FIAT KOBELCO Ex255t Service Manual PDF

EX255-EX285 Tier2
TECHNICAL MANUAL - OPERATIONAL PRINCIPLE

TECHNICAL MANUAL- TROUBLESHOOTING
WORKSHOP MANUAL EXCAVATOR
WORKSHOP MANUAL ENGINE
EXCAVATOR
TECHNICAL MANUAL
OPERATIONAL PRINCIPLE
(Tier 2)
All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication.
The right is reserved to make changes at any time without notice.
FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.

FORM No. 604.13.191 - Edition - July 2002
ENGINEERING
COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.

Documentation Centre
Strada di Settimo, 323 - S. MAURO T.SE ( TO ) ITALY
Reproduction of text or illustrations,

in whole or in part, is strictly prohibited
Print No. 604.13.191 - VII - 2002

Printed by Satiz - Turin (Italy)
Coordinamento Editoriale Satiz - Torino
EX255-EX285
IN-1
INTRODUCTION
TO THE READER
This manual is written for an experienced technician to provide technical information needed to
maintain and repair this machine.
- Be sure to thoroughly read this manual for correct
information concerning the service procedures.
- If you have any questions or comments, or if you

found any errors regarding the contents of this
manual, please contact:
FIAT KOBELCO CONSTRUCTION
MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALY
PRODUCT SUPPORT
Fax. ++39 011 6877357
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition
to this service manual:
- Operation and Maintenance Instruction
Manual
- Parts Catalog
SERVICE MANUAL COMPOSITION

The complete service manual consists of three
books:
- Technical Manual - Operational Principle
- Technical Manual - Troubleshooting
- Workshop Manual
- The Workshop Manual includes information needed

for maintenance and repair of the machine, tools and
devices needed for maintenance and repair, maintenance standards, removal/installation and assembly/disassembly procedures.
- The Technical Manual-Operational Principle includes the technical information concerning the
operation of main devices and systems.
The Service Manual for EX255 and EX285 Excavators consists of the following book/print numbers:
- The Technical Manual -Troubleshooting includes

the technical information needed for operational
performance tests, and troubleshooting procedures.
BOOK
PRINT NUMBER
604.13.191
604.13.196
- Workshop Manual
604.13.201
IN-2
EX255-EX285
INTRODUCTION
PAGE NUMBER
Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:
Example: T 1-2-3
Consecutive page number for each group
Group number (if exist)
Section number
T : Technical Manual
W : Workshop Manual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for
personal injury or machine damage.
This is the safety alert symbol.

When you see this symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed along with the safety alert symbol.
The safety alert symbol is also used to draw attentio in to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy
parts.
UNITS USED
SI Units (International System of Units) are used in this manual.
MKSA system units and English units are also indicated in parentheses just behinds SI units.
Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system units is shown below for reference purposes.
Quantity
To
convert
from (SI)
Into
(Others)
Multiply by
Quantity
To
convert
from (SI)
Into
(Others)
Multiply by
Lenght
mm
in
0.03937
Pressure
MPa
kgf/cm2
10.197
mm
ft
0.003281
MPa
psi
145.0
US gal
0.2642
kW
CV-PS
1.360
US qt
1.057
kW
HP
1.341
m3
yd
1.308
Temperature
C x 1.8 + 32
Velocity
Volume
Mass
kg
lb
2.205
Force
kgf
0.10197
lbf
0.2248
N.m
kgf.m
0.10197
N.m
lbf.ft
0.7375
Torque
Power
Flow rate
km/h
mph
0.6214
min-1
rpm
1.0
L/min
US gpm
0.2642
mL/rev
Cc/rev
1.0
TECHNICAL MANUAL
EX255-EX285
OPERATIONAL PRINCIPLE
SECTION AND GROUP CONTENTS
Section 1 -
GENERAL
Group 1
Group 2
Specifications
Component Layout
Section 2 -
SYSTEM
Group 1
Group 2
Group 3
Control System
Hydraulic System
Electrical System
Section 3 -
COMPONENT OPERATION
Group
Group
Group
Group
Group
Group
Group
Pump Device
Swing Device
Control Valve
Pilot Valve
Travel Device
Other components (Upperstructure)
Other components (Undercarriage)
1
2
3
4
5
6
7
SECTION 1
EX255-EX285
GENERAL
CONTENTS
Group 1 -
Specification
EX255 Excavator Dimensions ............. T1-1-1

EX285 Excavator Dimensions ............. T1-1-3
EX255 Excavator performance ............ T1-1-5
- Engine Data ....................................... T1-1-5
- Engine Accessory .............................. T1-1-6
- Hydraulic Devices .............................. T1-1-6
- Electrical Equipment .......................... T1-1-7
EX285 Excavator performance ............ T1-1-8
- Engine Data ....................................... T1-1-8
- Engine Accessory .............................. T1-1-9
- Hydraulic Devices .............................. T1-1-9
- Electrical Equipment .......................... T1-1-10
Group 2 -
Component layout
Main Components ................................ T1-2-1

Electrical System
(overall system) ................................... T1-2-2
Electrical System (cab) ........................ T1-2-3
Electrical System
(monitor and switch panels) ................. T1-2-5
Electrical System
(batteries compartment) ....................... T1-2-6
Electrical System (fuses) ..................... T1-2-7
Pump and related parts ........................ T1-2-8
Other Components ............................... T1-2-9
EX255-EX285
EX255
T1-1-1
SPECIFICATIONS
EX255 EXCAVATOR DIMENSIONS
(Monoblock Version)
E
G
D/D'
F
C
L
M
A
B
OM0253
VERSIONS
D (*)
3 463
4 260
1 090
2 950
2 937
10 170 1) 3 206 2 815
EX255 EL (mm) 3 845
4 642
1 090
2 950
2 937
10 170
EX255 LC
4 642
1 090
2 950
2 937
EX255
(mm)
3 845
F
(**)
2 940
960
460
2 815
2 940
960
460
10 170 4) 3 204 2 815
2 940
960
460
2) 3 237
3) 2 991
(mm)
(*) Rear swing radius
(**) Arm: 1) 2158 mm, 2) 2480 mm, 3) 2950 mm, 4) 3600 mm
EX255
EX255 EL
EX255 LC
M-Track shoe width
(mm)
600
700
800
900
600
700
800
900
600
700
800
900
N-Maximum width
(mm)
2 990
3 090
3 190
3 290
2 990
3 090
3 190
3 290
3 190
3 290
3 390
3 490
24 500 24 750 25 000 25 250 25 000 25 300 25 600 25 900 25 100 25 400 25 700
26 000
Working weight
Spec. Ground Press.
(kg)
(bar)
0.54
0.47
0.41
0.36
0.51
0.44
0.39
0.35
0.51
0.44
0.39
0.35
DIGGING DATA
6 000 mm Boom
OM0254
Arm
mm
2 158
2 480 2 950
3 600
mm
9 650
9 865 10 277 10 903
mm
9 462
9 681 10 100 10 737
mm
6 172
6 485 6 948
7 597
mm
5 940
6 253 6 737
7 429
mm
9 551
9 460 9 635
9 988
mm
6 770
6 759 6 946
7 279
mm
3 789
3 952 3 865
3 892
T1-1-2
EX255-EX285
EX255
SPECIFICATIONS
(Triple Articulation Version)
G
E
D/D'
H
C
L
M
A
B
N
OM0255
VERSIONS
D (*)
3 463
4 260
1 090
2 950
2 937
10 145 1) 3 083 2 815
EX255 EL (mm) 3 845
4 642
1 090
2 950
2 937
10 145
EX255 LC
4 642
1 090
2 950
2 937
EX255
(mm)
3 845
F
(**)
2 940
960
460
2 815
2 940
960
460
10 145 4) 3 290 2 815
2 940
960
460
2) 3 137
3) 3 019
(mm)
(**) Arm: 1) 2 158 mm, 2) 2 480 mm, 3) 2 950 mm, 4) 3 600 mm
EX255
M-Track shoe width
N-Maximum width
Working weight
Spec. Ground Press.
(mm)
(mm)
(kg)
(bar)
EX255 EL
EX255 LC
600
700
800
900
600
700
800
900
600
700
800
900
2 990
3 090
3 190
3 290
2 990
3 090
3 190
3 290
3 190
3 290
3 390
3 490
25 100 25 350 25 600 25 850 25 600 25 900 26 200 26 500 25 700 26 000 26 300
26 600
0.56
0.48
0.43
0.38
0.52
0.45
0.40
0.34
0.52
0.45
0.40
0.34
3 600
DIGGING DATA
3 100 mm Boom
OM0256
Arm
mm
2 158
2 480
2 950
mm
9 756
9 993
10 420 11 058
mm
9 570
9 812
10 246 10 895
mm
5 791
6 067
6 517
7 170
mm
5 678
5 958
6 414
7 077
mm
11 099 11 237 11 379 12 128
mm
6 306
8 146
5 840
5 248
mm
2 868
2 896
2 568
2 808
EX255-EX285
EX285
T1-1-3
SPECIFICATIONS
(Monoblock Version)
E / E'
G
D / D'
F
C
L
M
A
B
VERSIONS
(mm) 3 706
4 574
1 208
2 937
EX285 LC (mm) 4 011
4 879
1 210
2 937
EX285
D (*)
E (***)
F (**)
OM0540
1) 3 531
2 950 10 293 10 282 2) 3 350 2 815
3) 3 166
2 950 10 293 10 282 4) 3 295 2 815
(**) Arm: 1) 2 120 mm, 2) 2 400 mm, 3) 3 100 mm, 4) 3 750 mm
3 028
1 012
525.5
3 028
1 012
525.5
(***) Arm: 2 120 mm
EX285
EX285 LC
M-Track shoe width
(mm)
600
700
800
900
600
700
800
900
N-Maximum width
(mm)
3 000
3 100
3 200
3 300
3 190
3 290
3 390
3 490
(kg)
26 700
27 066
27 432
27 800
27 442
27 830
28 220
28 608
(bar)
0.65
0.57
0.50
0.45
0.62
0.54
0.48
0.43
Working weight
Spec. Ground Press.
DIGGING DATA
6 200 mm Boom
Arm
OM0254
mm 2 120
2 400
3100
3750
mm
9 834 10 062 10 705 11 299
mm
9 620
9 864 10 519 11 124
mm
6 120
6 538
7 230
7 878
mm
5 998
6 319
7 052
7 725
mm
9 802
9 638
9 978 10 242
mm
6 857
6 906
7 215
7 472
mm
4 269
4 307
4 146
4 124
T1-1-4
EX255-EX285
EX285
SPECIFICATIONS
(Triple Articulation Version)
G
E / E'
D / D'
F
C
L
M
A
B
VERSIONS
(mm) 3 706
4 574
1 208
2 937
EX285 LC (mm) 4 011
4 879
1 210
2 937
EX285
D (*)
E (***)
F (**)
1) 3 139
2 950 10 081 10 199 2) 3 166 2 815
3) 3 094
2 950 10 081 10 199 4) 3 376 2 815
(**) Arm: 1) 2100 mm, 2) 2400 mm, 3) 3100 mm, 4) 3750 mm
OM0255
3 028
1 012
525.5
3 028
1 012
525.5
(***) Arm: 2 120 mm
EX285
EX285 LC
M-Track shoe width
(mm)
600
700
800
900
600
700
800
900
N-Maximum width
(mm)
3 000
3 100
3 200
3 300
3 190
3 290
3 390
3 490
(kg) 27 400
27 766
28 132
28 498
28 140
28 506
28 872
29 238
0.58
0.52
0.46
0.69
0.60
0.53
0.48
Working weight
Spec. Ground Press.
(bar)
0.67
DIGGING DATA
3 200 mm Boom
OM0256
Arm
mm
2 120
2 400
3 100
3 750
mm
9 882 10 072 10 733 11 345
mm
9 680
9 875 10 548 11 170
mm
5 784
6 014
6 699
7 335
mm
5 671
5 905
6 600
7 244
mm 11 285 11 370 11 924 12 413
mm
8 175
8 264
8 813
9 302
mm
3 038
3 009
2 726
2 867
EX255-EX285
EX255
T1-1-5
SPECIFICATIONS
EX255 EXCAVATOR PERFORMANCE
GRADEABILITY .......................................................................................................... 35 (70%) in continuous
TRAVEL SPEED ................................................................................................... 2.2 / 3.4 mph (3.5/5.4 km/h)
- Slow ................................................................................................................... 0 to 2.2 mph (0 to 3.5 km/h)
- Fast .................................................................................................................... 0 to 3.4 mph (0 to 5.4 km/h)
EX255 ENGINE DATA

MAIN SPECIFICATIONS
- Manufacturer ........................................................................................................................................ ISUZU
- Model ................................................................................................................................. CC-6BG1 TRA-05
- Type .......................................................................... Diesel, 4 cycle, vertical, 6-cylinder inline, water-cooled,
direct injection type turbocharged, with intercooler
- Cyl. No.-bore x stroke .......................................................................... 6-105 mm x 125 mm (4.13 in x 4.92 in)
- Piston displacement ............................................................................................................ 6494 cm3 (475 in3)
- Rated output ........................................................................................ 118 kW/2000 min-1 (158 HP/2000 rpm)
HP Mode: 125 kW/2100 min-1 (168 HP/2100 rpm)
- Compression ratio .........................................................................................................................................18
- Dry weight ............................................................................................................................... 490 kg (1080 lb)
- Firing order ....................................................................................................................................... 1-5-3-6-2-4
- Rotation direction .............................................................................................. Clockwise (view from fan side)
COOLING SYSTEM
- Cooling fan ............................................................................................. Dia. 670 mm, 6 blades, draw-in type
- Fan pulley ratio .................................................................................................................... Engine rpm x 0.95
- Thermostat ....................................................... Cracking temp. : 82 C (180 F) (under atmospheric pressure)
Full open (Stroke: 10 mm or larger) temp. : 95 C (203 F)
- Water pump ........................................................................................................... Centrifugal type, belt driven
LUBRICATION SYSTEM
- Lubrication pump type ................................................................................................................... Gear pump
- Oil filter .............................................................................. Full-flow paper element type with bypass function
- Oil cooler ........................................................................................................................ Water-cooled, built-in
STARTING SYSTEM
Motor ............................................................................................ Magnetic pinion shift system, reduction type
Voltage-Output .............................................................................................................................. 24 V - 4.5 kW
PRE-HEAT SYSTEM
- Heating method ............................................................................................................................... Glow plug
ENGINE STOP SYSTEM
- Stop method ....................................................................................................................................... Fuel cut
ALTERNATOR
- Type ........................................................................................................................... AC type (with regulator)
- Voltage-Output .................................................................................................... 24 V - 50 A (Brush-less type)
SUPERCHARGING SYSTEM
- Type ............................................................................................................. Exhaust-gas-turbo type IHI RG6
FUEL SYSTEM
- Injection pump model .....................................................................................................................Bosch type
- Governor ..................................................................................................... Centrifugal all speed control RSV
- Injection nozzle ....................................................................................................................... Multihole nozzle
T1-1-6
EX255-EX285
EX255
SPECIFICATIONS
EX255 ENGINE ACCESSORY
RADIATOR ASSEMBLY
- Type ...................................................................... Radiator/Oil Cooler tandem type and intercooler assembly
- Mass .......................................................................................................................................... 85 kg (187 lb)
- Radiator Capacity ....................................................................................................................................... 8 L
- Oil Cooler Capacity ................................................................................................................................. 6.3 L
BATTERY
- Capacity ........................................................................................................................................ 160 Ah x 2
- Voltage ............................................................................................................................................... 12V x 2
HYDRAULIC DEVICES EX255

MAIN PUMP
- Model .......................................................................................................................................... HPV102FW
- Type ............................................................... Variable displacement plunger pump: regulator attached type
- Max. flow (theoretical value) ...................................................................................................... 194 L/min x 2
PILOT PUMP
- Model ................................................................................................................................... HY/ZFS 11/16.8
- Type ....................................................................................................... Fixed displacement type gear pump
- Max. flow (theoretical value) ........................................................................ 33.6 L/min; HP Mode: 35.3 L/min
CONTROL VALVE
- Model ......................................................................................................................................... KVMG-200H
- Type ................................................................................................................... Pilot pressure operated type
(4-spool + 5-spool)
- Main relief pressure ................................................................ Normal: 34.3 MPa (350 kgf/cm2) @ 140 L/min
Power Boost: 36.3 MPa (370 kgf/cm2) @ 140 L/min
- Overload relief pressure ........................................................................ 37.3 MPa (380 kgf/cm2) @ 50 L/min
(Boom raise / lower, Arm roll-in, Bucket roll-in)
39.2 MPa (400 kgf/cm2) @ 50 L/min
(Arm roll-out, Bucket roll-out)
SWING DEVICE
- Type ....................................................................................................... Two-stage planetary reduction type
SWING MOTOR
- Model .............................................................................................................................................. M2X146B
- Type ............................................................................. Swash-plate type, fixed-displacement plunger motor
SWING BRAKE VALVE
- Type ............................................................................................................. Non counter balance valve type
- Relief pressure .................................................................................... 31.4 MPa (320 kgf/cm2) @ 140 L/min
SWING PARKING BRAKE
- Type ............................................................................................................. Multiple-wet-plate negative type
- Cracking pressure for release ................................................................ 1.96 to 2.64 MPa (20 to 27 kgf/cm2)
TRAVEL DEVICE
- Type ..................................................................................................... Three-stage planetary reduction gear
TRAVEL MOTOR
- Model ............................................................................................................................................... HMV116
- Type ............................................................................. Bent-axis type, variable displacement plunger motor
EX255-EX285
EX255
T1-1-7
SPECIFICATIONS
TRAVEL BRAKE VALVE
- Type .................................................................................................................... Counter balance valve type
- Relief pressure .......................................................................................................... 34.8 MPa (355 kgf/cm2)
TRAVEL PARKING BRAKE
- Cracking pressure for release ............................................................ 0.95 to 1.02 MPa (9,7 to 10.4 kgf/cm2)
CYLINDERS
Rod diameter
Boom
Arm
Bucket
Positioning (*)
90 mm
100 mm
85 mm
90 mm
Cylinder inner diameter
125 mm
135 mm
125 mm
145 mm
Stroke
Fully retracted
length
1350 mm
1610 mm
1075 mm
1205 mm
1950 mm
2235 mm
1665 mm
1799 mm
(*) Triple articulation version
FRONT ATTACHMENT PILOT VALVE

- Model ................................................................................................................................. HVP04S-040-101
TRAVEL PILOT VALVE
- Model ................................................................................................................................. HVP05D-040-101
SOLENOID VALVE UNIT
- Functions ............................................................................................... SC: Arm regenerative control
SD: Speed sensing control
SG: Power boost control
SI: Travel motor swash angle control
OIL COOLER BYPASS CHECK VALVE
- Cracking pressure .......................................................................................... 392 KPa (4 kgf/cm2) at 5 L/min
EX255 ELECTRICAL EQUIPMENT

BATTERY RELAY
- Voltage - Current ........................................................................................................................ 24 V - 100 A
GLOW RELAY
- Voltage - Current .......................................................................................................................... 24 V - 30 A
HORN
- Specifications ........................................................................................................... 24 V - 1.5 A, 113 dB (A)
LIGHT
- Specifications ............................................................................................ Work lights: Halogen 24 V - 70 W
Dome light: 24 V - 10 W
AIR CONDITIONER
- Refrigerant .............................................................................................................................................. 134 a
- Temperature control .............................................................................................................. electronic control
EX285
EX255-EX285
T1-1-8
SPECIFICATIONS
EX285 EXCAVATOR PERFORMANCE
GRADEABILITY .......................................................................................................... 35 (70%) in continuous
TRAVEL SPEED ................................................................................................... 1.9 / 3.2 mph (3.0/5.1 km/h)

- Slow ................................................................................................................... 0 to 1.9 mph (0 to 3.0 km/h)
- Fast .................................................................................................................... 0 to 3.2 mph (0 to 5.1 km/h)
EX285 ENGINE DATA

MAIN SPECIFICATIONS
- Manufacturer ........................................................................................................................................ ISUZU
- Model ................................................................................................................................. CC-6BG1 TRA-06
- Type .......................................................................... Diesel, 4 cycle, vertical, 6-cylinder inline, water-cooled,
direct injection type turbocharged, with intercooler
- Cyl. No.-bore x stroke .......................................................................... 6-105 mm x 125 mm (4.13 in x 4.92 in)
- Piston displacement ............................................................................................................ 6494 cm3 (475 in3)
- Rated output ........................................................................................ 125 kW/2050 min-1 (168 HP/2050 rpm)
HP Mode: 132 kW/2150 min-1 (177 HP/2150 rpm)
- Compression ratio .........................................................................................................................................18
- Dry weight ............................................................................................................................... 490 kg (1080 lb)
- Firing order ....................................................................................................................................... 1-5-3-6-2-4
- Rotation direction .............................................................................................. Clockwise (view from fan side)
COOLING SYSTEM
- Cooling fan ............................................................................................. Dia. 670 mm, 6 blades, draw-in type
- Fan pulley ratio ................................................................................................................... Engine rpm x 0.95
- Thermostat .................................................... Cracking temp. : 82 C (180 F) (under atmospheric pressure)
Full open (Stroke: 10 mm or larger) temp. : 95 C (203 F)
- Water pump ......................................................................................................... Centrifugal type, belt driven
LUBRICATION SYSTEM
- Lubrication pump type ................................................................................................................... Gear pump
- Oil filter .............................................................................. Full-flow paper element type with bypass function
- Oil cooler ........................................................................................................................ Water-cooled, built-in
STARTING SYSTEM
Motor ............................................................................................ Magnetic pinion shift system, reduction type
Voltage-Output .............................................................................................................................. 24 V - 4.5 kW
PRE-HEAT SYSTEM
- Heating method ............................................................................................................................... Glow plug
ENGINE STOP SYSTEM
- Stop method ....................................................................................................................................... Fuel cut
ALTERNATOR
- Type ........................................................................................................................... AC type (with regulator)
- Voltage-Output .................................................................................................... 24 V - 50 A (Brush-less type)
SUPERCHARGING SYSTEM
- Type ............................................................................................................. Exhaust-gas-turbo type IHI RG6
FUEL SYSTEM
- Injection pump model .....................................................................................................................Bosch type
- Governor ..................................................................................................... Centrifugal all speed control RSV
- Injection nozzle ...................................................................................................................... Multihole nozzle
EX285
EX255-EX285
T1-1-9
SPECIFICATIONS
EX285 ENGINE ACCESSORY
RADIATOR ASSEMBLY
- Type ...................................................................... Radiator/Oil Cooler tandem type and intercooler assembly
- Weight ....................................................................................................................................... 85 kg (187 lb)
- Radiator Capacity ....................................................................................................................................... 8 L
- Oil Cooler Capacity ................................................................................................................................. 6.3 L
BATTERY
- Capacity ........................................................................................................................................ 160 Ah x 2
- Voltage .............................................................................................................................................. 12 V x 2
EX285 HYDRAULIC DEVICES

