TROUBLESHOOTING in this Section to facturer and other important information required to determine whether or not turbocharger repair or identify the unit when service inquiries are made. overhaul is required.
  • Page 935 EX355 W5-7-3 ENGINE INDUCTION Troubleshooting If the engine does not run well (insufficient output or irregular acceleration) - 1. Run the engine at idle. 2. Check for oil leakage from the turbocharger. 3. Listen for abnormal turbocharger noise. 4. Write down any abnormal conditions and their location. 5.
  • Page 936 W5-7-4 EX355 ENGINE INDUCTION Disconnect the air inlet hose at the turbocharger to perform the following inspection. Checkpoint Problem Countermesure Oil on air inlet inside and outside Air inlet Turbocharger OK surfaces resulting from oil leakage Loose or missing Shaft end nuts Foreign particles in turbocharger or blades Bearing abrasion...
  • Page 937 Limit: 0.205 mm (0.00807 in) be adjusted, repaired, or replaced. Contact your near- est FIAT KOBELCO Dealer to make arrangements If the measured value exceeds the specified limit, the for servicing. rotor shaft must be replaced.
  • Page 938 W5-7-6 EX355 ENGINE INDUCTION NOTE...

  • Page 939: Service Precautions

    EX355 W5-8-1 STARTING AND CHARGING SERVICE PRECAUTION ALTERNATOR • Be sure to use the correct fastener in the proper General Description location. If a used fastener is replaced with a new one, the new fastener must be identical to The engine uses a brushless alternator. Main alterna- the previous one.
  • Page 940 W5-8-2 EX355 STARTING AND CHARGING SM7342 Rear bracket 6. Rotor IC regulator 7. Bearing Bearing 8. Pulley Rectifier 9. Front bracket Stator 10. Field coil assembly...
  • Page 941 EX355 W5-8-3 STARTING AND CHARGING Main Data and Specifications Isuzu Part No. 181200-5902 Manufacturer’s code No. (MITSUBISHI) A004T05485 Rated voltage Rated output Rated speed (min 5000 Rated output (Amp./Volt/min 50/27/5000 No-load output at 0 Amp. (Volt/min 24/900 Direction of rotation as viewed Clockwise from pulley side Ground polarity...
  • Page 942 W5-8-4 EX355 STARTING AND CHARGING Disassembly SM7344 IC regulator Terminal stud Side entry terminal Side entry terminal (Terminal B) Terminal stud Rectifier assembly Tube...
  • Page 943 EX355 W5-8-5 STARTING AND CHARGING Scratch setting marks between the front and rear brackets and the alternator body (2 locations). This will ensure installation to its original position. Remove the 4 through bolts. Use the blade of a screwdriver to pry the front bracket and the stator apart.
  • Page 944 W5-8-6 EX355 STARTING AND CHARGING Inspections and Repair ROTOR 1. Turn the rotor. Listen for bearing noise (a scraping STATOR sound). Feel for rough rotation. Replace the rotor 1. Check the stator for damage, loose connections, if either of these conditions is present. and discolored windings.
  • Page 945 EX355 W5-8-7 STARTING AND CHARGING 3. Check the diode trio for continuity in both direc- • Bracket, rotor, and stator reassembly is difficult tions. If there is continuity and/or an open circuit in because of the tight fit of the components. To make both directions, the rectifier must be replaced.
  • Page 946 W5-8-8 EX355 STARTING AND CHARGING Bench testing CURRENT OUTPUT 1. Operate the alternator at minimum speed. Perform bench tests on the reassembled alternator. 2. Close switch 1. Check that the lamp lights. 3. Set the load resistor to its maximum resistance VOLTAGE REGULATION (minimum current).
  • Page 947 EX355 W5-8-9 STARTING AND CHARGING Troubleshooting Condition Possible Cause Correction No output Bad terminal connection Repair Open or shorted circuit Repair Open field coil Replace Defective diode Replace Defective IC regulator Replace Low output Loose terminal connection Tighten Loose cooling fan belt Adjust belt tension Defective diode Replace...