MAIN PUMP
- Model .......................................................................................................................................... HPV102FW
- Type ............................................................... Variable displacement plunger pump: regulator attached type
- Max. flow (Theoretical value) .................................................................................................... 209 L/min x 2
PILOT PUMP
- Model ................................................................................................................................... HY/ZFS 11/16.8
- Type ....................................................................................................... Fixed displacement type gear pump
- Max. flow (Theoretical value) ..................................................................... 34.4 L/min; HP Mode: 36.1 L/min
CONTROL VALVE
- Model ......................................................................................................................................... KVMG-200H
- Type ................................................................................................................... Pilot pressure operated type
(4-spool + 5-spool)
- Main relief pressure ................................................................ Normal: 34.3 MPa (350 kgf/cm2) @ 140 L/min
Power Boost: 36.3 MPa (370 kgf/cm2) @ 140 L/min
- Overload relief pressure ........................................................................ 37.3 MPa (380 kgf/cm2) @ 50 L/min
(Boom raise / lower, Arm roll-in, Bucket roll-in)
39.2 MPa (400 kgf/cm2) @ 50 L/min
(Arm roll-out, Bucket roll-out)
SWING DEVICE
- Type ....................................................................................................... Two-stage planetary reduction type
SWING MOTOR
- Model ........................................................................................................................................ M2X210CHB
- Type ............................................................................. Swash-plate type, fixed-displacement plunger motor
SWING BRAKE VALVE
- Type ............................................................................................................. Non counter balance valve type
- Relief pressure ......................................................................... 27.70.3 MPa (2823 kgf/cm2) @ 140 L/min
SWING PARKING BRAKE
- Cracking pressure for release ................................................................ 2.25 to 2.84 MPa (23 to 29 kgf/cm2)
TRAVEL DEVICE
- Type ..................................................................................................... Three-stage planetary reduction gear
TRAVEL MOTOR
- Model ............................................................................................................................................... HMV145
- Type ............................................................................. Bent-axis type, variable displacement plunger motor
T1-1-10
EX255-EX285
EX285
SPECIFICATIONS
TRAVEL BRAKE VALVE
- Type .................................................................................................................... Counter balance valve type
- Relief pressure .......................................................................................................... 34.8 MPa (355 kgf/cm2)
TRAVEL PARKING BRAKE
- Cracking pressure for release ............................................................ 0.95 to 1.02 MPa (9.7 to 10.4 kgf/cm2)
CYLINDERS
Rod diameter
Boom
90 mm
Arm
100 mm
Bucket
90 mm
Positioning (*)
90 mm
Cylinder inner diameter
135 mm
145 mm
135 mm
145 mm
Stroke
1340 mm
1555 mm
1070 mm
1205 mm
Fully retracted
length
1920 mm
2155 mm
1660 mm
1799 mm
FRONT ATTACHMENT PILOT VALVE

- Model ................................................................................................................................. HVP04S-040-101
TRAVEL PILOT VALVE
- Model ................................................................................................................................. HVP05D-040-101
SOLENOID VALVE UNIT
- Functions ............................................................................................... SC: Arm regenerative control
SD: Speed sensing control
SG: Power boost control
SI: Travel motor swash angle control
OIL COOLER BYPASS CHECK VALVE
- Cracking pressure .......................................................................................... 392 KPa (4 kgf/cm2) at 5 L/min
EX285 ELECTRICAL EQUIPMENT

BATTERY RELAY
- Voltage - Current ........................................................................................................................ 24 V - 100 A
GLOW RELAY
- Voltage - Current .......................................................................................................................... 24 V - 30 A
HORN
- Specifications ................................................................................................................. 24 V - 1.5 A, 113 dB
LIGHT
- Specifications ............................................................................................ Work lights:
Dome light:
Halogen 24 V - 70 W
24 V - 10 W
AIR CONDITIONER
- Refrigerant .............................................................................................................................................. 134 a
- Temperature control ............................................................................................................. Electronic control
EX255-EX285
T1-2-1
COMPONENT LAYOUT
MAIN COMPONENTS
SM5601
1
2
3
4
5
6
7
8
9
10
11
Bucket Cylinder
Arm Cylinder
Boom Cylinder
Center Joint
Swing Bearing
Swing Device
Fuel Tank
Hydraulic Oil Tank
Control Valve
Pilot Filter, Pilot Relief Valve
Pump Device
12
13
14
15
16
17
18
19
20
21
Engine
Radiator
Oil Cooler
Intercooler
Battery
Travel Device
Shockless Valve
Pilot Shut-Off Valve
Travel Pilot Valve
Front/Swing Pilot Valve
T1-2-2
EX255-EX285
COMPONENT LAYOUT
ELECTRICAL SYSTEM (overall system)
SM5402
1 2 3 4 5 6 7,8 9 10 11 12 13 14 15 16 17 18 -
Wiper Motor
Monitor Panel
Relays, Relays box
Windshield
Horn
Work Light
Fuel Sensor with Low Fuel Level Switch
Solenoid Valve Unit
Pressure Switch (Travel)
Hydraulic Oil Level Switch
PC Pressure Sensor (Upper: 4-Spool Side)
PC Pressure Sensor(Lower: 5-Spool Side)
EC Motor
EC Sensor
Pump Delivery Pressure Sensor 1
N (Engine Speed) Sensor
19
20
21
22
23
24
25
26
27
28
29
30 31 32 33 -
Engine Oil Pressure Switch

Coolant Temperature Switch (Engine Preheat Circuit)
Engine Oil Level Switch (on oil pan)
Overheat Switch
Coolant Temperature Sensor
Battery Relay
Coolant Level Switch
Battery
Starter Relay
Air Cleaner Restriction Switch
Pressure Switch (Boom Raise), Pressure Sensor (Arm
Roll-In)
Pressure Switch (Front)
Fuse Box
MC (Main Controller)
QOS Controller
EX255-EX285
T1-2-3
COMPONENT LAYOUT
ELECTRICAL SYSTEM (cab)
SM5603
1
2
3
4
5
6
7
8
9
10
11
12
Relay box
Air conditioner relays (if installed)
Connection for cab light (ceiling)
WWES connection for wiper cut-off microswitch
Heater connection
Air conditoner connection
Loudspeakers connection
Cab ground
Main controller (MC)
Q.O.S. controller
Load momentum alarm buzzer provision
Load momentum alarm relay provision (R1)
13
14
15
16
17
18
19
20
21
22
23
24
Breaker relay (R2) variant provision

R.H. Rotation bucket relay (R3) variant provision
L.H. Rotation bucket relay (R4) variant provision
Cab light relay (R5)
Rear cab light relay (R6)
A, B, K junction connector
C, D juncton connector
E, F junction connector
G, H junction connector
Dr. EX. connector
Engine learning switch
Fuse box
T1-2-4
EX255-EX285
COMPONENT LAYOUT
SM5604
1
2
3
4
5
6
Connectors for monitor and switch panels

Cigarette lighter
Connectors to cab harness
Connectors not used
Windshield wiper controller
(1) connector for breaker switch
(2) connector for cab light switch
(3) connector for bucket rotation
(4) connector for load momentum alarm switch
(5) connector for rear cab light
7
8
- Connector not used

- Connector
EX255-EX285
T1-2-5
COMPONENT LAYOUT
ELECTRICAL SYSTEM (monitor and switch panels)
10
24
11
12
23
13
22
14
21
20
15
16
17
19
3
18
T157-07-02-001
SM0610
5
25
6
4
32
7
8
26
31
27
28
30
T157-01-01-009
SM0611
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Monitor Panel
Switch Panel
Power Boost Switch
Key Switch
Cigar Lighter
HP Mode Switch
E Mode Switch
Engine Control Dial
Air Conditioner Panel
Warm Up Complete Indicator
Fuel Gauge
E Mode Indicator
Auto-Idle Indicator
Hydraulic Oil Level Indicator
Preheat Indicator
Air Filter Restriction Indicator
29
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
T157-01-01-018
SM0612
Fuel Level Indicator

Overheat Indicator
Alternator Indicator
Engine Oil Pressure Indicator
Engine Oil Level Indicator
Coolant Level Indicator
HP Mode Indicator
Coolant Temperature Gauge
Work Light Switch
Wiper Switch
Travel Mode Switch
Work Mode Switch
Buzzer Stop Switch
Auto-Idle Switch
Washer Switch
Level Check Switch
T1-2-6
EX255-EX285
COMPONENT LAYOUT
ELECTRICAL SYSTEM (batteries compartment)
1
8
2
7
6
4
1
2
3
4
Battery relay
Fuse link (Box B - Fuse 3-60A)
Fuse link (Box A - Fuse 1-40A, Fuse 2-40A)
Connection box
SM5605
5
6
7
8
Safety relay
Engine coolant level switch
Ground joint connector
Glow relay
EX255-EX285
T1-2-7
COMPONENT LAYOUT
ELECTRICAL SYSTEM (fuses)
FUSES IN THE BOX
Fuse
No.
LABEL
PROTECTED
CIRCUIT
Rating
(A)
SW. BACK UP
Backup power
source
ENGINE C/U
MC
(Power Source)
10
E.C. MOTOR
EC
Motor
10
AUXILIARY
Auxiliary
Power supply
REAR CAB
LIGHT
Rear cab light

power supply
10
HAMMER
Breaker
10
ROTARY
BUCKET
Bucket
rotation
10
SOLENOID
Solenoid valve
power supply
SW. BOX
Switches
panel
10
HEATING
SEAT
Heating seat
10
11
WIPER
Windshield wiper
10
12
HEATER
Heater
20
13
LIGHT
Light
15
14
CAB LIGHT
Cab light
15
15
RADIO
Radio
16
LIGHTER
Cigar light
15
17
HORN
Horn
10
18
GLOW
RELAY
Glow relay
power supply
19
POWER ON
Power supply on
20
AIR
CONDITION
Air
conditoner
10
OM0231
9 10
11 12 13 14 15 16 17 18 19 20
OM1150
Fuses in the fuse box
FUSES IN THE BATTERIES COMPARTMENT

FUSE 1
BOX A
Main power
supply with
key
40
FUSE 2
BOX A
Glow plug
and fuel transfer
supply
40
FUSE 3
BOX B
Charge
circuit
supply
60
BOX B
OM1304
Fuses in the batteries compartment
T1-2-8
EX255-EX285
COMPONENT LAYOUT
PUMP AND RELATED PARTS
3-4
8
12
11
10
9
SM3004
1
2
3
4
5
6
Pilot Filter
Pilot Relief Valve
EC Motor
EC Sensor
Pilot Pump
Regulator (Pump 2)
7
8
9
10
11
12
N Sensor
Regulator (Pump 1)
Pump Delivery Pressure Sensor (Pump 1)
Pump 1
Pump 2
EX255-EX285
T1-2-9
COMPONENT LAYOUT
OTHER COMPONENTS
Shockless Valve
Swing Device
9
8
6
7
SM0626
T157-01-01-011
Travel Device
SM0627
T157-07-03-018
Solenoid Valve Unit
FRONT
10
11
12
13
3
SM0628
T157-01-01-012
1
2
3
4
5
6
7
Swing Relief Valve

Counterbalance Valve
Travel Relief Valve
Shockless Valve
Pilot Pressure Switch (Boom Raise)
Check Valve
Shockless Valve
SM0629
W157-02-11-020
8
9
10
11
12
13
Check Valve
Pilot Pressure Sensor (Arm Roll-In)
Solenoid Valve Unit (SC)
Solenoid Valve Unit (SD)
Solenoid Valve Unit (SI)
Solenoid Valve Unit (SG)
T1-2-10
EX255-EX285
COMPONENT LAYOUT
NOTES
SECTION 2
EX255-EX285
SYSTEM
CONTENTS
Group 1 -
Control system
Outline .................................................... T2-1-1

Engine control ........................................ T2-1-2
Pump control .......................................... T2-1-8
Valve control ..........................................T2-1-10
Other control functions ......................... T2-1-14
Group 2 -
Hydraulic system
Main circuit .......................................... T2-2-1

Pilot circuit ........................................... T2-2-2
Neutral circuit ...................................... T2-2-3
Single actuator operation .................... T2-2-3
Combined operation ............................ T2-2-4
Group 3 -
Electrical system
Outline ................................................... T2-3-1

Electric power circuit
(Key Switch: OFF) ................................. T2-3-2
Bulb Check Circuit (Key Switch: ON) ..... T2-3-4
Accessory Circuit (Key Switch: ACC) .... T2-3-6
Preheat Circuit
(Key Switch: ON or START) .................. T2-3-8
Starting Circuit
(Key Switch: START) ........................... T2-3-10
Charging Circuit
(Key Switch: ON) ................................. T2-3-12
Surge Voltage Prevention Circuit ......... T2-3-16
Engine Stop Circuit
(Key Switch: OFF) ............................... T2-3-18
Engine and pump control circuit .......... T2-3-20
Monitor circuit ...................................... T2-3-24
EX255-EX285
T2-1-1
CONTROL SYSTEM
OUTLINE
Microcomputer built-in main controller (MC) is provided to control machine operation. Electronic sensing signals from the engine control dial, various
sensors and switches are sent to the MC.
After processing the sensing signals in the logic

circuits, the MC sends out the control signals to the
EC motor and solenoid valve unit to control the
engine, pump, and valve operations.
Sensing signals (Input signals)
Control signals (Output signals)
EC sensor
Engine control dial
Pump control pressure sensor
Pump delivery pressure sensor
N sensor
Pressure switches
(Travel - Front - Boom raise)
Pilot pressure sensor
(Arm roll-in)
Auto-idle switch
Learning switch
Power boost switch
HP mode switch
E mode switch
Travel mode switch
Work mode switch
Key switch
EC motor:
Solenoid valve (SD):
Engine control
Normal control
HP mode control
E mode control
Auto-Idle control
Engine learning control
Pump control
Speed sensing control
MC
Solenoid valve (SC, SG, SI):
Valve control
Power Boost control
Arm regenerative control
Travel motor swash
angle control
EC Motor
Solenoid Valve Unit
(SC, SG)
Work Mode Control

General Purpose Mode
Grading Mode
Precision Mode
Attachment Mode
T2-1-2
EX255-EX285
CONTROL SYSTEM
ENGINE CONTROL
The engine control system has the following control
functions:
Normal control
HP mode control
E mode control
Auto-Idle control
Engine learning control.
Layout of engine control system

(Arm Roll-in)
Pressure switch (Travel)
Pressure
switch
(Front)
Learning switch
P/V
Key switch
EC sensor
Engine control dial
ENGINE
M
Auto-Idle switch
A/I
MC
EC motor
HP mode switch
H/P
E mode switch

(Pump 1, 2)
SM0101
EX255-EX285
T2-1-3
CONTROL SYSTEM
Normal Control
Purpose: To control engine speed in response to the
operation angle of the engine control dial on the
switch panel.
Operation: In response to the operation angle of the
engine control dial, the MC drives the EC motor,
causing the governor lever to move to control engine
speed.
NOTE - Normally, the governor lever does not come

into contact with the full side stopper even if the
engine control dial is turned to the full speed position.
(Refer to HP Mode Control).
The EC sensor feedbacks the position of the EC

motor to the MC.
This confirms that the EC motor moves according to
commands from the MC.
P/V
Engine control dial
EC sensor
ENGINE
M
Stop
Full
MC
A/I
EC motor
Governor lever
H/P
E
SM0102
T2-1-4
EX255-EX285
CONTROL SYSTEM
HP Mode Control
Purpose: To instantaneously increase the engine
speed only when a little more hydraulic power is
required for arm roll-in operation. For example, to
increase the arm roll-in power while conducting a
deep ditching work.
Engine speed
HP mode operation line
100 min-1 (rpm)
Operation: Only when the following conditions are

satisfied, the MC drives the EC motor to operate the
engine faster than normal operation.
1800 min-1 (rpm)
Engine Control Dial Setting: 1600 min-1 or faster

HP Mode Switch: ON
Operation: Arm Roll-In
Average Delivery Pressures of Pump 1 and 2:
Higher Range
NOTE - The engine governor stopper position is

adjusted in accordance with the HP mode operation.
Therefore, the governor lever does not come into
contact with the stopper in the Normal Control mode.
1600 min-1 (rpm)
Fast Idle (Max. Speed)
Slow Idle
Slow Idle
Fast Idle
(Max. Speed)
SM0103

(Arm Roll-in)
P/V
Engine control dial
ENGINE
M
Min.
Max.
MC
A/I
EC motor
Governor lever
HP mode switch
H/P
E
SM0104
EX255-EX285
T2-1-5
CONTROL SYSTEM
E Mode Control
Purpose: To decrease the engine speed at a fixed
rate.
Engine speed
When the E mode switch

is not depressed
Operation: When the E mode switch is ON, the MC

instructs the EC motor to run the engine in the speed
range slower than normal operation in proportion to
the engine control dial set angle.
When the E mode

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

Slow Idle
Fast Idle
(Max. Speed)
SM0105
P/V
Engine control dial
ENGINE
M
MC
A/I
EC motor
Governor lever
H/P
E mode switch
SM0106
T2-1-6
EX255-EX285
CONTROL SYSTEM
Auto-Idle Control
Purpose: To slow the engine speed when all control
levers are in neutral to reduce fuel consumption and
noise.
Operation: When the auto-idle switch is ON and all
control levers are kept in neutral (the pressure

switches for travel and front operations are off) for
more than four seconds, the MC instructs the EC
motor to reduce the engine speed to the auto-idle
speed.
Pressure switch (Travel)
Pressure switch
(Front)
P/V
Engine control dial
ENGINE
M
Auto-Idle switch
A/I
MC
EC motor
Governor lever
H/P
E
SM0107
EX255-EX285
T2-1-7
CONTROL SYSTEM
Engine Learning Control
Purpose: To check the governor lever stopper positions to run the engine at full-speed or to stop as
engine control standard data.
Operation: When the learning switch in the rear
console is turned to the engine learning side, the EC
motor is driven by the signal from the MC. Then, the
EC motor moves the governor lever to the Idle,
FULL, and STOP positions in that order.
Thereby, the EC sensor checks the stopper positions
for the FULL and STOP operation. The signals
corresponding to each stopper position are sent to
the MC from the EC sensor, and the MC stores the
data.
Rear Console
Fuse Box
Learning Switch
Engine Learning
IMPORTANT - Be sure to operate the engine learning control system after replacing the engine, engine
control cable, EC motor, or MC. The procedure is
listed in the Technical Manual "Troubleshooting" on
page T5-4-60.
Neutral (OFF)
SM0108
NOTE - The replacement of batteries does not require operation of the engine learning control system.
Learning switch
P/
V
Key switch
EC Sensor
ENGINE
M
Stop
Full
MC
A/I
EC Motor
Governor Lever
H/P
E
SM0109
T2-1-8
EX255-EX285
CONTROL SYSTEM
PUMP CONTROL
The pump operation is regulated by the speed sensing system and the pump control valve.
The speed sensing system works via the MC.
The pump control valve is provided in the control

valve. (Refer to the Control Valve Group in the
COMPONENT OPERATION Section).
EX255-EX285
T2-1-9
CONTROL SYSTEM
Speed Sensing Control
Purpose: To control the pump drive torque in response to the variation of loads to the engine or the
output of the hydraulic pumps to utilize the engine
output more efficiently.
Operation: The target engine speed is selected by
setting the engine speed with the engine control dial.
The MC receives signals for the target engine speed,
and actual engine running speed from the N sensor.
After processing these input data, the MC sends out
the control signals to the solenoid valve unit (SD).
According to the control signals from the MC, the

solenoid valve unit (SD) supplies pilot oil pressure to
the pump regulators to control the pump flow rate.
When poor quality fuel is used or if the machine is
operated at high altitudes, the engine output torque
may decrease, causing the engine to run slower than
the target speed. As the MC in the speed sensing
control system instructs the solenoid valve unit (SD)
to reduce the pump flow rate, the pump drive torque
is reduced. Thereby, engine speed reduction or
engine stall is avoided.
N sensor
Engine control dial

Solenoid Valve
unit
MC
S D
ENGINE
REG
REG
SM0110
T2-1-10
EX255-EX285
CONTROL SYSTEM
VALVE CONTROL
The valve control consists of the power boost control,
arm regenerative control, and travel motor swash
angle control.
Pump control pressure sensor

(5-Spool Side)
Pilot pressure sensor (Arm Roll-In)
Pressure switch (Boom Raise)
Travel motor swash angle
selector valve
Power Boost switch
Pressure switch
(Front)
Travel motor
Pressure switch
(Travel)
Travel mode switch
Relief valve
P/V
Arm cylinder
MC
To MC
S G
Pump delivery
pressure sensor
Solenoid
valve unit
SI
S C
Arm regenerative
valve
REG
Swing motor
From pump control

pressure sensor
(4-Spool Side)
REG
Pump control pressure

sensor (4- Spool Side)
SM0111
EX255-EX285
T2-1-11
CONTROL SYSTEM
Power Boost Control
Purpose: To increase hydraulic power by temporarily increasing the main relief pressure.
Operation: When the power boost switch is turned
ON, the MC magnetizes solenoid valve unit (SG) for

8 seconds. When magnetized, solenoid valve unit
(SG) supplies pilot oil pressure to the relief valve to
increase the relief set pressure.
Relief Valve
Power Boost switch
MC
Solenoid
Valve Unit
SM0112
T2-1-12
EX255-EX285
CONTROL SYSTEM
Arm Regenerative Control
Purpose: To increase arm roll-in speed and prevent
the arm roll-in hesitation.
Operation: When the signals to the MC from the
pump delivery pressure sensor (pump 2), pilot pressure sensor (arm roll-in), and pressure switch (boom
raise) fall into the following conditions, the MC magnetizes the solenoid valve unit (SC). Then, the solenoid valve (SC) starts to deliver the pilot pressure to
actuate the arm regenerative valve, closing the return
circuit to the hydraulic oil tank from the arm cylinder
rod side.
Thereby, the return oil from the arm cylinder rod side
is combined with the pump delivery oil and supplied

to the arm cylinder bottom side, increasing the arm
roll-in speed and preventing arm roll-in hesitation.
Operation Conditions:
- Pump Delivery Pressure Sensor (Pump 2): Delivery pressure from pump 2 is low (requiring less arm
operating force).
- Pilot Pressure Sensor (Arm Roll-In): Output is large
(operating the arm control lever with a great
stroke).
- Pressure Switch (Boom Raise): ON
Pilot pressure sensor (Arm Roll-In)

Pressure Switch (Boom Raise)
Bucket
Arm cylinder
MC
Arm 1
Bucket
cylinder
Pump delivery
pressure sensor (Pump 2)
Solenoid
valve unit
Arm regenerative
valve
SM0113
EX255-EX285
T2-1-13
CONTROL SYSTEM
Travel Motor Swash Angle Control
Purpose: To change fast/slow travel speed.
Operation: When the travel mode switch is in
position, the travel motor swash angle is held at a
large angle, causing the machine to travel at a slow
speed.
When the travel mode switch is in
position and the
signals to the MC from the pressure switch (travel),
pump delivery pressure sensors (pump 1 and 2) fall
into the following conditions, the MC magnetizes
solenoid valve (SI), allowing pilot oil pressure to
change the travel motor swash angle control valve
port. Thereby, the travel motor swash angle is reduced to cause the machine to travel at a fast speed.
Pump control Pressure Sensor

(5-Spool Side)
Operation Conditions:
- Pressure Switch (Travel): ON
- Pressure Switch (Front): OFF
- Pump Delivery Pressure Sensors (Pump 1 and 2):
Pump delivery pressure is low.
- Pump Displacement Target Angle (controlled by
the MC according to signals from sensors and
switches): Large
NOTE - Even if the track is revolved with the track
raised, one side pump displacement target angle
remains small so that the travel motor speed does not
increase.
The pump displacement target angle is different from
the travel motor displacement target angle.
Travel motor swash angle

control valve
Travel motor
Pressure switch (Front):

OFF signal
Pressure switch (Travel):
ON signal
Left side travel
Right side
travel
Travel mode
switch
MC
To MC
Pump delivery
Pressure Sensors
(Pump 1 and 2)
Solenoid
valve unit
Pump control
Pressure Sensor
(4-Spool side)
Front pump control

Pressure Sensor
(4-Spool side)
SM0114
T2-1-14
EX255-EX285
CONTROL SYSTEM
OTHER CONTROL FUNCTION
Work Mode Control
The work mode includes the four modes of GENERAL PURPOSE, GRADING, PRECISION, and
ATTACHMENT, which can be selected by the work
mode switch.
of the full speed to be set when the engine control dial

is placed in the full position.
The main relief pressure is increased in boom raise
operation. (Refer to T2-1-11)
GENERAL PURPOSE MODE

Normal control is applied.
NOTE - Operating speed is reduced but operating

force is unchanged.
GRADING MODE
To decrease the arm leveling speed, the arm regenerative control is deactivated.
(Refer to T2-1-12)
ATTACHMENT MODE
Only when the attachment option kit is installed, this
function works. In proportion to the auxiliary pilot
valve lever stroke, the engine speed is controlled by
the MC so as to meet the installed attachment
operation. The engine speed setting for the attachment mode is made by the Dr.EX.
PRECISION MODE
In all work modes, engine speed is reduced to 70 %
EX255-EX285
T2-2-1
HYDRAULIC SYSTEM
MAIN CIRCUIT
The main pumps (pump 1 and pump 2) draw hydraulic oil from the hydraulic oil tank. Pump 1 delivers oil
to the 4-spool control valve while pump 2 delivers oil
to the 5-spool control valve.
Pressure oil from the main pumps are routed to the
motors and cylinders in response to respective control valve spool shifts.
Return oil from the motors and cylinders flows back
to the hydraulic oil tank via the control valves and the
oil cooler. When oil temperature is low (viscosity is
high), return oil flowing through the oil cooler will be
hampered because of the increased flow resistance
in the oil cooler. If that happens, the bypass check
valve opens, allowing the return oil to directly flow
back to the hydraulic oil tank.
Boom Cylinder
Arm cylinder
Positioning cylinder (*)
Bucket cylinder
Center joint
Swing motor
Travel (R)
Travel (L)
Bucket
Boom 1
Aux.
Hydraulic oil tank
Boom 2
Full-flow filter
Arm 1
Suction filter
Bypass check valve
Swing
Arm 2
Pump 1
Engine
Pump 2
Oil cooler
Pressure oil
Return oil
(*) Triple articulation
version
Center joint
Left travel motor
Right travel motor
SM3005
T2-2-2
EX255-EX285
HYDRAULIC SYSTEM
PILOT CIRCUIT
control circuit, and in the swing parking brake release
line.
Pressure oil from the pilot pump acts as working

pressure in pilot operating circuit, in the pump/valve
Posit.
pilot valve
Left pilot
valve
Right pilot
valve
Travel pilot
valve
(*)
Pilot operating circuit
Pilot shut-off
valve
Manifold for shockless valves, pressure

sensor, and for pressure switch
Swing motor
Hydraulic oil
tank
Swing parking brake

release
Suction filter
Solenoid valve unit

SG
Pump / Valve
control circuit
SI
Main pump
regulator
2
Control valve
SD
SC
Pilot pump
Relief valve
Travel motor
Pilot filter
Travel motor
SM3006
EX255-EX285
T2-2-3
HYDRAULIC SYSTEM
NEUTRAL CIRCUIT
SINGLE ACTUATOR OPERATION
When the control levers are in neutral, pressure oil

from the main pumps returns to the hydraulic oil tank
via the control valves. (Refer to the Control Valve
Group in the COMPONENT OPERATION Section).
Pressure oil from pump 1 flows to the spools (Travel

(R), Bucket, Boom 1, and Arm 2) in the 4-spool side
section in the control valve. Pressure oil from pump
2 flows to the spools (Swing, Arm 1, Boom 2 , Aux.,
and Travel (L)) in the 5-spool side section in the
control valve.
When arm or boom is operated, pressure oil from
both pumps is combined and flows together into the
respective cylinder.
Left travel motor
Right travel motor
Pump control valve
Travel (R)
Travel (L)
Bucket cylinder
Bucket
Aux.
Boom 2
Boom cylinder
Arm cylinder
Boom 1
Arm 1
Arm 2
Swing
Pump control
valve
4-Spool side
5-Spool side
Hydraulic oil tank
Swing motor
Pump 2
Pump 1
SM0117
T2-2-4
EX255-EX285
HYDRAULIC SYSTEM
COMBINED OPERATION
Swing and Boom Raise Operation
When swing and boom raise operations are performed at the same time, pilot pressure shifts the
swing, boom 1, and boom 2 spools in the control
valves.
Then, pressure oil from pump 1 flows into the boom
cylinder via the parallel passage in the 4-spool side
section in the control valve to raise the boom. Pressure oil from pump 2 flows into the swing motor to
swing the upperstructure. A portion of the pressure oil

from pump 2 is detoured to the boom cylinder.
The detoured oil flow is combined with the oil flow
from pump 1 after flowing through the parallel passage and boom 2 spool in the 5-spool side section in
the control valve. The boom is raised by combined oil
flow from pump 1 and pump 2.
Parallel passage
Boom cylinder
Boom 2
Boom 1
Swing
Parallel Passage
4-Spool Side
5-Spool Side
Swing motor
Pump 2
Pump 1
SM0118
EX255-EX285
T2-2-5
HYDRAULIC SYSTEM
Travel and Arm Roll-In Operation
When travel and arm roll-in operations are performed
at the same time, pilot pressure shifts the travel, arm
1, and arm 2 spools. Pressure in the non-travel signal
pilot pressure circuit rises due to arm spool movement, shifting flow combiner valve.
Then, pressure oil from pump 1 flows into the right
travel motor via the travel (R) spool, actuating it.
A portion of the pressure oil from pump 1 is detoured
Left travel motor
to the left travel motor via the flow combiner valve and
travel (L) spool, actuating it. For this reason, the
machine can travel straight even when the arm rollin operation is performed at the same time, blocking
oil flow from pump 2 to the left travel motor.
Pressure oil from pump 2 flows into the arm cylinder
via the arm 1 spool, actuating it.
Flow combiner
valve
Right travel motor
Pilot pump
Travel (R)
Travel (L)
Signal Pilot
Pressure Circuit
Arm Cylinder
Arm 1
Arm 2
Pump 2
Pump 1
SM0119
T2-2-6
EX255-EX285
HYDRAULIC SYSTEM
NOTES
EX255-EX285
T2-3-1
ELECTRICAL SYSTEM
OUTLINE
The electrical system is roughly classified into the
main circuit, control circuit, and monitor circuit.
Main circuit:
Related to circuit for the engine and accessories.
Control circuit:
The control circuit of the engine, hydraulic pump,
and valves (including actuators such as solenoid
valves, MC (Main Controller), switch box, sensors,
and pressure switches, and so on).
Monitor circuit:
This circuits indicates machine operating conditions. (The circuits consisting of the monitors, sensors, and switches, and soon).
In this group, the main functions and construction of

the main circuit and some functions of control and
monitor circuit are explaned.
Electric Power Circuit:
Supplies electric power to all electric system on this
machine.
(Key Switch, Batteries, Fuses (Fuse Box and Fusible links), Battery Relay)
Preheat Circuit:
Helps start the engine in cold weather.
(Key Switch, QOS Controller, Glow relay, Glow
plugs)
Starting Circuit:
Starts the engine.
(Key Switch, Starter, Starter Relay)
Charging Circuit:
Recharges batteries and supplies electricity to the
system.
(Alternator, Regulator)
Surge Voltage Prevention Circuit:
Prevents surge voltage from occurring when the
engine is stopped.
(Anti Load Dump Relay)
Engine Stop Circuit:
Stops the engine with the EC motor
(MC, EC Motor).
Bulb Check Circuit:

Checks for blown warning lights and indicator bulbs
on monitor.
Engine and pump control circuit:

Operates the EC motor in order to control the
engine speed.
Control the pump displacement (Main Controller
(MC).
EC motor, Engine control dial, E and HP mode
switch, pressure switches, pressure sensors, solenoid valve unit).
Accessory Circuit:
Works with the key switch placed in the ACC
position.
Monitor control circuit:

Shows the operation conditions of the excavator.
(Monitor panel, pressure switches and sensors).
T2-3-2
EX255-EX285
ELECTRICAL SYSTEM
ELECTRIC POWER CIRCUIT
(Key switch: OFF)
The battery negative terminal is grounded to the
vehicle. Current from the positive terminal flows as
follows with the key switch OFF.
Fuse
link 2 (40 A) Glow relay (Power Source)
Battery
Terminal 1 -
Radio (Backup Power Source)

Monitor (Backup Power Source)
Terminal 2 -
MC (Power Source)
Terminal 3 -
MC (EC Motor)
Terminal 4 -
Auxiliary source
(relay box)
Relay box
(terminal 14 - Relay R1 Anti Load Dump)
Terminal B -
Key switch
Fuse
link 1 (40 A) Fuse box
Coolant
temperature
switch
Glow plugs
Alternator
to Monitor (42)
Safety relay
Starter
motor
Battery relay
Batteries
Glow relay
To fuel transfer
pump motor (opt)
Fuse link
Q.O.S. Controller
Relay box
to monitor (18)
Fuse
box
to Monitor (43)
Key switch
EX255-EX285
T2-3-3
ELECTRICAL SYSTEM
SM5607
Auxiliary power
EC motor
Radio (pow. b.u.)
MC pow. supply
T2-3-4
EX255-EX285
ELECTRICAL SYSTEM
BULB CHECK CIRCUIT
(Key switch: ON)
When the key switch is turned to the ON position, key
switch terminal B connects with key switch terminals
M and ACC.
The current from terminal M flows throught the diode
D2, located inner the relay box, and excites the
battery relay.
Then, the battery power is routed to the monitor

through the battery relay, the fuse box and the wiper
box, turning the warning lights and indicators on (for
bulb check).
Batteries
Glow relay
To fuel transfer
pump motor (opt)
Alternator
To monitor (42)
Safety relay
Starter motor
Glow plugs
Coolant
temperature switch
Battery relay
Fuse link
QOS Controller
Relay box
To motor (18)
Fuse
box
To monitor (43)
Monitor
Key switch
Wiper
box
EX255-EX285
T2-3-5
ELECTRICAL SYSTEM
SM5608
T2-3-6
EX255-EX285
ELECTRICAL SYSTEM
ACCESSORY CIRCUIT
(Key Switch: ACC)
When the key switch is turned to the ACC position,
terminal ACC is connected to terminal B in the key
switch.
Then, the battery current flows through the fuse box

terminal 15, 16 and 17, to each accessory circuits
(horn, radio, cigar lighter, power outlet, room lamp.
Batteries
Fuse link
Horn
Radio
Room light
Key switch
To monitor (30)
EX255-EX285
T2-3-7
ELECTRICAL SYSTEM
SM5609
Power outlet
Cigar lighter
T2-3-8
EX255-EX285
ELECTRICAL SYSTEM
PREHEAT CIRCUIT
(Key switch: ON or START)
When the key switch is turned to the ON or START
position, the key switch terminal B is connected to
terminal M in the key switch. The current from terminal
M flows to terminal #1 of QOS controller via the fuse
#18 and supply power to glow relay. Throught the
relay box.
When the coolant temperature switch is OFF, QOS
controller allows to preheat the engine for approx. 30
seconds. When QOS controller terminal #4 is
grounded, glow plug relay comes ON, so that the glow
plugs are heated.
Terminal #6 of QOS controller grounds to vehicle for

8 seconds while preheat, therefore glow signal is ON.
(When preheat is not done, glow signal is ON for 0.3
seconds to check the blown bulb.)
NOTE - Coolant temperature switch becomes OFF

when coolant temperature is less than 10 C (50 F).
Glow plugs
N.C. 10 C
Coolant
temperature switch
Batteries
Glow relay
Fuse link
QOS Controller
Relay box
To monitor (18)
Fuse box
Key switch
Monitor panel
EX255-EX285
T2-3-9
ELECTRICAL SYSTEM
SM5610
T2-3-10
EX255-EX285
ELECTRICAL SYSTEM
STARTING CIRCUIT
(Key Switch: START)
When the key switch is turned to the START position,
terminal B on the key switch is connected to terminals,
M, and ST. The current from terminal M magnetizes
the battery relay, leading the battery current to terminals B on the starter and starter relay via the battery
relay.
Terminal ST of the key switch is connected to terminal
S on the starter relay so that the battery current flows
through the coil in the starter relay, allowing the relay
to close the circuit. Then, the battery current can flow
to terminal C on the starter, closing the inner starter
relay.
Thereby, the starter begins to rotate.
The current from terminal M flows to the MC,
instructing that the key switch is positioned at ON or
START. When this signal arrives at the MC, the MC
actuates the EC motor which moves the governor
lever.
Starter Relay Operation

When the key switch is turned to the START
position, key switch terminal B and ST have continuity in the key switch. Then, the current flows to the
base of transistor (Q2) via resistance R4 in the
starter relay, switching transistor (Q2) ON.
Thereby, the current flows through coil (L) of relay,
closing the circuit between starter terminals B and
C. Then, the starter begins to rotate.
Once the engine is started, the alternator begins
to charge the batteries so that the voltage at
starter relay terminal R rises. When the voltage at
terminal R reaches 21 to 22 V, zener diode (Z)
comes ON. Accordingly, transistor (Q1) is switched
ON so that the base current to transistor (Q2) is cut,
switching transistor (Q2) OFF. At this time, continuity between starter terminal B and C is opened.
Then, the starter is switched OFF.
Capacitor C1 shown in the figure is used to stabilize
the operating voltage. Diode D4 protects the circuit
from damage when the batteries are inversely
connected.
Starter Relay
S
B
R4
(1)
R3
To Alternator
Terminal L
R2
C
(2)
D2
D3
Q1
(1)
C
M B
Q2
(2)
C1
Starter
E
D4
12V
B
ST
Key Switch
Batteries
12V
SM4015A
Alternator
To monitor (42)
Safety relay
Starter motor
Batteries
Battery relay
Fuse link
Relay box
To monitor (18)
Fuse box
Main controller
(MC)
Key switch
EX255-EX285
T2-3-11
ELECTRICAL SYSTEM
SM5611
T2-3-12
EX255-EX285
ELECTRICAL SYSTEM
CHARGING CIRCUIT
(Key Switch: ON)
After the engine starts and the key switch is released,
the key switch is returned to the ON position. With the
key switch kept ON, key switch terminal B is connected to terminals ACC and M.
After the engine starts, the alternator begins power
generation. Current from terminal B on the alternator

flows to the batteries through the battery relay recharging the batteries.
In addition, this current from Alternator terminal L
flows to the monitor to turn off the charge lamp.
Starter motor
Alternator
Batteries
Battery relay
Monitor panel
Relay box
Fuse box
Key switch
EX255-EX285
T2-3-13
ELECTRICAL SYSTEM
SM5612
T2-3-14
EX255-EX285
ELECTRICAL SYSTEM
Power Generation
The alternator consists of field coil FC, stator coil SC,
and diodes D.
The regulator consists of transistors T1 and T2, zener
diode ZD, and resistors R1 and R2.
Alternator terminal B is connected to:
BRRF(R)R1Base B for Transistor T1
When the key switch BS is turned ON, the battery
voltage flows to base B for transistor T1 in the regulator, allowing current to flow from collector C to
emitter E.
Accordingly, field coil FC is grounded through transistor T1.
At first, the current does not flow to field coil FC.

When the rotor starts to rotate, alternating voltage is
generated in stator coil SC due to residual magnetism
in the rotor.
Thereby, the current starts to flow through field coil
FC, magnetizing the rotor further and increasing
generating voltage.
As generating voltage increases, the flowing current
through field coil FC is increased further, causing the
generating voltage to increase more. Thus, the batteries are recharged.
Alternator
Regulator
B
R
RF
L
(R)
BS
R3
R4
R5
R6
D
Monitor
R2
ZD
Batteries
SC
FC
(F)
R1
D1
B
C
T2
E
T1
(E)
E
SM4056A
EX255-EX285
T2-3-15
ELECTRICAL SYSTEM
Regulator Operation
When the generating voltage increases higher than
the set voltage of zener diode ZD, the current from the
alternator flows through the zener diode to base B for
transistor T2, connecting collector C to emitter E.
Accordingly, the current flowing through base B for
transistor T1 is cut so that transistor T1 is turned OFF.
Thereby, the current flowing through field coil FC is
cut, causing the SC generating voltage to decrease.
Then, when the voltage to be applied to zener diode

ZD becomes lower than the set voltage of zener diode
ZD, transistor T2 is turned OFF, turning transistor T1
ON again. Thus, the current is allowed to flow through
field coil FC to increase the generating voltage by
stator coil SC. As this operation is repeated, the
alternator generating voltage is maintained at the
specified level.
RF
R3
BS
R4
R5
R6
ZD
R2
SC
A
C
FC
R1
(F)
D1
T2
B
C
E
T1
(E)
SM4057
T2-3-16
EX255-EX285
ELECTRICAL SYSTEM
SURGE VOLTAGE PREVENTION CIRCUIT
When the engine is stopped (key switch is OFF), the
current from key switch terminal M is cut so that
battery relay is turned OFF.
The engine does not stop immediately by the key
switch OFF, due to inertia and the alternator continues to generate electricity. Because the alternator
generating current dose not flow to the batteries, the
surge voltage (Voltage rise) is developed in the circuit. This is the cause of failure of electrical parts and
components.
On account of this, the surge voltage prevention
circuit has been provided.
While the batteries are being recharged, the generating current from terminal L on the alternator is led to
terminal #42 on the monitor, turning the output transistor ON for terminal #18 on the monitor.
In the conditions, the batteries current holds the Anti
Load Dump relay R1, located in the relay box, energised.
Accordingly, even if the key switch is turned OFF
while the engine is running, the battery current can be
supplied through the anti load dump relay (R1) to
magnetize the battery relay, holding the battery relay
ON until the alternator stops generating.
Alternator
Safety relay
Starter motor
Batteries
Battery relay
Fuse link
Relay box
Fuse box
Monitor panel
Key switch
EX255-EX285
T2-3-17
ELECTRICAL SYSTEM
SM5613
T2-3-18
EX255-EX285
ELECTRICAL SYSTEM
ENGINE STOP CIRCUIT
(Key Switch: OFF)
When the key switch is turned from the ON position to
the OFF position, the signal instructing the MC that
the key switch is ON is cut.
Then, the MC moves the EC motor to the stop position

causing the engine to stop.
Batteries
Fuse link
Fuse box
To monitor (39)/
To Radio
Key switch
Main Controller (MC)
EC
Sensor
EC
Motor
EX255-EX285
T2-3-19
ELECTRICAL SYSTEM
SM5614
T2-3-20
EX255-EX285
ELECTRICAL SYSTEM
ENGINE AND PUMP CONTROL CIRCUIT
The main controller (MC) monitors all digging functions, travel functions, and hydraulic pump functions
Further the main controller stores possible malfunction conditions of hydraulic and electrical system
generating faults codes that can be detected from
the diagnostic instrument (Dr.EX).
The main controller(MC) receives as input signals:
- from panel switch the signals related to the travel
speed, the auto idle position and work mode selection;
- from the R.H. control lever hand grip the input signal
of power boost;
- from engine speed control dial panel the engine
speed signal and mode switches E and HP signals.
To provide the required functions, the main controller
(MC), compares these input signals with instant conditions detect from various pressure switches and
sensors and provide output signals for the engine
speed control (by means of the operation of EC
motor), and for the pump control circuit (by means of
solenoid valves operation).
Engine speed control circuit

The engine speed control circuit consists of engine
control dial, E and HP mode switches Auto Idle
switch, N sensor and EC motor and angle sensor
assembly.
The engine control dial adjusts the engine revolutions independently of positions of E mode, HP
mode switches.
The engine control dial sends an electrical signal to
the main controller proportionally to the engine
control dial angle. (This signal can be detected from
Dr.EX with monitor function by selecting: Target
engine speed).
The N sensor supply signal to the main controller
indicating the engine speed. (This signal can be
detected from Dr.EX with monitor function by selecting: Actual engine speed).
In order to change the engine speed, the main
controller sends signals to the EC motor, that revolves and controls the governor lever. (This signal
can be detected from Dr.EX with monitor function by
selecting: EC motor position).
The EC angle sensor detects the position of EC

motor and supplies signals to the main controller to
indicate the position of the governor lever. (This
signal can be detected from Dr.EX with monitor
function by selecting: EC angle).
The main controller (MC) compares and processes
the input signals and if the engine requires engine
speed changes, it supplies power to the EC motor
in order to change the position of governor lever.
Fuse box
From fuse link 3 60 A
Solenoid valve group
Key switch
Pressure switch
To/from
monitor
N Sensor
EC
Motor
From relay box

(R14)
Pressure sensor
to monitor
panel
EX255-EX285
T2-3-21
ELECTRICAL SYSTEM
SM5615
T2-3-22
EX255-EX285
ELECTRICAL SYSTEM
Pump control circuit
The pump control circuit consists of pilot pressure
switches related to boom up, Front attachment and
travel, Pump 1 and 2 delivery pressure sensors,
Arm roll-in pilot pressure sensor , Pump 1 and 2
control pressure sensors, work mode selector,
travel mode selector and solenoid valve group.
(The operation of each pressure sensor can be

detected from Dr.EX with monitor function by selecting: Pump 1 or 2 Delivery pressure, Pump 1 or 2
Control pressure, Arm Roll-in pilot pressure. The Dr
EX will detect the electrical signal and will show as
pressure value of the related Sensors)
The pilot pressure switches related to the boom up