  • Page 948: Starter Motor

    W5-8-10 EX355 STARTING AND CHARGING STARTER MOTOR General Description SM7352 The starter motor has a reduction gear assembly that uses planetary gears. Identification MITSUBISHI starter motor is identified by the name plate attached to the yoke (illustration). Manufacturer’s type Isuzu part number Bar code NOTE: Always check the identification number be- fore beginning a service operation.
  • Page 949 EX355 W5-8-11 STARTING AND CHARGING Main Data and Specifictions Isuzu Part No. 181100-4140 Mitsubishi code No. M008T60971 Rated voltage Rated output Rating Direction of rotation Clockwise (Viewed from the pinion side) Terminal voltage (No load) Minimum current (No load) Starter motor minimum operating speed 3300 (No load) Pinion gear...
  • Page 950 W5-8-12 EX355 STARTING AND CHARGING Disassembly SM7354 1. Snap ring 15. Ball 2. Stop ring 16. Gasket 3. Pinion 17. Plate 4. Pinion spring 18. Armature 5. Screw 19. Washer 6. Pinion case 20. Bearing 7. Lever 21. Gasket 8. Magnetic switch 22.
  • Page 951 EX355 W5-8-13 STARTING AND CHARGING Place matching marks on the magnetic switch and yoke to ensure reassembly to their original positions. Connect the starter motor to a battery. The pinion rises and begins to rotate. Open switch-2 to stop pinion rotation. SM7356 Pinion Clutch shaft...
  • Page 952 W5-8-14 EX355 STARTING AND CHARGING 3. Measure the commutator outside diameter. Inspection and Repair 4. If the measured diameter is less than the specified ARMATURE limit, the commutator must be replaced. Commutator outside diameter 1. Use a circuit tester to check armature continuity. Hold the circuit tester probes against 2 commuta- Standard: 32 mm (1.28 in) tor segments.
  • Page 953 EX355 W5-8-15 STARTING AND CHARGING 7. Inspect the gear for excessive wear and damage. BRUSH AND BRUSH HOLDER Replace if required. 1. Measure the brush length. If the brush length is 8. Rotate the commutator with your hand. Listen for less than the specified limit, the brush and/or yoke abnormal noise or rattling from the bearing.
  • Page 954 W5-8-16 EX355 STARTING AND CHARGING OVERRUNNING CLUTCH AND PINION MAGNETIC SWITCH 1. Wipe away dirt and grime adhering to the 1. Use a circuit tester to check for continuity between overrunning clutch and pinion. the magnetic switch terminal-M (1) and the body 2.
  • Page 955 EX355 W5-8-17 STARTING AND CHARGING SM7366 • Tighten the fixing bolts to the specified torque. ARMATURE SHAFT AXIAL PLAY Torque Install the ball to the top of the armature shaft. No adjustment is required. Nut (1) : 23 N•m (2.3 kgm/17 Ibft) Bolt (2) : 6.8 N•m (0.7 kgm/5.1 Ibft) GEAR SHAFT AXIAL PLAY Bolt (3) : 9.8 N•m (1.0 kgm/7.2 Ibft)
  • Page 956 W5-8-18 EX355 STARTING AND CHARGING PINION PROJECTION 1. Connect the starter motor to the battery. 2. Turn switch-1 and switch-2 on. The pinion moves forward to the cranking position and the armature rotates. 3. Turn switch-2 off. The armature stops rotating. 4.
  • Page 957 EX355 W5-8-19 STARTING AND CHARGING OVERRUNNING CLUTCH SHAFT RETURN 2. Turn the switch on. Press against the head of the overrunning clutch with 3. Measure the starter motor speed, the current, and your hand. Measure the movement (return) of the the voltage.
  • Page 958 W5-8-20 EX355 STARTING AND CHARGING NOTE...