(located on the shockless valve), front attachment
and travel (located on control valve), when receive
the actuating pressure, send a ground signal to the
MC controller. (The operation of each pressure
switch can be detected from Dr.EX with monitor
function by selecting: Pressure switch. The Dr EX
will detect the pressure switch ON or OFF condition
showing or deleting the related pressures switch
abbreviation BmH, Fr, Tr ).
As result of the position of the Work mode selector,

travel mode selector and the actual condition detected from various pressure switches and sensors, the MC controller processes the output signal
to operate the pump regulator solenoid valve (SD),
the travel motor swash angle solenoid valve (SI),
the arm regenerative solenoid valve (SC), and the
relief pressure solenoid valve (SG). (The operation
of each solenoid valve can be detected from Dr.EX
with monitor function by selecting the individual
solenoid valve. The Dr EX will detect the control
electrical signal and will show as controlled pressure value from each related solenoid valve).
The Pump 1 and 2 delivery and control pressure

sensors located on the pump device) and the Arm
Roll-in pilot pressure sensor (located on shockless
valve) send to controller MC an electrical signal that
is proportional to related pressure to be controlled.
Fuse box
Solenoid valve group
Key switch
Pressure switch
To/from
monitor
N Sensor
EC
Motor
From relay box

(R14)
Pressure sensor
to monitor
panel
EX255-EX285
T2-3-23
ELECTRICAL SYSTEM
SM5615
T2-3-24
EX255-EX285
ELECTRICAL SYSTEM
MONITOR CIRCUIT
The monitor circuit consists of circuits to operate the
hour meter, coolant temperature gauge, fuel gauge,
engine oil level indicator, engine oil pressure indicator, coolant level indicator, engine overheat indicator,
alternator charging indicator, fuel low level indicator,
air cleaner restriction indicator, hydraulic oil level
indicator and engine pre-heat indicator.
Hour meter operates when alternator is charging and
anti load dump relay is energized.
Monitor gauges receive signal from sensors to indicate fuel level and engine coolant temperature.
The monitor controller contains a logic circuit and
transistors to control ground signals for monitor indicator lights.
Monitor controller receives signals from engine oil
level switch, coolant level switch, hydraulic oil level
switch, engine overheating switch, engine oil pressure switch, fuel low level switch, air filter restriction
switch, Q.O.S. controller and alternator.
Monitor controller provides voltages to transistors if

temperature, pressures or levels are outside normal
limits to illuminate indicator lights.
Engine oil level switch is closed when oil level in the
oil pan is OK.
Coolant level switch is closed when coolant level in
the recovery tank is OK.
Hydraulic oil level switch is closed when level in the
hydraulic oil tank is OK.
Fuel low level switch is open when the fuel level in the
fuel tank is above the reserve
Engine overheat switch is open when coolant temperature is within normal operating range.
Engine oil pressure switch opens above 98 kPa
(14.2 psi) and closes when the oil pressure is below.
Engine air filter restriction switch closes when vacuum
is above approx. 635 mm (25 in.) water , and opens
when vacuum is below.
The pre-heating temperature switch is closed when
engine coolant temperature is lower to 10C (50 F).
NOTE: Shown with engine

stopped and correct
liquid level.
Fuse box
From fuse
link 3 (60 A)
From fuse
link 1 (40 A)
Key switch
Wiper box
Relay box
Monitor panel
}
to wiper box
EX255-EX285
T2-3-25
ELECTRICAL SYSTEM
SM5616
Relay box
Alternator
T2-3-26
EX255-EX285
ELECTRICAL SYSTEM
NOTES:
SECTION 3
EX255-EX285
COMPONENT OPERATION
CONTENTS
Group 1 -
Pump device
Group 5 -
Outline ................................................. T3-1-1

Main pump .......................................... T3-1-2
Regulator ............................................. T3-1-5
Pilot pump ........................................... T3-1-13
N sensor (Engine speed sensor) ......... T3-1-13
Pump pressure sensor ........................ T3-1-13
Group 2 -
Outline ................................................. T3-5-1

Travel reduction gear ............................ T3-5-3
Travel motor ......................................... T3-5-5
Travel brake valve ................................ T3-5-10
Parking brake ....................................... T3-5-13
Swing device
Group 6 -
Outline ................................................. T3-2-1

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

Shockless valve ................................... T3-6-2
Solenoid valve unit .............................. T3-6-4
Pilot relief valve ................................... T3-6-6
EC motor ............................................. T3-6-6
Control valve
Outline ................................................. T3-3-1

Hydraulic circuit ................................... T3-3-6
Flow combiner valve ............................ T3-3-8
Pump control valve .............................. T3-3-10
Main relief valve .................................. T3-3-12
Overload relief valve ............................ T3-3-13
Arm regenerative valve ........................ T3-3-14
Boom anti-drift valve,
arm anti-drift valve ............................... T3-3-16
Bucket flow control valve ..................... T3-3-16
Travel flow control valve ....................... T3-3-18
Travel/boom lower
selector valve ...................................... T3-3-18
Boom regenerative valve ..................... T3-3-20
Group 4 -
Travel device
Pilot valve
Outline ................................................. T3-4-1

Operation ............................................ T3-4-3
Group 7 -
Other components
(Undercarriage)
Swing bearing ...................................... T3-7-1

Center joint .......................................... T3-7-2
Track adjuster ...................................... T3-7-3
EX255-EX285
T3-1-1
PUMP DEVICE
OUTLINE
The pump device consists of a transmission, main
pump, and pilot pump. The transmission receives
engine power via coupling, then divides and transmits the power to pump 1 (1), pump 2 (2) and pilot
pump (3) via gears. Gear ratios on the main pump
drive side and the pilot pump side are 1.
Main pumps (1 and 2) are variable displacement,
bent-axis plunger-type pumps equipped with pump

delivery pressure sensors (5) and engine speed
sensor (4) for controlling of the pumps and valves.
These main pumps are incorporated into a single
housing.
Pilot pump (3) is a gear-type pump.
Transmission
SM3016
Transmission
5
SM3017
1
2
3
- Pump 1
- Pump 2
- Pilot Pump
SM3018
4
5
- Engine Speed Sensor (N Sensor)

- Pump Delivery Pressure Sensor
T3-1-2
EX255-EX285
PUMP DEVICE
MAIN PUMP
Operation
Main pump consists of pump 1 and pump 2, and
supplies hydraulic oil to actuate main components
such as motors and/or cylinders.
Shaft (3) is connected to cylinder block (6) via seven
plungers (4).
Therefore, the rotation of shaft (3) is transmitted to

cylinder block (6), causing cylinder block (6) to slide
along the surface of valve plate (5). Plungers (4)
reciprocate in the cylinder bores, thus discharging
hydraulic oil to the hydraulic circuits.
SM0005
1
2
4
5
SM0004
1
2
3
- Regulator
- Housing
- Shaft
SM0006
4
5
6
- Plunger
- Valve Plate
- Cylinder Block
EX255-EX285
T3-1-3
PUMP DEVICE
SM0007
T3-1-4
EX255-EX285
PUMP DEVICE
Increasing and Decreasing Main Pump Oil
Flow Rate
When the displacement angle of cylinder block (3) is
changed, the stroke length of plunger (2) changes.
Thus, oil flow rate of the main pump is controlled by
changing the displacement angle of cylinder block
(3). Servo piston (6) is jointed to valve plate (4) with
pin (5).
When servo piston (6) is moved up or down, valve

plate (4) moves too, changing the displacement
angle of cylinder block (3); cylinder block (3) is kept
in contact with the surface of valve plate (4) and slides
along it.
Maximum displacement angle
5
2
6
SM0006
SM0008
Minimum displacement angle
SM0009
2
3
4
- Plunger
- Cylinder Block
- Valve Plate
5
6
- Pin
- Servo Piston
EX255-EX285
T3-1-5
PUMP DEVICE
REGULATOR
Regulator Construction
pump pressure and the pilot pressure from the solenoid valve unit (SD) are routed to the section 2 of the
regulator. (Note that, viewed from a regulator, two
main pumps are said to be the applicable main pump
and the other main pump). Upon receiving various
signal pressures stated above, the regulator outputs
a pilot pressure to servo piston (10) to change the
displacement angle of cylinder block (11), thus controlling the pump oil flow rate.
Both main pumps (1 and 2) are equipped with a

regulator. Upon receiving various signal pressures,
the regulator controls main pump oil flow rate not to
exceed the engine horsepower.
Regulator mainly consists of spring (1), sleeve B (2),
spool B (3), piston (4), load piston (5), spool A (6),
sleeve A (7), outer spring (8), and inner spring (9).
The pump control pressure is routed to section 1 and
the applicable main pump pressure, the other main
Section I
}
5
Section II
9
SM0010
12
11
10
SM0006
1
2
3
4
Spring
Sleeve B
Spool B
Piston
5
6
7
8
Load Piston
Spool A
Sleeve A
Outer Spring
9
10
11
12
Inner Spring
Servo Piston
Cylinder Block
Link
T3-1-6
EX255-EX285
PUMP DEVICE
Regulator Functions
The regulator functions to control pump oil flow rate
as follows:
Control by Pump Control Pressure

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

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

Valve Unit (SD)
Processing the target engine speed, and the actual
engine speed, the main controller MC sends signal
to solenoid valve unit (SD). Solenoid valve unit, in
turn, routes a pilot pressure to the regulator. Then,
the regulator reduces pump delivery rate accordingly. (Speed Sensing (Horsepower Reducing)
Control) (Refer to the control system Group in the
SYSTEM Section).
Q
Flow rate
Pi
Pressure increase
Q
Flow rate
Flow rate decrease
Pressure
Q
Flow rate
Pressure
SM0011
EX255-EX285
T3-1-7
PUMP DEVICE
Regulator operation
3
Pi
12
10
Pps
11
9
13
Pd1 Pd2
5
SM0012
7
3
4
2
Pi
Pd1
11-12
Pps
Pd2
5
9
13
10
7
1
2
3
4
5
6
7
Piston
Spool B
Spring
Servo Piston
Link
Sleeve B
Large Chamber
4
8
9
10
11
12
13
8
Small Chamber
Load Piston
Spool A
Inner Spring
Outer Spring
Sleeve A
SM0013
T3-1-8
EX255-EX285
PUMP DEVICE
Flow Rate Control by Pump Control Pressure
Flow rate increase:

changed by the movement of the servo piston,
increasing the pump flow rate.
6. The movement of servo piston (4) is transmitted
to sleeve B (6) via link (5), moving sleeve B (6) in
the direction that spool B (2) has moved. When
sleeve B (6) moves for the same distance spool B
(2) has moved, large chamber (7) is closed to the
hydraulic oil tank line, stopping the servo piston
movement, thus stopping the increase of pump
flow rate at that point.
1. Pump control pressure Pi increases when a control valve spool is moved.

2. Piston (1) pushes spool B (2) and spring (3) to
move spool B (2) to the direction indicated by the
arrow.
3. Large chamber (7) at the end of servo piston (4)
is connected to the hydraulic oil tank line.
4. As a result, servo piston (4) moves to the direction
indicated by the arrow.
5. The displacement angle of the cylinder block is
Pi
Pressure increase
Pps
Q
Pd1 Pd2
Flow rate
Pi
5
SM0014
4
SM0015
1234-
Piston
Spool B
Spring
Servo Piston
5678-
Link
Sleeve B
Large Chamber
Small Chamber
EX255-EX285
T3-1-9
PUMP DEVICE
Flow rate decrease:
1. When the control valve spool is returned to neutral, the pump control pressure Pi decreases.
2. Spring (3) pushes back piston (1) and spool B (2),
returning spool B (2) to the direction indicated by
the arrow.
3. As a result, the servo pressure acting on small
chamber (8) is also routed to large chamber (7).
4. Servo piston (4) moves in the direction indicated
by the arrow, due to the size difference of the
pressure receiving area between both chambers.
5. The displacement angle of the pump decreases.

to sleeve B (6) via link (5), moving sleeve B (6) in
the direction that spool B (2) has moved. When
sleeve B (6) moves for the same distance spool B
(2) has moved, large chamber (7) is closed to the
hydraulic oil tank line, stopping the servo piston
movement, thus stopping the decrease of pump
flow rate at that point.
Pi
Pressure decrease
Pps
Q
Pd1 Pd2
Flow rate
Pi
5
SM0016
1234-
Piston
Spool B
Spring
Servo Piston
5678-
Link
Sleeve B
Large Chamber
Small Chamber
SM0017
T3-1-10
EX255-EX285
PUMP DEVICE
Summation Control (Flow Rate Control by Monitoring Both Main Pump Pressures)
Flow Rate Increase:

(Note that, viewed from a regulator, two main pumps
are said to be the applicable main pump and the other
main pump)
indicated by the arrow.

5. As the servo piston moves, the displacement
angle of the cylinder block changes, increasing
the pump flow rate.
to sleeve A (13) via link (5), moving sleeve A (13)
in the direction spool A (10) has moved. When
sleeve A (13) moves for the same distance spool
A (10) has moved, large chamber (7) is closed to
the hydraulic oil tank line, stopping the servo
piston movement, thus stopping the increase of
pump flow rate at that point.
1. The pressure from the applicable main pump

(Pressure Pd1) or from the other main pump
(Pressure Pd2) decreases.
2. Inner spring (11) and outer spring (12) pushes
load piston (9) and spool A (10), moving them in
the direction indicated by the arrow.
3. Large chamber (7) at the end of servo piston (4) is
connected to the hydraulic oil tank line.
4. As a result, servo piston (4) moves in the direction
13
10
Pi
11
Pps
Q
12
Flow rate
Pd1 Pd2
Pressure decrease
(Summation of two main

pump pressures)
Pd
5
SM0018
4
SM0015
4
5
7
8
9
Servo Piston
Link
Large Chamber
Small Chamber
Load Piston
10
11
12
13
Spool A
Inner Spring
Outer Spring
Sleeve A
EX255-EX285
T3-1-11
PUMP DEVICE
Flow rate decrease:
1. The pressure from the applicable main pump
(Pressure Pd1) or from the other main pump
(Pressure Pd2) increases.
2. Load piston (9) pushes spool A (10), inner spring
(11), and outer spring (12), moving spool A (10) in

6. When sleeve A (13) moves for the same distance
spool A (10) has moved, servo pressure routed to
large chamber (7) is shut out, stopping the servo
piston movement, thus stopping the decrease of
13
10
Pi
11
Flow rate
Pps
12
Pd1 Pd2
Pressure increase

pump pressures)
Pd
5
7
SM0019
4
SM0020
4
5
7
8
9
Servo Piston
Link
Large Chamber
Small Chamber
Load Piston
10
11
12
13
Spool A
Inner Spring
Outer Spring
Sleeve A
T3-1-12
EX255-EX285
PUMP DEVICE
Flow Rate Control by Pilot Pressure Guided from
Solenoid Valve Unit (SD).
Flow rate decrease:

1. Solenoid valve unit (SD) is activated by signals
from the main controller MC, guiding pilot pressure Pps.
2. Pilot pressure Pps, together with the applicable
main pump pressure or with the other main pump
pressure, acts on load piston (9).
3. Load piston (9) pushes spool A (10), inner spring
(11), and outer spring (12), moving spool A (10) in

7. When sleeve A (13) moves for the same distance
spool A (10) has moved, servo pressure routed to
large chamber (7) is shut out, stopping the servo
piston movement, thus stopping the decrease of
13
10
Pi
11
Pps
12
Pressure increase
Pd1 Pd2
Flow rate

pump pressures)
4
SM0021
SM0020
4
7
8
9
Servo Piston
Large Chamber
Small Chamber
Load Piston
10
11
12
13
Spool A
Inner Spring
Outer Spring
Sleeve A
EX255-EX285
T3-1-13
PUMP DEVICE
PILOT PUMP
Suction port
Drive gear (1) is rotated via the transmission to driven

gear (2).
1
2
- Drive gear
- Driven gear
Delivery port
SM0022
N SENSOR (ENGINE SPEED SENSOR)

The N sensor detects engine speed. Engine speed is
a necessary signal for various controls of the machine. The N sensor is installed close to the top of the
transmission gear; when the gear rotates, gear tooth
tops pass by the top of the N sensor. Then numbers
of gear teeth passing by are converted to electrical
pulse signals which are sent to the EC.
Thereby, engine speed is detected.
4
5
6
7
8
4
5
6
Coil
Magnet
Gear
Signal output terminal
Power supply (5 V)
8
SM0023
SM0024
PUMP PRESSURE SENSOR

The pump pressure sensor detects oil pressure. Oil
pressure is a necessary signal for various controls of
the machine.
Oil pressure is received by diaphragm (12).
Depending on the extent of deformation of the diaphragm, oil pressure is detected as an electrical
signal.
9
10
11
12
Grounding terminal
Output terminal
Power supply (5V) terminal
Pressure receiving section (diaphragm)
10
11
12
SM0025
T3-1-14
EX255-EX285
PUMP DEVICE
NOTE
EX255-EX285
T3-2-1
SWING DEVICE
OUTLINE
The swing device consists of the valve unit, the swing
motor, and the swing reduction gear.
The valve unit prevents cavitation and overload of the
swing circuit.
The swing motor is a swash-plate-type axial plunger
NOTE- The figure shows the swing device installed on

EX255
motor (with a built-in parking brake for swing), and is

driven by the pressure oil from the pump to rotate the
swing reduction gear.
The swing reduction gear rotates the upperstructure
by rotating the shaft by slow speed and large torque.
Valve unit
Swing motor
Swing reduction
gear
SM3019
T3-2-2
EX255-EX285
SWING DEVICE
NOTE - The figure shows the swing device installed on
EX285.
Valve unit
Swing motor
Swing reduction
gear
SM5001
EX255-EX285
T3-2-3
SWING DEVICE
SWING MOTOR
The swing motor consists of the swashplate, rotor,
plungers, valve plate, housing and swing parking
brake (consists of spring, brake piston, plate, friction
plate and switch valve).
The rotor is installed onto shaft with a spline coupling,
and the plungers are inserted in rotor.
The pressure oil is fed from the pump so that the
plungers are pushed.
The shoe of the plunger slides along swash plate, and

rotation occurs in rotor. The shaft end is connected to
first stage sun gear of the swing reduction gear by a
spline coupling. Therfore the rotation of shaft is
transmitted to the swing reduction gear.
NOTA - The figure shows the swing motor installed on EX255.
1-2
1
2
3
4
5
6
Valve Plate
Rotor
Housing
Plunger
Shoe
Shaft
7
8
9
10
11
Swash Plate
Switch valve
Plate and Friction Plate
Brake piston
Spring
SM0027
T3-2-4
EX255-EX285
SWING DEVICE
NOTE - The figure shows the swing motor installed on EX285.
11
10
2
3
9
8
5
SM5007
1
2
3
4
5
6
Valve Plate
Rotor
Housing
Plunger
Shoe
Shaft
7
8
9
10
11
Swash Plate
Switch valve
Plate and Friction Plate
Brake piston
Spring
EX255-EX285
T3-2-5
SWING DEVICE
Swing speed varies depending on the amount of oil
delivered from the pump. From port A, high pressure
oil is fed so that plunger (3) is pushed from the top to
the bottom.
Shoe (4) then slides along swash plate (5),
developing turning force.
Turning force is transmitted to the swing reduction

gear unit via shaft (6). The return oil flows to outlet
port B and returns to the hydraulic oil tank.
When pressure oil is fed to port B, the motor rotates
in the opposite direction.
4
5
SM0028
1
2
3
- Valve Plate
- Rotor
- Plunger
4
5
6
- Shoe
- Swash Plate
- Shaft
T3-2-6
EX255-EX285
SWING DEVICE
SWING PARKING BRAKE
The parking brake is a wet-type multiple disc brake.

The brake is released only when brake release
pressure enters into brake piston chamber (b),
(negative type brake). When swing and/or front attachment operation is made brake release pressure
is supplied from the pilot pump.
During operations other than swing and/or front, or
while the engine is stopped, brake release pressure
is routed to the hydraulic oil tank and the parking
brake is automatically applied by spring (1).
2
b
3
4
5
When the swing and/or front function is operated,

the brake is released:
When the swing and/or front control lever is operated, the control valve spool for swing and/or front
function is moved from the neutral position, closing
the spool passage for the signal pilot pressure
circuit. Then, the pilot oil pressure increases, and
the increased pressure pilot oil is sent to the pilot
port of the switch valve in the brake release circuit.
Therefore, the switch valve is opened, allowing the
brake release pilot oil pressure from the pilot pump
to act on brake piston (2) via the oil pressure timer
check valve. Accordingly, brake piston (2) is moved
up against spring (1), breaking contact between
friction plates (4) and plates (3). Then, the brake is
released.
When the swing and/or front function is not operated, the brake is applied:
When the swing and/or front control lever is not
operated, the control valve spool for swing and/or
front function is in the neutral position, holding the
spool passage for the signal pilot pressure circuit
open. Then, the pilot oil pressure does not increase. Therefore, the switch valve in the brake
circuit is kept closed, allowing the brake release
pilot oil pressure on brake piston (2) to flow out to
the hydraulic oil tank via the oil pressure timer
orifice. Accordingly, brake piston (2) is moved
down by spring (1) force so that friction plates (4)
come into contact with plates (3). As friction plates
(4) engage the inner circumference of motor housing (5) and plates (3) engage the outer circumference of rotor (6), rotor (6) is braked by friction
force developed between plates (3) and friction
plates (4).
6
1
2
3
- Spring
- Brake Piston
- Plate
SM0032
4
5
6
- Friction Plate
- Motor Housing
- Rotor
When the brake is released (OFF):

Oil pressure timer
Signal pilot pressure
circuit
Brake release
pressure
OFF
Swing motor
Spool
Switch valve
SM0033
When the brake is applied (ON):

Oil pressure timer
circuit
Brake release
pressure
ON
Swing motor
Switch valve
Spool
SM0034
EX255-EX285
T3-2-7
SWING DEVICE
VALVE UNIT
Relief valve
The valve unit consists of the make-up valve and the

relief valve.
The make-up valve prevents cavitation in the circuit,
and the relief valve prevents surge pressure and
overloads in the circuit.
Make-Up Valve
When swing is stopped, if the upperstructure tends to
keep rotating due to inertia force, causing the swing
motor to continue rotating further, and to begin sucking oil from the pump, developing cavitation in the
motor.
The make-up valve sucks hydraulic oil through the
return circuit (port M) to compensate for the lack of oil,
and prevent cavitation.
Make-up valve
Port M
Control valve
SM0029
Relief valve
Port M
Make-up valve
Control valve
SM5008
T3-2-8
EX255-EX285
SWING DEVICE
Relief Valve
When starting or stopping swing operation, oil
pressure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the specified pressure. Plunger (1) is pushed to
the left by pressure Pp at port (P) and pressurereceiving area A2.
However, plunger (1) is also pushed back to the right
by spring (2) force and pressure Pg at chamber (g)
and pressure-receiving area A1.
Chamber (g) is routed to port (P) through orifice (m).
When force acting on the right is higher than that on
the left, the relief valve operates.
Relief valve
PA
PB
Port M
Control valve
SM0029
1
m
A1
A2
SM0031
EX255-EX285
T3-2-9
SWING DEVICE
SWING REDUCTION GEAR
The swing reduction gear is a two-stage planetary
gear type. Ring gears (2 and 4) in the first and second
stages are provided on the inside of the housing.
The housing is bolted to the main frame so that ring
gears (2 and 4) are held stationary.
The motor output shaft of the swing motor drives first
stage sun gear (9).
Then, rotary power is transmitted to second stage
sun gear (7) via first stage planetary gear (1) and first
stage carrier (8). Second stage sun gear (7) rotates
shaft (5) via second stage planetary gear (3) and
carrier (6).
As shaft (5) meshes with the internal gear of the
swing bearing bolted to the undercarriage, the
upperstructure is rotated.
NOTE - The figure shows the swing reduction gear

installed on EX255.
9
8
2
3
SM3020
1
2
3
4
5
First Stage Planetary Gear

First Stage Ring Gear
Second Stage Planetary Gear
Second Stage Ring Gear
Shaft (Output Shaft)
6
7
8
9
Second Stage Carrier

Second Stage Sun Gear
First Stage Carrier
First Stage Sun Gear
T3-2-10
EX255-EX285
SWING DEVICE
NOTE - The figure shows the swing reduction gear
installed on EX 285.
9
8
1
2
3
4
SM5002
1
2
3
4
5

First Stage Ring Gear
Second Stage Ring Gear
6
7
8
9

First Stage Carrier
EX255-EX285
T3-3-1
CONTROL VALVE
OUTLINE
The control valve controls oil pressure, flow rate, and
flow direction in the hydraulic circuit. A 4-spool side
section and a 5-spool side section are bolted together.
The control valve is a pilot-pressure-operated type
which mainly consists of the main relief valve, pump
control valves, flow combiner valve, and main spools.
Machine Front
In the 4-spool side section, the Right Travel, Bucket,

Boom 1, and Arm 2 spool sections are arranged in
that order as viewed from the machine front.
In the 5-spool side section, the Left Travel, Auxiliary,
Boom 2, Arm 1, and Swing spool sections are arranged in that order as viewed from the machine
front.
Right travel
Bucket
Left travel
Main relief valve
Boom 1
Arm 2
Auxiliary
4-spool side section
Boom 2
Arm 1
Swing
Pump control valve (5-spool side)
5-spool side section
Machine Rear
SM0036
T3-3-2
EX255-EX285
CONTROL VALVE
Control valve layout
Left travel motor
3
2
10
Right travel motor
11
12
41
13
14
40
15
16
39
Bucket cylinder
38
37
36
35
34
Boom cylinder
17
18
Arm cylinder
33
32
31
19
20
30
29
21
22
23
26
27
28
24
25
Swing motor
1
2
3
- Hydraulic Timer
- Travel Flow Control Valve
- Load Check Valve (Travel Parallel
Circuit)
4 - Check Valve
5 - Main Relief Valve
6 - Check Valve
7 - Check Valve
8 - Flow Combiner Valve
9 - Load Check Valve (Bucket)
10 - Bucket Flow Control Valve
(Switch Valve A)
(Switch Valve B)
(Poppet Valve)
13 - Load Check Valve (Boom 1
Parallel Circuit)
Tandem Circuit)
SM0037
15
16
17
18
19
20 21 22 23 24 25 26 27 28 -
Overload Relief Valve (Bucket)

Overload Relief Valve (Boom)
Boom Anti-Drift Valve (Check Valve)
Boom Anti-Drift Valve (Switch
Valve)
Boom Regenerative Valve
Check Valve
Pump Control Valve (4-Spool
Side)
Check Valve
Restriction (4-Spool Side Parallel
Circuit)
Load Check Valve (Arm Parallel
Circuit)
Restriction (Arm 1 Parallel
Circuit)
Load Check Valve (Swing)
29 - Load Check Valve (Arm Tandem

Circuit)
30 - Check Valve
31 - Arm Regenerative Valve
32 - Check Valve
33 - Overload Relief Valve (Arm)
35 - Arm Anti-Drift Valve (Check Valve)
36 - Arm Anti-Drift Valve (Switch Valve)
Parallel Circuit)
38 - Travel/Boom Lower Selector Valve
39 - Check Valve
40 - Load Check Valve (Travel
Tandem Circuit)
41 - Pump Control Valve (5-Spool
Side)
EX255-EX285
T3-3-3
CONTROL VALVE
Section A
H
B
C
D
E
F
41
SM0036
SM0038
Section C
Bucket
Auxiliary
15
12
11
39
Section D
9
Boom 2
16
Boom 1
Section B
SM0040
L. Travel
R. Travel
38
17
37
3
2
20
21
19
13
14
40
10
18
SM0039
SM0041
T3-3-4
EX255-EX285
CONTROL VALVE
Control valve layout
Right travel motor
Left travel motor
3
2
10
11
12
41
13
14
40
15
16
39
Bucket cylinder
38
37
36
35
34
Boom cylinder
17
18
Arm cylinder
33
32
31
19
20
30
29
21
22
23
26
27
28
24
25
Swing motor
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
- Hydraulic Timer
- Travel Flow Control Valve
- Load Check Valve (Travel Parallel
Circuit)
- Check Valve
- Main Relief Valve
- Check Valve
- Check Valve
- Flow Combiner Valve
- Load Check Valve (Bucket)
- Bucket Flow Control Valve
(Switch Valve A)
(Switch Valve B)
(Poppet Valve)
- Load Check Valve (Boom 1
Parallel Circuit)
- Load Check Valve (Boom 1
Tandem Circuit)
- Overload Relief Valve (Bucket)
- Overload Relief Valve (Bucket)
SM0037
17 - Overload Relief Valve (Boom)

18 - Overload Relief Valve (Boom)
19 - Boom Anti-Drift Valve (Check Valve)
20 - Boom Anti-Drift Valve (Switch
Valve)
21 - Boom Regenerative Valve
31
32
33
34
35
22 - Check Valve
23 - Pump Control Valve (4-Spool
Side)
24 - Check Valve
25 - Restriction (4-Spool Side Parallel
Circuit)
26 - Load Check Valve (Arm Parallel
Circuit)
27 - Restriction (Arm 1 Parallel
Circuit)
28 - Load Check Valve (Swing)
Circuit)
30 - Check Valve
37 -
36 -
38 39 40 41 -
Arm Regenerative Valve

Check Valve
Overload Relief Valve (Arm)
Overload Relief Valve (Arm)
Arm Anti-Drift Valve (Check Valve)
Arm Anti-Drift Valve (Switch Valve)
Load Check Valve (Boom 2
Parallel Circuit)
Travel/Boom Lower Selector Valve
Check Valve
Load Check Valve (Travel
Tandem Circuit)
Side)
EX255-EX285
T3-3-5
CONTROL VALVE
Section E (2)
Arm 1
Arm 2
31
32
Section E (1)
Section F
Arm 1
Arm 2
Swing
SM0042
36
34
35
28
24
26
25
27
29
23
22
33
SM0043
SM0045
30
Section H
Section G
1
SM0044
SM0046
T3-3-6
EX255-EX285
CONTROL VALVE
HYDRAULIC CIRCUIT
Main Circuit
Pressure oil from pump 1 and from pump 2 is routed
to the 4-spool side section in the control valve and to
the 5-spool side section in the control valve, respectively.
A parallel passage is provided in both right and left
main circuits, making combined operations possible.
The main circuit pressure is restricted by the main
relief valve. Moreover, two overload relief valves are
provided in each of boom, arm, and bucket circuits.
Also, a pump control valve is provided at the most
downstream position of each of right and left neutral
passages.
Signal Pilot Pressure Circuit

The pilot pressure from the pilot pump flows through
the control valve.
When the causes the travel signal pilot pressure circuit
to be restricted, increasing the travel signal pilot pressure, thus turning on the pressure switch (travel) and
shifting the travel/boom lower selector valve.
When a control lever other than the travel levers is
operated, the signal pilot pressure in the front att.
signal pilot pressure circuit increases, thus turning on
the pressure switch (front) and shifting the flow
combiner valve, travel flow control valve, and swing
parking brake shift valve.
Flow combiner valve

Swing parking brake
shift valve
Pressure switch
(Front)
Pressure switch
(Travel)
Neutral passage
Main relief valve

circuit
Left travel motor
Pump control valve
(5-spool side)
Right travel motor
Auxiliary
Bucket
Travel flow control
valve
Travel/Boom lower
selector valve
Boom
Arm
Overload relief valves
Overload relief valves
Pump control valve

(4-spool side)
Parallel
passages
Swing
Main circuits
Neutral passage
5-spool side
4-spool side
Pilot pump
Pump 2
Pump 1
SM0047
EX255-EX285
T3-3-7
CONTROL VALVE
Pilot Valve Guided Pilot Pressure Circuit
Pilot pressure via the pilot valve exerts on the control
valve spools, shifting them. At the same time, it also
exerts on switch valves. (Arm anti-drift valve, Boom
anti-drift valve, Bucket flow control valve)
Besides shifting of control valve spools (when control
levers are operated), the pilot valve guided pilot
pressure functions as follows:
When the arm roll-in lever is operated, the pilot
pressure via the pilot valve exerts on the bucket
flow control valve and the anti-drift valve (switch
valve), shifting them.
When the boom raise lever is operated, the pilot
pressure exerts on the bucket flow control valve as
the valve shift pressure.
When the boom lower lever is operated, the pilot

pressure exerts on the boom anti-drift valve (switch
valve), shifting it.
In addition, an air bleed circuit is provided in the top
part of the control valve, automatically bleeding air
trapped in the circuit.
Solenoid Valve Guided Pilot Pressure Circuit

The pilot pressure guided via the solenoid valve unit
(SG and SC) shifts the main relief valve and the arm
regenerative valve. (Refer to the Control System
Group in the SYSTEM Section).
Main relief valve

From the solenoid valve unit (SG)
Bucket flow control valve
11
12
8
5
3
13
14
6
Arm anti-drift valve
Arm regenerative valve
From the solenoid valve

unit (SC)
Air bleed circuit
10
Pump 2
1
2
3
4
5
Left Travel Forward

Left Travel Reverse
Auxiliary
Auxiliary
Boom Raise
Boom anti-drift valve
Pump 1
6
7
8
9
10
Boom Lower
Arm Roll-out
Arm Roll-in
Swing Left
Swing Right
SM0048
11
12
13
14
Right Travel Reverse

Right Travel Forward
Bucket Roll-in
Bucket Roll-out
T3-3-8
EX255-EX285
CONTROL VALVE
FLOW COMBINER VALVE
When a control lever other than the travel levers is
operated, the signal movement of the control valve
spool restricts the signal pilot pressure in the front
attachment signal pilot pressure circuit, increasing
the pilot pressure to shift the flow combiner valve.

As a result, the pressure oil from the pump 1 is routed
to both right and left travel spools, securing straight
travel in travel combined operations.
EX255-EX285
T3-3-9
CONTROL VALVE
Front attachment signal

pilot pressure circuit
Left travel motor
Flow combiner valve
Right travel motor
Pilot pump
Arm cylinder
Pump 2
Pump 1
SM0049
T3-3-10
EX255-EX285
CONTROL VALVE
PUMP CONTROL VALVE
A pump control valve is provided on the most downstream part of the neutral passage in each of the 4spool and 5-spool side sections.
The pump control pressure altered by the pump
control valve exerts on the regulator, changing the
pump displacement angle. (Refer to the Pump Device Group in this section).
In addition, the pump control pressure sensor detects

the pump control pressure, sending signals to MC for
travel motor displacement angle control. (Refer to the
Control System Group in the SYSTEM Section).
Pump control valve

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

(4-spool side)
To the pump 1 regulator and

to the pump control pressure sensor
4-spool side
5-spool side
Neutral passage
SM0050
EX255-EX285
T3-3-11
CONTROL VALVE
Operation with Control Valve Spool Activated
When a control valve spool is shifted, oil flowing
through the neutral passage and through the pump
control valve decreases.
As oil flowing through the pump control valve
decreases, the pump control valve spool shifts to the
left, increasing the relief valve set pressure, thus
raising the pump control pressure.

This increased pump control pressure exerts on the
regulator and, in return, the regulator increases the
pump displacement angle, increasing the pump
delivery oil flow.
From the pilot pump

Pump control pressure passage
Pump control
pressure sensor
Hydraulic oil tank

Pressure
increase
Pump control valve
To the regulator
Neutral passage
Small oil flow
SM0051
Operation with Control Valve Spools in Neutral

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

minimum, the regulator decreases the pump
displacement angle to have the minimum pump
delivery flow, contributing to fuel efficiency.
From the pilot pump

Pump control pressure passage
Pump control
pressure sensor
Hydraulic oil tank
Pressure
Decrease
Pump control valve
To the regulator
Neutral passage
Large oil flow
SM0052
T3-3-12
EX255-EX285
CONTROL VALVE
MAIN RELIEF VALVE
The main relief valve regulates main circuit pressure.
The set pressure of the main relief valve is shifted by
the pilot pressure guided via the solenoid valve unit
(SG). (Refer to the Control System Group in the
SYSTEM Section).
When oil pressure at port Hp matches the spring set

force, the pilot poppet opens. Oil at port Hp flows to
port Lp through passage A.
As the pilot poppet opens, oil pressure in spring
chamber A decreases, opening the main poppet,
thus directly routing pressure oil at port Hp to port Lp.
Valve Operation
When the pilot pressure is not guided to the main
relief valve via the solenoid valve unit (SG):
Main poppet
Pilot poppet
Lp
Port SG
Hp
Lp
Spring A
Passage A
SM0053
When the pilot pressure is guided to the main relief

valve via the solenoid valve unit (SG):
When the pilot pressure via the solenoid valve unit
exerts on port (SG), the piston is pushed to the left in
the set position, increasing the compressional force
of spring B, thus requiring higher port Hp pressure to

open the pilot poppet.
For this reason, the main relief valve set pressure
increases.
Pilot poppet
Piston
Lp
Port SG
Hp
Lp
Spring B
SM0054
EX255-EX285
T3-3-13
CONTROL VALVE
OVERLOAD RELIEF VALVE
(With Make-Up Function)
Overload relief valves are provided in each port of
the boom, bucket, and arm cylinders, and regulate
oil pressure in the cylinder circuits to protect them
from damage due to excessive high pressure that
might develop if a cylinder is moved by excessive
external force.
Moreover, these relief valves function to suction oil

from the return (hydraulic oil tank) line to prevent the
occurrence of cavitation if negative oil pressure
arises in a cylinder (the make-up function).
10
SM0055
1
2
3
4
5
Spring
Plug
Pilot Poppet
Spring
Spring
6
7
8
9
10
Adjusting Screw
Plug
Main Poppet
Sleeve
Piston
T3-3-14
EX255-EX285
CONTROL VALVE
ARM REGENERATIVE VALVE
The arm regenerative valve is shifted by the pilot
pressure guided via the solenoid valve unit (SC).
When the arm regenerative valve is shifted, the
return oil line from the cylinder rod side is closed.
Then, the return oil is combined with the pump
delivery oil to be supplied to the cylinder bottom side,
increasing the arm roll-in speed, improving the arm

controllability in general, and preventing arm movement hesitation from occurring in arm roll-in operations. (Refer to the Control System Group in SYSTEM Section).
Arm cylinder
From the solenoid valve unit (SC)

SM0056
EX255-EX285
T3-3-15
CONTROL VALVE
Arm 1
From the solenoid valve
unit (SC)
Pump 2
Pump 1
SM0057
T3-3-16
EX255-EX285
CONTROL VALVE
BOOM ANTI-DRIFT VALVE, ARM ANTIDRIFT VALVE
An anti-drift valve is provided on the bottom side of
the boom cylinder and on the rod side of the arm
cylinder so as to reduce cylinder drift.
When the control valve spool is in neutral, the switch
valve part of the anti-drift valve is not shifted and the
pressure in the boom cylinder bottom side (the arm
cylinder rod side) exerts on the check valve of the
anti-drift valve via the switch valve, closing the check
valve.
When the arm roll-in or boom lower is operated, the

pilot pressure via the pilot valve shifts the switch valve
of the anti-drift valve. The oil pressure exerted on the
check valve is returned to the hydraulic oil tank via the
restriction in the switch valve.
(The check valve is designed to close by a signal
pressure, which arises when the switch valve is not
shifted, and to open when the signal pressure is not
exerted (when the switch valve is shifted.)).
Boom cylinders
Boom 1
Boom lower
pilot pressure
Anti-drift valve (check valve)

Anti-drift valve (switch valve)
SM0058
BUCKET FLOW CONTROL VALVE

The bucket flow control valve restricts the bucket
circuit in the combined operations of the bucket, arm
roll-in, and boom raise, so as to raise the boom
sufficiently.
When the arm is rolled in, the arm roll-in pilot pressure
shifts switch valve (A) of the bucket flow control
valve. If the boom is raised at the same time, the
boom raise pilot pressure is routed through the switch
valve (A), shifting the switch valve (B) of the bucket

flow control valve.
Thus, the back pressure exerting on the poppet
valve rises, applying a force to close the poppet
valve, thus restricting oil flow through the poppet
valve. For this reason, the oil flow to the bucket is
restricted, supplying an oil flow to the higher-loadapplied boom raise side.
Arm roll-in pilot pressure

Poppet valve
Switch valve A
Boom raise pilot pressure

Bucket
Switch valve B
Bucket pilot pressure
Bucket cylinder
SM0059
EX255-EX285
T3-3-17
CONTROL VALVE
Bucket flow control valve
Arm anti-drift valve
Boom anti-drift
valve
Pump 2
Pump 1
SM0048
T3-3-18
EX255-EX285
CONTROL VALVE
TRAVEL FLOW CONTROL VALVE
When the front attachment is operated while
traveling, the non-travel signal pilot pressure exerts
on the travel flow control valve, which is located in the
parallel circuit, after flowing through the hydraulic
timer, so as to gradually restrict the parallel circuit.

As the parallel circuit is gradually restricted, shock
loads, occurring due to the front attachment operation, are reduced.
Hydraulic timer
To the travel motor

Left
travel spool
Non-travel signal pilot pressure
Travel flow control valve
Non-travel spool
SM0060
Travel parallel circuit
TRAVEL/BOOM LOWER SELECTOR VALVE

The boom lower operation is actuated by the oil flow
via the boom 1 section. However, in travel-combined operations, the oil flow from pump 1 does not
flow in the downstream boom 1 spool as it goes to
the upstream travel spool. If the boom is positioned
up in the air at the moment, the boom would be
lowered by its own weight. However, if the travelcombined boom lower operation is performed with
the base machine raised off the ground, the boom
does not lower.
To prevent this from occurring, in travel-combined

boom lower operations, the boom 2 spool is shifted to
route the oil flow from pump 2 to the boom lower
section so that the boom lowers to sufficiently perform the machine jack-up operation.
When the travel spool is shifted, the travel signal pilot
pressure shifts the travel/boom lower selector valve,
allowing the boom lower pilot pressure to exert on the
boom 2 spool. Thus, the boom lower operation is
sufficiently performed in travel-combined operations.
Right travel spool
Boom 2
Boom 1
To the boom cylinder
Travel/Boom lower
selector valve
Pump 2
SM0061
EX255-EX285
T3-3-19
CONTROL VALVE
Hydraulic timer
Travel flow
control valve
Signal pilot pressure circuit
Left travel motor
Right travel motor
Bucket
Travel/Boom lower
selector valve
Boom
Parallel passages
Pilot pump
Pump 2
Pump 1
SM0047
T3-3-20
EX255-EX285
CONTROL VALVE
BOOM REGENERATIVE VALVE
In boom lower operations, the return oil from the
cylinder bottom side is combined with the oil flow from
the pump, supplying an additional oil flow to the
cylinder rod side, via the check valve in the boom
spool.
By this boom regenerative valve operation, the boom

lower operation is improved and cavitation is prevented from occurring.
Boom regenerative
valve
Boom cylinders
Boom 1
Boom lower
pilot pressure
SM0062
EX255-EX285
T3-4-1
PILOT VALVE
OUTLINE
The pilot valve controls pilot pressure oil to move the
control valve spools. There are two types of pilot
valves. One is for front/swing operation; the other is
for travel operation. Both have standard four oil ports.
An optional two-oil-port type is available.
Except for the cam construction to push the pusher

down, the construction of the pilot valve in both the
front/swing pilot valve and the travel pilot valve is the
same.
Right and left pilot valves (Front/Swing)

Port No.
Control
Bucket roll-out
Boom lower
Bucket roll-in
Boom raise
Swing right
Arm roll-out
Swing left
Arm roll-in
Right
Left
T
3
P
4
1
SM0065
4
SM0063
T3-4-2
EX255-EX285
PILOT VALVE
Travel pilot valve
Port No.
Control
Left travel forward
Left travel reverse
Right travel reverse
Right travel forward
T
T
P
4
P
SM0064
SM0066
Positioning pilot valve (triple articulation version)