  • Page 959: Troubleshooting

    EX355 W5-9-1 TROUBLESHOOTING HARD STARTING Condition Possible Cause Correction Starter motor does not Loose battery cable terminals turn over Poor battery connections due to rusting Clean and/or retighten the battery cable terminals Battery discharged or weak Recharge or replace the battery Fusible link shorted Replace the fusible link Defective starter switch or starter relay...

  • Page 960: Unstable Idling

    W5-9-2 EX355 TROUBLESHOOTING UNSTABLE IDLING Condition Possible Cause Correction Trouble in the engin Poor return of the engine stop button Completely return the engine stop stop mechanism button Trouble in the fuel Fuel system leakage or blockage Repair or replace the fuel system system Air in the fuel system Bleed the air from the fuel system...

  • Page 961: Insufficient Power

    EX355 W5-9-3 TROUBLESHOOTING INSUFFICIENT POWER Condition Possible Cause Correction Trouble in the air Clogged air cleaner element Clean or replace the air cleaner intake system element Trouble in the fuel Water particles in fuel system Replace fuel system Clogged fuel filter element Replace the fuel filter element or cartridge Clogged strainer or defective fuel feed...

  • Page 962: Excessive Fuel Consumption

    W5-9-4 EX355 TROUBLESHOOTING EXCESSIVE FUEL CONSUMPTION Condition Possible Cause Correction Trouble in the fuel Fuel leakage Repair or replace the fuel system system related parts Injection nozzle starting pressure too Adjust or replace the injection nozzle Improper spray condition Adjust or replace the injection nozzle Injection timing improperly adjusted Adjust the injection timing...

  • Page 963: Engine Cooling Trouble

    EX355 W5-9-5 TROUBLESHOOTING ENGINE COOLING TROUBLE Condition Possible Cause Correction Overheating Insufficient coolant Replenish coolant Defective pressure cap or clogged Replace the radiator pressure cap or radiator core clean radiator core Defective water pump Repair or replace the water pump Defective sealing cap resulting in the Replace the sealing cap cooling water leakage...

  • Page 964: Lubrication Problems

    W5-9-6 EX355 TROUBLESHOOTING LUBRICATION PROBLEMS Condition Possible Cause Correction Oil pressure does not Improper engine oil viscosity Replace the engine oil rise Insufficient engine oil Add engine oil Defective oil pressure gauge or unit Repair or replace the oil pressure gauge or unit Clogged oil filter element Replace the oil filter element or...

  • Page 965: Abnormal Engine Noise

    EX355 W5-9-7 TROUBLESHOOTING ABNORMAL ENGINE NOISE Start the engine and allow it to warm up before beginning the troubleshooting procedure. Condition Possible Cause Correction Engine knocking Use of wrong fuel Use correct fuel Fuel injection timing improperly Adjust the injection timing adjusted Improper injection nozzle starting Adjust or replace the injection nozzle...

  • Page 966: Alternator

    W5-9-8 EX355 TROUBLESHOOTING ALTERNATOR Condition Possible Cause Correction Battery dead Loose alternator drive belt Adjust Low battery fluid Replenish Defective battery terminals Replace Blown fuse Replace Poor contact between the fuse holder Repair and fuse Low battery fluid specific gravity Adjust Broken or poorly connected starter Repair...

  • Page 967: Starter Motor

    EX355 W5-9-9 TROUBLESHOOTING STARTER MOTOR Condition Possible Cause Correction Starter and magnetic Low battery fluid level Replenish switch does not operate Low battery specific gravity Recharge or replace Poor battery switch contacts Replace Defective starter switch Replace Defective magnetic switch pull-in coil Replace and plunger Broken armature coil...

  • Page 968: Turbocharger

    W5-9-10 EX355 TROUBLESHOOTING TURBOCHARGER Condition Possible Cause Correction Engine has less than Restricted air cleaner Clean or replace normal power Restricted intake pipe and hose Clean or replace Loose connection of the turbocharger Repair inlet and outlet Restricted exhaust and silencers Repair Restricted air breather Clean or replace...

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