Port No.
Control
Positioning raise
(Positioning cylinder retraction)
Positioning lower
(Positioning cylinder extension)
T
1
2
T
P T
2
SM3043
SM3021
EX255-EX285
T3-4-3
PILOT VALVE
OPERATION
Front and Swing Pilot Valve
The lower face of spool (8) head is suspended by the
upper face of spacer (4); they are kept in contact by
setting force of balance spring (6). Spacer (4) is
installed between pusher (3) and spring guide (5) and
supported by return spring (7). Piston (9) is located
inside spool (8). The lower end of piston (9) makes
contact with the plate, preventing the piston from
moving further downward.
Above piston (9), a chamber is provided and it is led
to the outside of spool (8) through holes provided in
spool (8).
In neutral
(Corresponding to A to B in the output diagram):
When control lever (1) is in the neutral position (no
pusher stroke), spool (8) completely blocks pressure
oil from entering port P. Since the delivery port is open
to port T, pressure at the delivery port equals that in
the hydraulic oil tank.
When control lever (1) is slightly moved, cam (2)
moves together, pressing down on pusher (3).
Then, pusher (3), spacer (4), and spring guide (5)
move downward as a unit, compressing return spring
(7).
The lower face of spool (8) is kept in contact with the
upper face of spacer (4) by setting force of balance
spring (6) and moves downward together with spacer
(4). However, even if control lever (1) is moved
further, until clearance (A) at section (a) reaches
zero, the delivery port remains open to port T, keeping pressure at the delivery port equal to that in the
hydraulic oil tank.
Delivery port
pressure
(pilot pressure)
A B
Pusher stroke
OUTPUT DIAGRAM
4
5
6
Section (a)
(A)
7
8
Port T
(A)=0
Delivery port
Port P
SM0067
1
2
3
4
5
Control Lever
Cam
Pusher
Spacer
Spring Guide
6
7
8
9
Balance Spring
Return Spring
Spool
Piston
T3-4-4
EX255-EX285
PILOT VALVE
Ready to start operation
(Corresponding to B to C section in the output diagram):
When control lever (1) is tilted slightly further from the
position where clearance (A) in section (a) reaches
zero, and pusher (3) is pushed downward, spool (8)
is moved downward, opening notched section (b) to
allow pressure oil at the port P to flow into the delivery
port.
This oil pressure is also led to the inside of spool (8)
via orifice (10), and acts to push spool (8) upward.
Until this oil pressure force reaches the setting force
of balance spring (6), balance spring (6) will not be
compressed so that spool (8) is not moved upward,
closing the clearance at section (a), keeping the
notch at section (b) opened, and letting the oil pressure to increase at the delivery port.
If the oil pressure at the delivery port increases, and the
upward-pushing force of spool (8) slightly exceeds the
setting force of balance spring (6), spool (8) moves

upward against setting force of balance spring (6).
Once spool (8) moves upward, upper clarance at
section (a) is opened and lower notch section at
section (b) is closed, leading oil pressure at the
delivery port to port T, and decreasing oil pressure at
the delivery port.
When oil pressure at the delivery port decreases, the
force to push up spool (8) is reduced so that balance
spring (6) stretches to move spool (8) downward,
closing both the clearance and the notch at sections
(a and b).
Thus, original position of spool (8) is kept resumed.
The oil pressure will continue to increase until it is
equal to setting force of balance spring (6) (shown by
the point C in the output diagram).
Delivery port
pressure
(Pilot pressure)
C
B
Pusher stroke
OUTPUT DIAGRAM
Section (a)
Port T
Clearance (A) reaches zero
Delivery port
Section (b)
10
Port P
9
SM0068
1
3
6
- Control Lever
- Pusher
- Balance Spring
8 - Spool
9 - Piston
10 - Orifice
EX255-EX285
T3-4-5
PILOT VALVE
Operation corresponding to the control lever stroke
(Corresponding to C to D in the output diagram):
As control lever (1) is moved further to push pusher
(3) downward, spool (8) is pushed down to open the
notch at section (b), increasing oil pressure at the
delivery port.
As pressure increases, the force to push up spool (8)
increases. Then, when force to push up spool (8)
exceeds the setting force of balance spring (6), spool
(8) starts to move upward, compressing balance
spring (6).
When spool (8) moves upward until the clearance at

section (a) opens, the delivery port is opened to port
T, stopping oil pressure increase at the delivery port
and stopping movement of spool (8).
Accordingly, when compressed by pusher (3), spring
force of balance spring (6) increases in proportion to
the pusher stroke, Then, oil pressure increases to
counteract against this spring force.
Delivery port
pressure
(Pilot pressure)
C
Pusher stroke
OUTPUT DIAGRAM
3
Section (a)
8
Port T
Delivery port
Section (b)
Port P
SM0069
1
3
- Control Lever
- Pusher
6
8
- Balance Spring
- Spool
T3-4-6
EX255-EX285
PILOT VALVE
Operation close to pusher stroke end
(Corresponding to D to E in the output diagram):
As pusher (3) is pressed down, balance spring (6) is
compressed, reducing clearance (B) between
pusher (3) and the top of spool (8) (shown at section
(c)), finally to zero.
After that, pusher (3) directly pushes spool (8).
Even if oil pressure at the delivery port increases,
spool (8) cannot move upward, closing the oil passage from the delivery port to port T, and opening the
oil passage from the delivery port to port P.
Then, oil pressure at the delivery port increases until
it reaches port P pressure.
Delivery port
pressure
(Pilot pressure)
Pusher stroke
OUTPUT DIAGRAM
3
Section (c)
Clearance (B) reaches zero
6
8
Port T
Delivery port
Port P
SM0070
3
6
- Pusher
- Balance Spring
- Spool
EX255-EX285
T3-4-7
PILOT VALVE
Full stroke operation
(Corresponding to E to F section in the output diagram):
Even if control lever (1) is tilted further to push down
pusher (3), spool (8) moves downward along with
pusher (3), only widening the notch at lower section
(b) of spool (8).
Thus, oil pressure at the delivery port is kept same as
at port P. Pusher (3) can be pressed down until spring
guide (5) comes into contact with the shoulder (sec-
tion (d)) of the casing.

This position is the stroke end of pusher (3) (corresponding to F position in the output diagram).
This process corresponds with E to F section in the
output diagram.
The total stroke of the control lever is decided by
dimension C.
Delivery port
pressure
(Pilot pressure)
E F
Pusher stroke
OUTPUT DIAGRAM
Section (d)
5
8
Port T
Delivery port
Section (b)
Port P
SM0071
1
3
- Control Lever
- Pusher
5
8
- Spring Guide
- Spool
T3-4-8
EX255-EX285
PILOT VALVE
Travel Pilot Valve
In neutral
(Corresponding to A to B in the output diagram):
Lever - In Neutral (Pusher Stroke: A to B)
In neutral, spool (6) closes port P (the input port) and
tank port T is connected to delivery port through
clearance (A). Thus, the pressure at delivery port is
the same as that at tank port T.
When the control lever is moved slightly from A to B,
pusher (2) and spring guide (3) together move down
against return spring (5) and balance spring (4). At
this time, as both oil pressures above and below
spool (6) are the same as the tank pressure, spool (6)
moves down together with spring guide (3) until
clearance (A) becomes zero.
Operation corresponding to the control lever stroke

(Corresponding to C to D in the output diagram):
Lever - Operated
(Pusher Stroke: C to D Metering)
When the control lever is moved further to push
pusher (2) down, port P is connected to delivery port
through notch (B) and passage in spool (6), routing
pilot pump pressure. However, when the pressure
applied into spool (6) overcomes the balance spring
force, spool (6) moves up, closing port P. When
pusher (2) is moved further down, compressing return spring (5) and balance spring (4), the larger the
balance spring force; thus, the output pressure increases in proportion to the increase in the balance
spring force.
Full stroke operation:

Lever - Full Stroke (Pusher Stroke)
When the control lever is moved full stroke, pusher
(2) is moved down until spring guide (3) comes into
contact with the shoulder of the valve casing (Lever
Stroke End), opening notch (B) further to port P.
The output pressure (pilot pressure to the control
valve) remains at the pilot system pressure (the port
P pressure).
Dimension (C) in the figure right shows the control
lever full stroke.
Delivery port
pressure
(Pilot pressure)
C
A
Pusher stroke
OUTPUT DIAGRAM
SM0072
EX255-EX285
T3-4-9
PILOT VALVE
Pusher stroke: A to B
1
3
4
5
Port T
Clearance A: 0
(A)
Port P
Delivery port
SM0073
Pusher stroke: C to D
SM0075
Pusher stroke: full stroke
2
2
(C)
4
5
Port T
Port T
(B)
Port P
Port P
Delivery port
Delivery port
SM0076
SM0074
1
2
3
- Cam
- Pusher
- Spring Guide
4
5
6
- Balance Spring
- Return Spring
- Spool
T3-4-10
EX255-EX285
PILOT VALVE
NOTE
EX255-EX285
T3-5-1
TRAVEL DEVICE
OUTLINE
The travel device consists of travel motor (14), planetary reduction gears (1 to 10, 12, 13), and sprocket
(11).
NOTE - The figure shows the travel device installed
on EX255.
3
5
8
7
11
6
9
12
10
13
14
SM3022
1
2
3
4
5
6
7
Cover
First Stage Carrier
8
9
10
11
12
13
14
Third Stage Sun Gear

Third Stage Planetary Gear
Ring Nut
Sprocket
Housing (Ring Gear)
Hub (Third Stage Carrier)
Travel Motor
T3-5-2
EX255-EX285
TRAVEL DEVICE
NOTE - The figure shows the travel device installed
on EX285.
12
13
14
4
5
6
8
9
7
1
10
2
11
SM5003
1
2
3
4
5
6
7
Ring Gear
Propel Shaft
First Stage Carrier
8
9
10
11
12
13
14

Third Stage Carrier
Sprocket
Drum
Housing
Travel Motor
EX255-EX285
T3-5-3
TRAVEL DEVICE
TRAVEL REDUCTION GEAR
Third stage carrier (2) is part of the hub and as the
housing (1) (ring gear) and sprocket (11) are bolted
together, they all rotate.
The travel reduction gear is a third stage planetary

gear type. The travel motor rotates first stage sun gear
(7) and this driving force is transmitted to the housing
(1) via first stage planetary gear (8), first stage carrier
(6), second stage sun gear (5), second stage planetary gear (9), second stage carrier (4), third stage sun
gear (3), and third stage planetary gear (10).
NOTE - The figure shows the travel reduction gear

installed on EX255.
10
5
7
12
12
12
7
11
8
11
10
Third Second First

stage
stage stage
SM3023
1
2
3
4
5
6
Ring Gear (housing)

Third Stage carrier
First Stage Carrier
7
8
9
10
11
12
First Stage Sun gear (Propel Shaft)

Sprocket
Hub
T3-5-4
EX255-EX285
TRAVEL DEVICE
NOTE - The figure shows the travel reduction gear
installed on EX285.
6
7
12
10
9
1 2
11
7
12
11
10
Third
stage
Second
stage
First
stage
SM5004
1
2
3
4
5
6
Ring Gear (housing)

Third Stage Carrier
First Stage Carrier
7
8
9
10
11
12
Propel Shaft
Sprocket
Hub
EX255-EX285
T3-5-5
TRAVEL DEVICE
TRAVEL MOTOR
This travel motor is a variable-displacement bentaxis axial-plunger type that includes a parking brake
(wet-multi-disc negative type).
The main parts of the motor are plate (1), valve plate
(2), rotor (14), plungers (13), center shaft (5), drive
disc (7), servo piston (16), parking brake piston (12),
friction plates (11), and plates (10).
Rotor (14) is pre-loaded against valve plate (2) by

spring (4). As oil pressure in the rotor bores increases, the pressure acts on end faces (A) of the
rotor bores and assists spring (4) to force rotor (14)
against valve plate (2).
NOTE - The figure shows the travel motor installed on

EX255.
4
5
6
8
9
16
10
11
15
12
14
A
13
1
2
3
4
5
6
7
8
Plate
Valve Plate
Disc Spring
Spring
Center Shaft
Housing
Drive Disc
Roller Bearing
9
10
11
12
13
14
15
16
Roller Bearing
Plate
Friction Plate
Brake Piston
Plunger
Rotor
Link
Servo Piston
SM3024
T3-5-6
EX255-EX285
TRAVEL DEVICE
NOTE - The figure shows the travel motor installed on
EX285.
4
5
6
10
10
16
15
14
13
12
11
11
12
A
SM5005
1
2
3
4
5
6
7
8
Plate
Valve Plate
Disc Spring
Spring
Center Shaft
Housing
Drive Disc
Roller Bearing
9
10
11
12
13
14
15
16
Roller Bearing
Plate
Friction Plate
Brake Piston
Plunger
Rotor
Link
Servo Piston
EX255-EX285
T3-5-7
TRAVEL DEVICE
Pressure oil supplied to port AM of the valve plate (1)
flows into the rotor bores (2) underneath port AM,
pushing the plungers (3). The vertical component
force (FV) of plunger pushing force (F) rotates the
drive disc (4). As the drive disc (4) rotates, the rotor
(2) also rotates.
When the plungers (3) moves to port BM side, oil is

routed to the hydraulic oil tank.
Whether pressure oil from the pump is supplied to
port AM or BM determines travel direction.
3
BM
4
AM
FR
FV
F
SM0080
1
2
- Valve plate
- Rotor
3
4
- Plunger
- Drive disc
T3-5-8
EX255-EX285
TRAVEL DEVICE
Travel Speed Selection
Servo piston (1) is interconnected to valve plate (6)
via link (5) so that when servo piston (1) is moved,
swash angle of rotor (7) is shifted through valve plate
(6), leading to travel speed change.
Slow speed
When the slow speed travel mode is selected, the
MC (Main Controller) does not send out an electronic control signal to the solenoid valve unit (SI).
Therefore, speed change pilot pressure is not
routed to servo piston (1). Thus, spool (3) is held
down by spring (2). Then, pressure oil P from the
motor port is led to both chambers B and C.
Since the pressure-receiving area in chamber C is

larger than that in chamber B, servo piston (1)
moves upward, increasing swash angle to the
maximum.
Accordingly, as the stroke of the plungers in the
motor is increased, slower revolution of the travel
motor for low speed mode is obtained.
6
1
2
Drain
3
5
4
Pilot pressure
SM0081
1
2
3
4
Servo Piston
Spring
Spool
Orifice
5
6
7
- Link
- Valve Plate
- Rotor
EX255-EX285
T3-5-9
TRAVEL DEVICE
Fast speed
travel mode
When the fast speed travel mode is selected,

corresponding to travel loads, the MC sends out an
electronic control signal to the solenoid valve unit
(SI). Therefore, speed change pilot pressure is
routed to chamber D, moving spool (3) upward.
Then, passage E opens and oil in chamber C is
drained through the inner passages in spool (3).
As pressure oil P from the motor port is led to
chamber B, servo piston (1) is moved down,

reducing the swash angle of rotor (7).
Accordingly, as the stroke of the plungers in the
motor is decreased, faster revolution of the travel
motor for fast speed mode is obtained.
(Refer to the Control System Group in the SYSTEM
Section).
1
6
7
2
Drain
P
B
Pilot pressure
Drain
P
C
D
Position of servo piston at initial
stage of fast speed travel operation
Pilot pressure
Position of servo piston during

stage of fast speed travel operation
SM0082
1
2
3
4
Servo Piston
Spring
Spool
Orifice
5
6
7
- Link
- Valve Plate
- Rotor
T3-5-10
EX255-EX285
TRAVEL DEVICE
TRAVEL BRAKE VALVE
The travel brake valve is located on the travel motor
head and consists of the following valves.
- Overload Relief Valve (4):

Prevents overloads and surge pressure in the
motor circuit.
- Check Valve (1):

Ensures smooth starts and stops, and prevents
cavitation from occurring in the motor circuit by
functioning together with counterbalance valve (5).
- Counterbalance Valve (5):

Ensures smooth starts and stops and prevents
overrunning when traveling down slopes.
- Reducing Valve (2):

Reduces parking brake release pressure and prevents sudden operation of the brake.
- Servo-Piston Operating Shuttle Valve (6):

Leads divided hydraulic oil flow for travel motor
operation to the servo-piston.
- Parking Brake Release Shuttle Valve (3):

Leads travel motor drive pressure to the parking
brake.
NOTE - The figure shows the travel brake valve

installed on EX255.
Section B-B
1
1
3
2
4
AM
BM
5
C
BV
AV
Section A-A
Section C-C
SM0083
1
2
3
- Check Valve
- Reducing Valve
- Parking Brake Release Shuttle Valve
4
5
6
- Overload Relief Valve

- Counterbalance Valve
- Servo-Piston Operating Shuttle Valve
EX255-EX285
T3-5-11
TRAVEL DEVICE
NOTE - The figure shows the travel brake valve
installed on EX285.
6
3
4
Section B-B
1
1
Section C-C
5
A
4
BM
AM
C
.
.
C
.
AV
BV
5
Section A-A
1
2
3
- Check Valve
- Reducing Valve
- Parking Brake Release Shuttle Valve
4
5
6
- Overload Relief Valve

- Counterbalance Valve
- Servo-Piston Operating Shuttle Valve
SM5010
T3-5-12
EX255-EX285
TRAVEL DEVICE
Travel Operation
When supply oil from the control valve is routed to
port BV, supply oil flows around spool CB, opens
check valve BC (9) and is led to motor port BM.
However, return oil from motor port AM is blocked by
check valve AC (8) and spool CB (7).
As supply oil pressure at port BV increases, supply oil
is routed to chamber G through orifice F in spool
CB (7), moving spool CB (7) to the left against spring
force.
Consequently, return oil from motor port AM starts to
flow into port AV through notch H in spool CB (7),
allowing the travel motor to rotate.
When the travel levers are returned to the neutral
position, the oil in both ports AV and BV are routed to
the hydraulic oil tank through the control valve. Thus,
oil pressure in chamber G decreases, and spool CB
(7) is moved back to the original position by spring
force. Then, the oil flow circuit is blocked, causing the
travel motors to stop rotating.
draws oil, oil pressure at port BV and chamber G

decreases, causing spool CB (7) to move to the right.
Then, the return oil flow from the motor is restricted
by the spool, increasing pressure at port AM.
The increased pressure at port AM brakes the motor.
Thus, the restricted return oil flow increases the
pressure at port BV again, moving spool CB (7) back
to the left. This repeat movement of the spool (hydraulic brake action) prevents the machine from
overrunning.
Circuit Protectors
If pressure in the circuit increases over the setting
pressure of the overload relief valve (4), this valve
opens to relieve peak pressure to the lower pressure
side to protect the motor from overloading. This valve
also functions to release shock pressure caused by
inertia force developing when the motor stops.
When the motor draws oil because of pumping operation, check valve BC (9) opens to make up vacuum,
so that cavitation will not develop in the circuit.
Descending Operation
When the machine travels down a slope, the travel
motors are forcibly driven by the machine weight so
that the motor draws oil like a pump. When the motor
4
9
8
AM
BM
AV
BV
F
SM0084
4
7
- Overload relief valve

- Spool CB
8
9
- Check valve AC
- Check valve BC
EX255-EX285
T3-5-13
TRAVEL DEVICE
PARKING BRAKE
NOTE - The figure shows the parking brake installed

on EX255.
When the brake is applied:
When the brake is released:

M
K
1
2
3
M
4
5
SM3025
1
2
3
- Disc Spring
- Piston
- Friction Plate
4
5
6
- Plate
- Housing
- Drive Disc
T3-5-14
EX255-EX285
TRAVEL DEVICE
NOTE - The figure shows the parking brake installed
on EX285.
When the brake is applied:
When the brake is released:
SM5006
1
2
3
- Disc Spring
- Piston
- Friction Plate
4
5
6
- Plate
- Housing
- Drive Disc
EX255-EX285
T3-5-15
TRAVEL DEVICE
The parking brake is a negative-type brake released
when oil pressure K is applied to parking brake
chamber M. Whenever the travel control valve
spools are in neutral, the parking brake is automatically applied.
Friction plates (3) are connected to drive disc (6), and
plates (4) to motor housing (5) via spline coupling
respectively. When disc spring (1) pushes piston (2)
to the right, friction plates (3) come into contact with
plates (4), applying the parking brake.
chamber G located at the end of spool CB (9).

Parking brake release pressure is blocked by spool
CB (9). When pressure increases, spool CB (9)
moves to the right. Pressurized oil flows to reducing
valve (7) via the orifice I of spool CB (9), then flows
to parking brake chamber M to release the travel
parking brake.
When the machine is not traveling:
Pressure oil from the travel motor is not routed
through shuttle valve (8), and parking brake chamber
M is led to the drain circuit through reducing valve
(7). Piston (2) is gradually forced to the right by disc
spring (1), making friction plates (3) come into contact with plates (4).
Starting to travel:
When travel lever is pulled reverse, pressurized oil
from the pump flows to port AM via the control valve.
The pressurized oil flows to the travel motor and
Drain
AM
BM
SM0086
7
8
- Reducing valve
- Shuttle valve
- Spool CB
T3-5-16
EX255-EX285
TRAVEL DEVICE
NOTE
EX255-EX285
T3-6-1
OTHER COMPONENTS (Upperstructure)

PILOT SHUT-OFF VALVE
To pilot valve
The pilot shut-off valve is a manual-operated switch

valve. The spool in the pilot shut-off valve is rotated
by moving the pilot control shut-off lever to turn on or
off the pilot oil flow to the pilot valves.
To hydrayulic
oil tank
From pilot
pump
From pilot valve
To shockless valve
SM0087
Valve Operation with Pilot Control Shut-Off

Lever in LOCK Position
The pilot shut-off valve is set in the neutral position.
Pressure oil from the pilot pump does not flow into
the pilot valves, but it is routed to the shockless
valve. Pilot oil on the pilot valve side is routed to the
hydraulic tank as drain passages in the pilot shutoff valve open.
From pilot valve
To shockless valve
To hydraulic
oil tank
From pilot
pump
SM0088
Valve Operation with Pilot Control Shut-Off

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

SM0089
T3-6-2
EX255-EX285

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

and pilot pressure switch (for boom raise) are built
into the shockless valve block in addition to the
shockless valves.
The shockless valves regulate secondary pilot pressure (pilot pressure between the pilot valves and the
control valve spools) for the arm roll-out and for boom
raise functions, preventing abrupt and rapid movement of the respective control valve spools.
6
5
SM0090
When the arm roll out or the boom raise is operated,

secondary pilot pressure from the pilot valve is
routed to the side B of the shockless valve. Immediately after operating the control lever, the secondary pilot pressure routed to the side B flows to the
control valve spool via orifice (9). As the secondary
pilot pressure increases, check valve (7) opens.
To control
valve spool
From pilot
valve
SM0091
7
Return oil from the control valve spool flows back to
the hydraulic oil tank via orifice (9). As the pressure
at the side A increases, spool (8) moves in proportion to the pressure increase, regulating the return
oil flow.
A
From control
valve spool
To hydraulic
oil tank via
pilot valve
SM0092
1
2
3
4
5
6
7
8
9
Shockless Valve
Check Valve
Check Valve
Shockless Valve
Pilot Pressure Sensor (Arm Roll In)
Check Valve
Spool
Orifice
EX255-EX285
T3-6-3

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

heated oil flows into the shockless valve and into the
pilot valves.
To pilot valve
To control valve
To pilot valve
To control valve
To pilot valve
To control valve
To pilot valve
To control valve
Shockless valve
Pilot shut-off valve
From pilot pump
SM0093
T3-6-4
EX255-EX285

SOLENOID VALVE UNIT
Front
The solenoid valve unit functions to control the pump

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

(Travel Speed Selection)
SG : Functions to increase the main relief valve

pressure setting
SC
SD
SG
SI
SM0094
EX255-EX285
T3-6-5

Proportional Solenoid Valve
Upon receiving an electric current signal from the
MC, the proportional solenoid valve outputs hydraulic
pressure proportional to the degree of the electric
current.
When not energized (In neutral):
The spring pushes the spool to the right, connecting the output port S to the tank port T.
When energized:
The solenoid pushes the spool to the left for a
distance proportional to the electric current flowing
through the solenoid. Pilot oil from port (P) flows
into output port S, increasing the pressure at output

port S. The pressure at port S acts on the two banks
of walls on the spool. (See detail a.).
Because of the pressure receiving area difference
between the two walls, the pressure at port S acts
as a force to push the spool to the right. As the
pressure at port S increases, the force to push the
spool to the right also increases. When this force
overcomes the force to push the spool to the left by
solenoid, the spool moves back to the right side,
closing the passage between output port S and port
P. As a result, pressure increase at port S stops.
Spool
Spring
Solenoid
SM0095
T3-6-6
EX255-EX285

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
SM2200
EC MOTOR
The EC motor is used to control engine speed. A
worm gear is incorporated into the EC motor to
prevent a loss of synchronism from occurring. The
EC sensor is provided to detect the degrees of the EC
Output shaft
motor rotation to calculate the governor lever position. (Refer to the Control System Group in SYSTEM
Section).
Worm gear
Output gear
Sensor gear
Motor
EC sensor
Worm wheel
SM0097
EX255-EX285
T3-7-1
OTHER COMPONENTS (Undercarriage)

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

output shaft of the swing reduction gear.
2
5
6
4
SM0098
1
2
3
- Outer Race
- Seal
- Inner Race
4
5
6
- Seal
- Supports
- Ball
T3-7-2
EX255-EX285

CENTER JOINT
The center joint is a 360 rotating joint. When the
upperstructure is rotated, the center joint avoids
twisting of hoses and allows hydraulic oil to flow
smoothly to or from the travel motors. Spindle (1) is
attached to the main frame, and body (2) is bolted to
the swing center of the undercarriage.
To left travel
motor (Reverse)
To right travel
motor (Forward)
To left travel
motor (Forward)
To right travel
motor (Reverse)
Hydraulic oil flows to the right and left travel motors

via spindle (1) and the oil ports of body (2). Seals (3)
prevent oil leaks between spindle (1) and body (2)
into adjacent passages.
To left travel
motor (Forward)
To right travel
motor (Forward)
To left travel
motor (Reverse)
To right travel
motor (Reverse)
1
Pilot pressure for
travel speed selection
Pilot pressure for

Drain
2
Drain
Drain
3
Drain
Forward
Reverse
Pilot pressure for
SM0099
1
2
- Spindle
- Body
- Seal
EX255-EX285
T3-7-3

TRACK ADJUSTER
The track adjuster located on the side frame is
composed of spring (5) and adjuster cylinder (6).
Spring (5) absorbs loads applied to the front idler.
Adjuster cylinder (6) adjusts track sag.
CAUTION
Do not loosen valve (1) quickly or loosen too much
since high-pressure grease in the adjusting cylinder may spout out.
Loosen carefully, keeping body parts and face
away from valve (1). Never loosen grease fitting.
Grease is applied through grease fitting into chamber (A) of adjuster cylinder (6) as illustrated below.
The pressure of the grease pushes piston rod (8)
out and decreases track sag.
To increase track sag, loosen valve (1) 1 to 1.5
turns counterclockwise to release grease from the
track adjuster cylinder through the grease discharge hole.
Grease fitting
Grease discharge hole
SM0100
1
2
3
4
Valve
Nut
Flange
Spacer
5
6
7
- Spring
- Adjuster Cylinder
- Piston Rod
T3-7-4
EX255-EX285

NOTE
COPYRIGHT BY FIAT - HITACHI EXCAVATORS S.p.A.


Print No. 604.13.082 - X - 2001

EXCAVATOR
TECHNICAL MANUAL
TROUBLESHOOTING
(Tier 2)
All information, illustrations and specifications in this manual are based on the latest product information available
at the time of publication.

ENGINEERING
EX255-EX285
IN-1
INTRODUCTION
TO THE READER
This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.

MACHINERY S.p.A.
Strada Settimo, 323
10099 ITALY
PRODUCT SUPPORT
Fax. ++39 011 6877357
Manual
- Parts Catalog

books:
- Workshop Manual

The Service Manual for EX255-EX285 Excavators

consists of the following book/print numbers:
- The Technical Manual-Troubleshooting includes the

technical information needed for operational performance tests, and troubleshooting procedures.
BOOK
PRINT NUMBER
604.13.191
604.13.196
- Workshop Manual
604.13.201
IN-2
EX255-EX285
INTRODUCTION
PAGE NUMBER
Example: T 1-2-3
Section number
W : Workshop Manual
SYMBOLS

parts.
UNITS USED
Example: 24.5 MPa (250 kgf/cm2, 3 560 psi)
Quantity
To
convert
from (SI)
Into
(Others)
Multiply by
Quantity
To
convert
from (SI)
Into
(Others)
Multiply by
Lenght
mm
in
0.03937
Pressure
MPa
kgf/cm2
10.197
mm
ft
0.003281
MPa
psi
145.0
US gal
0.2642
kW
CV-PS
1.360
kW
HP
1.341
Volume
US qt
1.057
yd
1.308
Temperature
C x 1.8 + 32
kg
lb
2.205
Velocity
km/h
mph
0.6214
m
Mass
Force
Torque
Power
kgf
0.10197
lbf
0.2248
N.m
kgf.m
0.10197
N.m
lbf.ft
0.7375
min
Flow rate
-1
rpm
1.0
L/min
US gpm
0.2642
mL/rev
cc/rev
1.0
EX255-EX285
S-1
SAFETY PRECAUTIONS
RECOGNISE SAFETY INFORMATION
This is your SAFETY ALERT SYMBOL.
- When you see this symbol on your machine or in
this Manual, be alert of the potential for personal
injury.
- Follow recommended precautions and safe
operating practices.
S0021
UNDERSTAND SIGNAL WORDS

In this Manual you will find the following words:
- DANGER;
- WARNING;
- CAUTION.
referring to different hazard risks.
These words are always accompanied by the safety
alert symbol.
DANGER
WARNING
DANGER: indicates an imminent hazardous

situation which, if not avoided, will result in death or
serious injury.
CAUTION
WARNING: indicated a potential hazardous

situation which, if not avoided, could result in death or
serious injury.
IMPORTANT
CAUTION: indicates a potential hazardous situation

which, if not avoided, may result in minor or moderate
injury.
NOTE
IMPORTANT: indicates a situation which, if not

avoided, may cause damage to the machine.
NOTE: indicates an additional explanation for
information purposes.
ENVIRONMENTAL PROTECTION
This Manual also contains this symbol
accompanying instructions for correct behaviour
as regards environmental protection.
S0024
S-2
EX255-EX285
SAFETY PRECAUTIONS
FOLLOW SAFETY PRECAUTIONS
Carefully read and observe all safety signs on the
machine and read all safety precautions in this
Manual.
Safety signs should be installed, maintained, and
replaced when necessary.
- If a safety sign or this Manual are damaged or
missing, obtain a replacement from your FIAT
KOBELCO Dealer in the same way you order a
spare part (be sure to detail machine model and
serial number upon ordering).
Learn how to operate the machine and its controls
correctly and safely.
Allow only trained, qualified, authorised personnel
to operate the machine.
S0022
Keep the machine in proper working conditions.

- Unauthorised changes to the machine may
impair function and/or safety and affect machine
life.
Safety messages in this Chapter SAFETY
PRECAUTIONS, are intended to illustrate basic
safety procedures of the machine. However, it is
impossible for these safety messages to cover
every hazardous situation you may encounter. If
you have any doubts, consult your direct
supervisor prior to operating or servicing the
machine.
PREPARE FOR EMERGENCIES

Be prepared if a fire starts or an accident occurs.
- Keep the first-aid kit and fire extinguisher on
hand.
- Thoroughly read and understand the label
attached to the fire extinguisher to use it properly.
- Establish emergency priority procedures to cope
with fires and accidents.
- Keep emergency numbers for doctors,
ambulance service, hospitals and fire
department posted near the telephone.
S0023
EX255-EX285
S-3
SAFETY PRECAUTIONS
WEAR PROTECTIVE CLOTHING
Wear close-fitting clothing and safety equipment
appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask.
Be sure to correctly wear equipment and clothing
for the job.
- Do not take any chances.
- Avoid wearing loose clothing, jewellery, or other
items that can catch on control levers or other
parts of the machine.
S0025
Operating equipment safely requires the full

attention of the operator. Do not wear radio or
music headphones while operating the machine.
PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause
impairment or loss of hearing.
- Wear a suitable hearing protection such as
earmuffs or earplugs to protect objectionable or
uncomfortably loud noise.
S0026
INSPECT THE MACHINE

Inspect the machine carefully every day or workshift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.
- In the walk-around inspection, be sure to cover all
points detailed in the Chapter "MAINTENANCE",
paragraph "EXTERNAL VISUAL INSPECTION"
of the OPERATION AND MAINTENANCE
INSTRUCTION MANUAL.
S0027
S-4
EX255-EX285
SAFETY PRECAUTIONS
USE HAND HOLDS AND STEPS
Falling is one of the major causes of personal injury.
- When you get on and off the machine, always
face the machine and maintain a three-point
contact with the steps and handrails.
- Do not use any control as a handhold.
- Never jump off the machine. Never get on and
off a moving machine.
- Be careful of slippery conditions of platforms,
steps, and handrails when leaving the machine.
S0028
ADJUST THE OPERATOR'S SEAT

A seat poorly adjusted for operator or work
requirements may quickly fatigue the operator
leading to improper operations.
- The seat should be adjusted whenever machine
operator changes.
- The operator should be able to fully press the
pedals and correctly move the control levers with
his back resting against the seat back.
- If not, move the seat fore and aft, and check
again.
S0029
EX255-EX285
S-5
SAFETY PRECAUTIONS
FASTEN SEAT BELT
Should the machine overturn, the operator may
become injured and/or thrown from the cab. Not
only, the operator may be crushed by the
overturning machine resulting in serious injury or
even death.
- Prior to operating the machine, thoroughly
examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
S0030
- Be sure to remain seated with the seat belt

securely fastened at all times when the machine
is in operation to minimise injury hazard in case
of accident.
- After a significant accident, replace the seat belts
even though they do not look damaged.
MOVE AND
SAFELY
OPERATE
MACHINE
Bystanders can be run over.

- Pay the utmost attention not to run over
bystanders.
- Be sure and aware of the location of bystanders
before moving, swinging or operating the
machine.
- If fitted, keep the travel alarm and horn sounding
to warn people that the machine is about to move.
S0031
- When operating, swinging, or moving the

machine in a congested area use a signal man.
- Co-ordinate hand signals before starting the
machine.
S-6
EX255-EX285
SAFETY PRECAUTIONS
OPERATE ONLY FROM THE DRIVER'S
SEAT
Inappropriate engine starting procedures may
cause the machine unexpected movement,
possibly resulting in serious injury and even death.
- Start the engine only from the operators seat.
- NEVER start the engine while standing on the
track or on the ground.
- Do not start the engine by shorting across starter
motor terminals.
S0032
- Before starting the engine, ensure that all control

levers are in the neutral position.
KEEP RIDERS OFF THE MACHINE

Riders on the machine are subject to injuries such
as being struck by foreign objects and being thrown
off the machine.
- Only machine operator is
machine. Keep riders off.
allowed on the
- Riders also obstruct the operators visibility,

resulting in the machine being operated
unsafely.
S0033
CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN
Incorrect travel controls operation may result in
serious injury and even death.
- Before driving the machine, be aware of the
undercarriage position relative to the operators
position. If travel motors are located at the front
of the cab, the machine will move reverse when
travel controls are moved towards cab front.
S0037
EX255-EX285
S-7
SAFETY PRECAUTIONS
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
To avoid back-over and swing accidents:
- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
- Keep the travel alarm in working condition (if
equipped).
- ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
S0042
- USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
- Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
- No machine motions shall be made unless
signals are clearly understood by both signalman
and operator.
- Learn the meanings of all flags, signs, and
markings used on the job and confirm with the
person in charge of signalling.
- Keep windows, mirrors, and lights clean and in
good condition.
- Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
- Read and understand all operating instructions in
the OPERATION AND MAINTENANCE
INSTRUCTION MANUAL.
S0043
S-8
EX255-EX285
SAFETY PRECAUTIONS
DRIVE MACHINE SAFELY
Before starting the machine carefully read the

OPERATION AND MAINTENANCE INSTRUCTION MANUAL. (Refer to the OPERATING INSTRUCTIONS chapter).
Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.
- Pushing down on the front of the travel pedals or
pushing the levers forward moves the machine
towards the idlers. (Refer to the OPERATION
AND
MAINTENANCE
INSTRUCTION
MANUAL).
S0038
Traveling on a grade may cause the machine to slip

or to overturn, possibly resulting in serious injury or
death.
- When traveling up or down a grade, keep the
bucket in the direction of travel, approximately 20
to 30 cm (A) above the ground.
- If machine starts to skid or becomes unstable,
lower the bucket immediately.
S0039
- Traveling across the face of a slope may cause

the machine to skid or to overturn. When
travelling (ascending/descending) on a slope, be
sure to point the tracks uphill/downhill.
S0004
- Turning on an incline may cause the machine to

tip over.
If turning on an incline is absolutely unavoidable,
do so at a place where the slope is gentle and the
surface is firm.
- When operating on a grade and the fuel reserve
indicator light lights, immediately refuel.
WRONG
S0005
EX255-EX285
S-9
SAFETY PRECAUTIONS
AVOID OVERTURNING
The danger of tipping is always present when
operating on a grade, possibly resulting in serious
injury or death.
To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the bucket low to the ground and close to
the machine.
- Reduce machine operating speed to avoid
tipping or slipping.
- Avoid changing direction when travelling on
grades.
- NEVER attempt to travel across a grade steeper
than 15 degrees.
- Reduce swing speed as necessary when
swinging loads.
S0002
Be careful when working on frozen ground.

- Temperature increases will cause the ground to
become soft and make ground travel unstable.
S0047
PARK MACHINE SAFELY

To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Turn auto-idle (A/I) switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Pull the safety lever (pilot-control shut-off lever) to
the LOCK position.
- Close windows, roof window, and cab door.
- Lock all access doors and compartments.
S0049
S-10
EX255-EX285
SAFETY PRECAUTIONS
AVOID INJURY FROM UNEXPECTED
MACHINE MOVEMENT
Death or serious injury may result if you attempt to
get on or off a moving machine.
To avoid roll-aways:
- Select level ground when possible to park
machine.
- Do not park the machine on a grade.
- Lower the bucket and/or other work tools to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
- Turn the auto-idle switch off.
- Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
- Stop the engine and remove the key from the key
switch.
- Pull the pilot shut-off lever to LOCK position.
- Block both tracks.
- Position the machine to prevent overturning.
- Park a reasonable distance from other machines.
S0040
S0041
PROVIDE SIGNALS FOR JOBS

INVOLVING A NUMBER OF MACHINES
For jobs involving several machines, provide
signals commonly known by all personnel involved.
Also, appoint a signal person to co-ordinate the job
site. Make sure that all personnel obey the signal
persons directions.
S0036
EX255-EX285
S-11
SAFETY PRECAUTIONS
INVESTIGATE JOB SITE BEFORE HAND
When working at the edge of an excavation or on
a road shoulder, the machine could overturn,
possibly resulting in serious injury or death.
- Investigate the configuration and ground
conditions of the job site beforehand to prevent
the machine from overturning and prevent the
ground, stockpiles, or banks from collapsing.
- Make a work plan. Use machines appropriate to
the work and job site.
- Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
- When working on an incline or road shoulder,
employ a signal person as required.
Confirm that your machine is equipped with a
F.O.P.S. (Falling Object Protective Structure)
cab before working in areas where there is the
possibility of falling stones or landslides.
- When footing is weak, reinforce the ground
before starting the work.
- When working on frozen ground, be extremely
alert. As ambient temperature rises, footing
becomes loose and slipped.
S0034
PROTECT AGAINST FALLING STONES

AND LANDSLIDES
F.O.P.S. (Falling Object Protective Structure) cab
before working in areas where there is the
possibility of falling stones.
S0035
S-12
EX255-EX285
SAFETY PRECAUTIONS
DIG WITH CAUTION
Accidental severing of underground cables or gas
lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
- Before digging, check the location of cables, gas
lines, and water lines.
- Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic
cable should be accidentally severed, do not look
into the end. Doing so may result in serious eye
injury.
- Contact local authorities and/or the utility
companies directly (electric power, gas,
telephone, water, sewers, telecommunications,
etc.) to obtain information about underground
utility lines.
S0009
OPERATE WITH CAUTION

If the front attachment or any other part of the
machine hits against an overhead obstacle, such
as a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury may
results as well.
- Take care to avoid hitting overhead obstacles
with the boom or arm.
S0008
AVOID ELECTRIC LINES

Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.
- When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m plus twice the line insulator length (L).
- Check and comply with any local regulations that
may apply.
- Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
- Keep all bystanders or co-workers away from the
site.
S0205
EX255-EX285
S-13
SAFETY PRECAUTIONS
KEEP PERSONNEL CLEAR FROM
WORKING AREA
A person may be hit severely by the swinging front
attachment or counterweight and/or may be
crushed against an other object, resulting in serious
injury or death.
- Keep all persons clear from the area of operation
and machine movement.
- Before operating the machine, set up barriers to
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.
S0044
NEVER MOVE THE BUCKET OVER ANY

ONE
Never lift, move, or swing bucket above anyone or
a truck cab.
Serious injury or machine damage may result due
to bucket load spill or due to collision with the
bucket.
S0045
AVOID UNDERCUTTING
In order to retreat from the edge of an excavation if
the footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.
- If the footing starts to collapse and if sufficient
retreat is not possible, do not panic. Often, the
machine can be secured by lowering the front
attachment, in such cases.
S0011
S-14
EX255-EX285
SAFETY PRECAUTIONS
NEVER UNDERCUT A HIGH BANK
The edges could collapse or a land slide could
occur causing serious injury or death.
S0048
SAFETY LOADS MOVING

The excavator is no lifting and transportation
means, therefore it should not be used to position
loads accurately. Should it be exceptionally used to
lift and lay building components, special caution
must be taken as follows:
- The machine must be equipped without failure
with the appropriate variant supplied, upon
request, by FIAT KOBELCO. Also, totally comply
with the safety precautions for the operation of the
excavator as a lifting equipment.
- Secure the loads to be raised using cables or
chains fastened with appropriate hooking
mechanisms.
- Never hook cables or chains to the bucket teeth.
- Nobody should be allowed to remain under the
raised load or within the excavator operating
range for any reason whatever.
S0165
- Never exceed specified loading capacity.

Incorrect fastening of slings or chains may cause
boom/arm failure or failure of the lifting means
with consequent bodily injuries and even death.
- Always ensure that slings and chains used for
lifting are adequate to the load and in good
condition.
- All loading capacities are referred to the
machine on a level surface and should be
disregarded when working on a slope.
EX255-EX285
S-15
SAFETY PRECAUTIONS
SAFETY TRANSPORTING
The danger of tipping is present when loading/
unloading the machine onto/from a truck or trailer
bed.
- Be sure to observe local regulations when
transporting the machine on public roads.
- Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading/
unloading the machine:
1. Select firm level ground.
2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when loading/
unloading the machine.
4. Always turn the auto-idle (A/I) switch OFF when
loading or unloading the machine, to avoid
unexpected speed increase due to unintentional
operation of a control lever.
5. Always select the slow speed mode with the
travel speed selector. In the high speed mode,
travel speed may automatically increase.
6. Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify travelling direction, and begin to
drive again.
7. Do not operate any levers besides the travel
levers when driving up or down the ramp.
8. The top end of the ramp where it meets the
flatbed is a sudden jolt. Take care when traveling
over it.
9. Prevent possible injury from machine tipping
while the upperstructure is rotating.
10. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11. Securely fasten machine frame using chains or
cables. Refer to TRANSPORT chapter in the
OPERATION
AND
MAINTENANCE
INSTRUCTION MANUAL for details.
S0052
S-16
EX255-EX285
SAFETY PRECAUTIONS
SAFE MAINTENANCE
To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Kepp the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it is
in motion.
- Kepp hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Switch off the Auto-Idle (A/I).
4. Let the engine idle with no load for at least five
minutes until it has cooled down.
5. Move the key-start switch to the OFF position
to stop the engine.
6. Remove the ignition key from the start switch.
7. Apply the "Maintenance in progress" tag .
This tag can be applied o the left-hand control
lever, safety lever or cab door.
8. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
9. Let the engine cool down.
- Do not leave the machine unattended if servicing
requires the engine running .
- If the machine is to be raised, place boom and arm
at an angle 90 to 110. Lock machine components
which should be raised for maintenance or repair
using suitable supporting means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary.
Refer to the the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL.
- Keep all components in good condition and
properly install. Immediately repair any fault.
- Immediately repair any damage.Replace worn or
failed components. Remove grease, oil, debris
build-ups.
- Disconnect the negative cable () from the battery
before carry out any work on the electrical system
or arc-welding on the machine.
S0053
S0054
EX255-EX285
S-17
SAFETY PRECAUTIONS
WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause
serious injury.
- Before performing any work on the machine,
attach a maintenance in progress tag. This tag
can be applied o the left-hand control lever,
safety lever or cab door.
S0055
SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without
securing the machine first.
- Always lower the attachment or tool to the ground
before working on the machine.
- If you must work on a lifted machine or
attachment, securely support the machine or
attachment.
- Do not support the machine on cinder blocks,
bollow tires, or props that may crumble under
continuous load.
- Do not work under a machine that is supported
solely by a jack.
S0054
STAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause serious
injury.
To prevent accidents, care should be taken to
ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working near
rotating parts.
S0056
S-18
EX255-EX285
SAFETY PRECAUTIONS
DISPOSE OF WASTE IN THE
APPROPRIATE MANNER
Waste improperly disposed of represents a danger
for the envinronment. Potentially dangerous waste
used on the FIAT KOBELCO excavators includes
lubricants, fuel, coolant, brake fluid, filters and
batteries.
- Used sealed containers when discharging fluids.
Do not use containers for food or beverages
which may induce drinking.
- Do not spill waste over the ground, into drains, or
water beds.
S0064
- Obtain information about the correct methods to

recycle or dispose of waste from local
Authorities, collection centres or your Dealer.
WORK IN A CLEAN AREA

Before starting an operation, clean the working
area.
Clear the area from all the objects that can be
dangerous for mechanics or people in the working
area.
S0166
PROPERLY LIGHT THE WORKING AREA

Properly and safely light the working area.
- Use safe portable lamps in order to work inside
and under the machine.
- Make sure that the lamp is shielded by a cage;
the incandescent filament of a lamp, accidentally
broken, can cause fuel or oil fire.
F1480
S0167
EX255-EX285
S-19
SAFETY PRECAUTIONS
REGULARLY WASH THE MACHINE
Remove all the traces of grease, oil and deposits,
in order to avoid people accidents or damages to
things.
- Do not spray water or steam in the cab.
F1462
S0153
F1463
S0058
STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic
breakers and blades can fall and cause serious
injury or death.
- Securely store attachments and implements to
prevent falling.
- Keep bystanders away from storage areas.
PREVENT ACID SCALDS

The sulphuric acid, contained in the battery, is
poisonous.
It is strong enough to scald the skin, corrode
clothes and cause blindness, if it is sprayed into
the eyes.
To avoid dangers:
- Fill the batteries in airy areas.
- Wear eye protections and rubber gloves.
- Avoid breathing the electrolyte vapours when
topping up.
- Avoid spilling or dripping the electrolyte.
- Use proper emergency starting techniques.
If you are touched with acid sprays:
- Rinse your skin well with water.
- Put on your skin sodium bicarbonate or clay to
help the acid neutralization.
- Rinse your eyes with water for 10-15 minutes.
- Immediately see a doctor.
If you have swallowed the acid:
- Drink a big quantity of water or milk, swallow
milk of magnesia, scrabbled eggs or vegetal oil.
F1474
S0168
S-20
EX255-EX285
SAFETY PRECAUTIONS
STARTING THE ENGINE WITH
BOOSTER BATTERIES
Battery gas may explode causing serious damages
and injuries.
- If the engine is to be started using booster
batteries, ensure to comply with all procedures
detailed in the chapter OPERATING
INSTRUCTIONS of the OPERATION AND
- The operator should be sitting in the drivers seat
to keep the machine under control when the
engine starts. Starting the engine with booster
batteries is a two man operation.
S0001
- Do not use batteries that have been stored in the

cold for a long time.
- Mistakes in following procedures detailed for
starting the engine with slave batteries may
cause the batteries to explode or machine to
move unexpectedly.
PREVENT BATTERY EXPLOSIONS

Battery gas can explode.
- Keep sparks, lighted matches, and flames away
from the top of battery.
- Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
- Do not charge a frozen battery; it may explode.
Warm battery to 16 C.
Battery electrolyte is poisonous. If the battery

should explode, battery electrolyte may be
splashed into eyes, possibly resulting in blindness.
- Be sure to wear eye protection when checking
electrolyte specific gravity.
S0001
EX255-EX285
S-21
SAFETY PRECAUTIONS
PREVENT BURNS
Hot spraying fluids:
After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
- To prevent possible injury from hot spraying
water. DO NOT remove the radiator cap until the
engine is cool. When opening, turn the cap slowly
to the stop. Allow all pressure to be released
before removing the cap.
- The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.
S0019
Hot fluids and surfaces:

Engine oil, reduction gear oil and hydraulic oil also
become hot during operation.
The engine, hoses, lines and other parts become
hot as well.
- Wait for the oil and components to cool down
before starting any maintenance or inspection
work.
S0059
KEEP CLEAN THE MACHINE

Keep clean the engine compartment, radiator,
batteries, hydraulic pipes, fuel tank and operator's
position.
The engine compartment temperature can quickly
rise, after stopping the engine.
IN THESE CASES, BE CAREFUL TO POSSIBLE
FIRES.
Open the access doors in order to quicken the engine
cooling process and clean the compartment.
S0177
S-22
EX255-EX285
SAFETY PRECAUTIONS
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
- Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
SA0016
- Tighten all connections before applying

pressure.
- Search for leaks with a piece of cardboard; take
care to protect hands and body from highpressure fluids. Wear a face shield or goggles for
eye protection.
SA0017
- In an accident occurs, see a doctor familiar with

this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA0018
PREVENT PARTS FROM FLYING OFF

Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result
in serious injury, blindness, or death.
- NEVER attempt to remove GREASE FITTING
or VALVE ASSEMBLY.
- As pieces may fly off, be sure to keep body and
face away from valve.
Travel reduction gears are under pressure.

face away from AIR RELEASE PLUG to avoid
injury. REDUCTION GEAR OIL is hot. Wait for
gear oil to cool down, then gradually loosen the air
release plug to release pressure.
F3635
S0178
EX255-EX285
S-23
SAFETY PRECAUTIONS
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body,
serious injury may result.
- Guard against injury from flying pieces of metal or
debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.
S0046
HANDLE FLUIDS SAFELY - AVOID FIRES

Handle fuel with care: it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur,
- Do not refuel the machine while smoking or when
near open flame or sparks.
- Always stop the engine before refuelling the
machine.
- Fill the tank outdoors.
S0050
All fuels, most lubrificants, and some antifreeze

fluids are flammable.
- Store flammable fluids well away from fire
hazards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn
spontaneously.
S0051
S-24
EX255-EX285
SAFETY PRECAUTIONS
PREVENT FIRES
Check for Oil Leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other,
damage to the oil-cooler, and loose oil-cooler
flange bolts which may cause oil leaks.
- Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oilcooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts circuits which could cause fires:
- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
Check Key-start Switch:
- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF position
to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:
- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S0051
EX255-EX285
S-25
SAFETY PRECAUTIONS
EVACUATING IN CASE OF FIRE
If a fire breaks out, evacuate the machine in the
following way:
- Stop the engine by turning the key-start switch to
the OFF position if there is time.
- Use a fire extinguisher if there is time.
- Exit the machine.
S0060
BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
- If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
S0061
USE APPROPRIATE TOOLS

Use tools appropriate for the job to be performed.
- Inappropriate tools, parts and procedures might
generate dangerous conditions.
- Use tools of correct size to tighten or loosening
securing elements, in order to avoid injuries
caused by a wrench getting out of control.
- Do not use U.S. Standard or British Standard
tools on metric fasteners and vice versa.
Use only FIAT KOBELCO genuine spare parts
(please refer to the PARTS CATALOG).
S0120
S-26
EX255-EX285
SAFETY PRECAUTIONS
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable materials.
Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other
materials when welding, soldering, etc.
S0062
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
- Do not weld or flame cut pipes or tubes that contain
flammable fluids.
- Clean them thoroughly with non-flammable solvent
before welding or flame cutting them.
REMOVE PAINT BEFORE WELDING OR

HEATING
Hazardous fumes can be generated when paints is
heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
- Avoid breathing potentially toxic fumes and dust.
- Do all such work outside or in a well-ventilated
area.
- Dispose of paint and solvents properly.
- Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the
dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
S0063
TECHNICAL MANUAL
EX255-EX285
TROUBLESHOOTING
Section 4 -
OPERATIONAL PERFORMANCE TEST
Group 1
Group 2
Group 3
Group 4
Group 5
Introduction
Standard
Engine Test
Excavator Test
Component Test
Section 5 -
TROUBLESHOOTING
Group
Group
Group
Group
Group
Group
Group
Diagnosing Procedure
Component Layout
Troubleshooting A
Troubleshooting B
Troubleshooting C
Electrical System Inspection
Harness Check
1
2
3
4
5
6
7
SECTION 4
EX255-EX285
OPERATIONAL PERFORMANCE
CONTENTS
Group 1 -
Introduction
Operational performance test ............... T4-1-1

Preparation for performance tests ........ T4-1-2
Group 2 -
Standard
EX255 Operational Performance

standard tables .................................... T4-2-1
EX255 Main pump P-Q diagram ........... T4-2-5
EX285 Operational Performance
standard tables .................................... T4-2-6
EX285 Main pump P-Q diagram ........... T4-2-10
Group 3 -
Engine Test
Engine speed ....................................... T4-3-1

Engine check and adjustment .............. T4-3-3
Group 4 -
Excavator Test
Travel speed ......................................... T4-4-1

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

Secondary pilot pressure ..................... T4-5-3
Solenoid valve set pressure ................. T4-5-4
Main pump delivery pressure ............... T4-5-6
Main relief valve set pressure .............. T4-5-7
Overload relief valve set
pressure ............................................... T4-5-11
Main pump flow test ............................. T4-5-14
Swing motor drainage ........................... T4-5-18
Travel motor drainage ........................... T4-5-20
EX255-EX285
T4-1-1
INTRODUCTION
OPERATIONAL PERFORMANCE TEST
Use operational performance test procedure to quantitatively check all system and functions on the machine.
Purpose of Performance Tests

1. To comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machines performance to the desired
standard.
3. To economically operate the machine under optimal conditions.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the
operational performance of each component
such as hydraulic pump, motor, and various kinds
of valves.
Performance Standards
Performance Standard is shown in tables to evaluate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
The machine performance does not always deteriorate as the working hours increase. However, the
machine performance is normally considered to reduce in proportion to the increase of the operation
hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall
consider the number of the machines working hours.
Definition of Performance Standard

1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.
T4-1-2
EX255-EX285
INTRODUCTION
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out
performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make
a full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
SM0131
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among
coworkers. Once the test is started, be sure to
communicate with each other using these signals,
and to follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
MAKE PRECISE MEASUREMENT
1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
SM3026
EX255
T4-2-1
STANDARD
EX255 OPERATIONAL PERFORMANCE
STANDARD TABLES
The standard Performance values related to excavator test are listed in the table 1 shown below. In table
2 are listed the standard performance related to
component test.
Refer to the Group T4-3 to T4-5 for performance test
procedures.
Values indicated in parentheses are reference values.
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance

tests unless otherwise instructed in each performance test procedure:
Engine Control Dial
: Fast Idle
E Mode Switch
: OFF
HP Mode Switch
: OFF
Work Mode Switch
: General Purpose Mode
Hydraulic Oil Temperature : 50 5 C (122 9 F)
NOTE - 1 kgf = 9.807 N
Table 1 - Excavator performance (EX255)

Ref.
pag.
Performance test designation
T4-3-1/2
ENGINE SPEED
Fast idle speed with E and HP modes

OFF
2180 100
Fast idle speed with E mode ON
1980 50
Fast idle speed with HP mode ON
50 or more higher
than fast idle speed
measured with E
and HP modes
OFF and arm roll-in
circuit relieved
1200 100
ENGINE COMPRESSION PRESSURE

MPa (kgf/cm2)
(mm)
NOZZLE INJECTION PRESSURE

MPa (kgf/cm2)
INJECTION TIMING
(Before TDC)
Extend the arm cylinder to

relieve the arm roll-in circuit
850 100
Auto-idle speed (A/I)
VALVE CLEARANCE
(IN, EX)
Remarks
(rpm)
Slow idle speed
T4-3-3
Performance
standard
EX255
(deg.)
3 (31)
0.4
18.1 (185)
With the engne hot

(approx. 75 C)
Allowable limit: 2.5 (26)
Difference cylinder pressure
compression exceeding
200 kPa (2.0 kgf/cm2) is
inacceptable
With the engine cold
T4-2-2
EX255
STANDARD
Ref.
pag.
13.2 1
Slow speed
20 2
TRACK REVOLUTION
SPEED
26.5 2
28.8 2
MISTRACK
(mm/20 m)
(With fast and slow travel speed modes)
200 or less
TRAVEL PARKING FUNCTION

CHECK
1/6 or less
(rev)
(mm/5 min)
Travel slow speed only
SWING SPEED
(s/3 rev)
T4-4-7
SWING FUNCTION DRIFT

CHECK
SWING MOTOR
LEAKAGE
SWING BEARING PLAY
13.3 1
(mm/180)
1500 or less
(mm/5 min)
(mm)
MAXIMUM SWINGABLE SLANT
ANGLE
(deg.)
HYDRAULIC CYLINDER
CYCLE TIME
T4-4-10
(s/3 rev)
EX255
EX255 LC
Travel motor
leak
Remarks
(s/20 m)
Fast speed
T4-4-9 T4-4-8
T4-4-6
T4-4-5
T4-4-4
T4-4-3
T4-4-2
T4-4-1
TRAVEL SPEED
Performance
standard
EX255
1.3 or less
19.2 or more
2950 arm (Mono) or 2158 arm

(Triple articulation) and 1.1 m3
bucket (SAE heaped)
bucket (SAE heaped)
Allowable limit: 4.3 mm
2950 arm (Mono) and 1.1 m3
bucket (SAE heaped)
bucket (SAE heaped)
(s)
Boom
(Mono version)
Raise
Lower
3.1 0.3
2.5 0.3
Boom (Triple
articulation version)
Raise
Lower
4.1 0.3
3.6 0.3
Arm
Roll-in
Roll-out
3.9 0.3
2.6 0.3
Bucket
Roll-in
Roll-out
4.1 0.3
2.5 0.3
Positioning (Triple
ariticulation version)
Roll-in
Roll-out
6.0 0.3
3.9 0.3
EX255
T4-2-3
STANDARD
Ref.
pag.
T4-4-12
DIG FUNCTION DRIFT

CHECK
20 or less
Positioning cylinder
(Triple articulation version)
20 or less
Arm cylinder
20 or less
Bucket cylinder
20 or less
Mono
Triple articulation
T4-4-13
CONTROL LEVER OPERATING

FORCE
T4-4-14
150 or less
150 or less
(kgf)
Boom lever
2.0 or less
Arm lever
2.0 or less
Bucket lever
1.7 or less
Swing lever
1.7 or less
Travel lever
2.5 or less
CONTROL LEVER STROKE
(mm)
Boom lever
105 10
Arm lever
105 10
Bucket lever
83 10
Swing lever
83 10
Travel lever
115 10
BOOM RAISE/SWING
(Bucket empty)
(s)
Bucket teeth height: H
(mm)
Mono
NOTE - 1 kgf = 9.807 N.
Remarks

bucket (SAE heaped)
(mm/5 min)
Boom cylinder
Total drop
T4-4-15
Performance
standard
EX255
3.7 0.3
6700 or more
2950 arm (mono) and 1.1 m3

bucket (SAE heaped)
T4-2-4
EX255
STANDARD
Table 2 - Component performance standard (EX255)
Performance
standard
EX255
Remarks
(kgf/cm2)
40 +10
5
SECONDARY PILOT
PRESSURE
(kgf/cm2)
(34 40)
SOLENOID VALVE SET

PRESSURE
(kgf/cm2)
Value indicated on
Dr. EX 2
MAIN PUMP DELIVERY

PRESSURE
(kgf/cm2)
25 +15
7
Value indicated on Dr. EX
MAIN RELIEF VALVE SET

PRESSURE
(kgf/cm2)
Boom, Arm and Bucket
350 +20
5
Swing
330 +20
5
Travel
350 +20
5
Power Boost
370 +20
10
T4-5-7
PRIMARY PILOT
PRESSURE
T4-5-3
T4-5-6 T4-5-4
T4-5-1
Ref.
pag.
T4-5-14
T4-5-11

SET PRESSURE
(kgf/cm2)
(Engine: Fast idle and slow idle)

Value indicated on Dr. EX (Lever:
Full stroke)
Reference values
at 50 L/min
Boom (raise/lower), arm roll-in and

bucket roll-in
380 +10
0
Arm roll-out and

bucket roll-out
400 +10
0
MAIN PUMP FLOW

TEST
(Engine: Fast idle)
(L/min)
Refer to page T4-2-5
With constant maximum speed
(L/min)
0.2 1.0
Allowable limit: 2.0
With the motor

relieved
(L/min)
Allowable limit: 16
With the track jacked up
(L/min)
1.5 2.0
With the motor

relieved
(L/min)
(1.5 4.8)
T4-5-18
SWING MOTOR DRAINAGE
T4-5-20
TRAVEL MOTOR DRAINAGE
NOTE - 1 kgf/cm2 = 0.09807 MPa.
Allowable limit: (5.2)
EX255
T4-2-5
STANDARD
EX255 MAIN PUMP P-Q DIAGRAM
(Reference: Measured at Test Stand)
Points on P-Q Line
Rated Engine Speed

: 2000 min1 (rpm)
Hydraulic Oil Temperature : 50 5 C
A
B
C
D
NOTE - Refer to T4-5-14.
Delivery Pressure
kgf/cm2
144
202
354
370
Flow Rate
L/min
196+3
6
(154)
84 10
The value indicated in parentheses is only a reference value.
NOTE - 1 kgf/cm2 = 0.09807 MPa.
L/min
Flow
Rate
(Q1 + Q2) / 2
Delivery Pressure (P1 + P2) / 2
kgf/cm2
SM3027
T4-2-6
EX285
STANDARD
EX285 OPERATIONAL PERFORMANCE
STANDARD TABLES
The standard Performance values related to excavator test are listed in the table 1 shown below. In table
2 are listed the standard performance related to
component test.
Refer to the Group T4-3 to T4-5 for performance test
procedures.
Values indicated in parentheses are reference values.
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance

tests unless otherwise instructed in each performance test procedure:
Engine Control Dial
: Fast Idle
E Mode Switch
: OFF
HP Mode Switch
: OFF
Work Mode Switch
: General Purpose Mode
Hydraulic Oil Temperature : 50 5 C (122 9 F)
NOTE - 1 kgf = 9.807 N
Table 1 - Excavator performance (EX285)

Ref.
pag.
T4-3-1/2
ENGINE SPEED
Fast idle speed with E and HP modes

OFF
2230 100
Fast idle speed with E mode ON
2030 50
Fast idle speed with HP mode O
50 or more higher
than fast idle speed
measured with E
and HP modes
OFF and arm roll-in
circuit relieved
Slow idle speed
900 100
Auto-idle speed (A/I)
1200 100
VALVE CLEARANCE
(IN, EX)
(mm)
NOZZLE INJECTION PRESSURE

MPa (kgf/cm2)
INJECTION TIMING
(Before TDC)
Remarks
(rpm)
ENGINE COMPRESSION PRESSURE

MPa (kgf/cm2)
T4-3-3
Performance
standard
EX285
(deg.)
3 (31)
0.4
18.1 (185)
Extend the arm cylinder to

relieve the arm roll-in circuit
With the engne hot

(approx. 75 C)
Allowable limit: 2.5 (26)
Difference cylinder pressure
compression exceeding
200 kPa (2.0 kgf/cm2) is
inacceptable
With the engine cold
EX285
T4-2-7
STANDARD
Ref.
pag.
T4-4-9 T4-4-8 T4-4-7
T4-4-6
T4-4-5
T4-4-4
T4-4-3
T4-4-2
T4-4-1
TRAVEL SPEED
14.1 1.0
Slow speed
23.2 2.0
TRACK REVOLUTION
SPEED
(s/3 rev)
EX285
EX285 LC
32.5 2.0
34.5 2.0
MISTRACK
(mm/20 m)
(With fast and slow travel speed modes)
200 or less
TRAVEL PARKING FUNCTION

CHECK
1/6 or less
Travel motor
leak
Remarks
(s/20 m)
Fast speed
(rev)
(mm/5 min)
Travel slow speed only
SWING SPEED
(s/3 rev)
SWING FUNCTION DRIFT
CHECK
SWING MOTOR
LEAKAGE
16 1.0
(mm/180)
1300 or less
(mm/5 min)

bucket (SAE heaped)
bucket (SAE heaped)
SWING BEARING PLAY

(mm)
MAXIMUM SWINGABLE SLANT
ANGLE
(deg.)
HYDRAULIC CYLINDER
CYCLE TIME
T4-4-10
Performance
standard
EX285
1.3 or less
18,7 or possibly
more
Allowable limit: 4.3 mm

3100 arm (Mono) and 1.05 m3
bucket (SAE heaped)

bucket (SAE heaped)
(s)
Boom
(Mono version)
Raise
Lower
3.4 0.3
2.7 0.3
Boom (Triple
(articulation version)
Raise
Lower
5.0 0.3
4.1 0.3
Arm
Roll-in
Roll-out
3.9 0.3
2.8 0.3
Bucket
Roll-in
Roll-out
4.5 0.3
2.7 0.3
Positioning (Triple
ariticulation version)
Roll-in
Roll-out
6.0 0.3
4.4 0.3
T4-2-8
EX285
STANDARD
Ref.
pag.
T4-4-12
DIG FUNCTION DRIFT

CHECK
20 or less
Positioning cylinder
(Triple articulation version)
15 or less
Arm cylinder
20 or less
Bucket cylinder
15 or less
Mono
Triple articulation
T4-4-13
CONTROL LEVER OPERATING

FORCE
T4-4-14
150 or less
150 or less
(kgf)
Boom lever
2.0 or less
Arm lever
2.0 or less
Bucket lever
1.7 or less
Swing lever
1.7 or less
Travel lever
2.5 or less
(mm)
Boom lever
105 10
Arm lever
105 10
Bucket lever
83 10
Swing lever
83 10
Travel lever
115 10
BOOM RAISE/SWING
(Bucket empty)
(s)
Bucket teeth height: H
(mm)
NOTE - 1 kgf = 9.807 N.
Remarks

bucket (SAE heaped)
(mm/5 min)
Boom cylinder
Total drop
T4-4-15
Performance
standard
EX285
3.8 0.3
7000 or more
3100 arm (mono) and 1.05 m3

bucket (SAE heaped)
EX285
T4-2-9
STANDARD
Table 2 - Component performance standard (EX285)
Performance
standard
EX285
Remarks
(kgf/cm2)
40 +10
5
SECONDARY PILOT
PRESSURE
(kgf/cm2)
(34 40)
SOLENOID VALVE SET

PRESSURE
(kgf/cm2)
Value indicated on
Dr. EX 2
MAIN PUMP DELIVERY

PRESSURE
(kgf/cm2)
25 +15
7
MAIN RELIEF VALVE SET

PRESSURE
(kgf/cm2)
Boom, Arm and Bucket
350 +20
5
Swing
292 +20
5
Travel
350 +20
5
Power Boost
+20
370 10
T4-5-7
PRIMARY PILOT
PRESSURE
T4-5-3
T4-5-6 T4-5-4
T4-5-1
Ref.
pag.
T4-5-14
T4-5-11

SET PRESSURE
(kgf/cm2)
Engine: Fast idle and slow idle)

(Lever: Full stroke
Reference values
at 50 L/min
Boom (raise/lower), arm roll-in and

bucket roll-in
380 +10
0
Arm roll-out and

bucket roll-out
400 +10
0
MAIN PUMP FLOW

TEST
(Engine: Fast idle)
(L/min)
Refer to page T4-2-5
With constant maximum speed
(L/min)
With the motor

relieved
(L/min)
Allowable limit: 31
With the track jacked up
(L/min)
(3.0)
Measured at test stand
With the motor

relieved
(L/min)
(6.0)
Measured at test stand
T4-5-18
T4-5-20
NOTE - 1 kgf/cm2 = 0.09807 MPa.
T4-2-10
EX285
STANDARD
EX285 MAIN PUMP P-Q DIAGRAM
(Reference: Measured at Test Stand)
Points on P-Q Line
Rated Engine Speed

: 2050 min1 (rpm)
Hydraulic Oil Temperature : 50 5 C
A
B
C
D
NOTE - Refer to T4-5-14.
Delivery Pressure
kgf/cm2
150
206
354
370
Flow Rate
L/min
+3
2076
(160)
84 10
(76)
The value indicated in parentheses is only a reference value.
NOTE - 1 kgf/cm2 = 0.09807 MPa.
L/min
Flow
Rate
(Q1 + Q2) / 2
Delivery Pressure (P1 + P2) / 2
kgf/cm2
SM3027
EX255-EX285
T4-3-1
ENGINE TEST
ENGINE SPEED
Summary:
1. Use Dr.EX. if Dr.EX is not available, use an engine
tachometer.
3
2. Measure the engine speeds in each mode.
NOTE - Measure the engine speed before performing all other tests to check that the engine speed
meets specification. Because, if the engine speed is
not adjusted correctly, all other performance data will
be unreliable.
Preparation:
1. Connect Dr.EX to the diagnosing connector beside the fuse box located behind the operators
seat, and select the monitor function. When using
an engine tachometer, install speed pickup (2) to
injection pipe (3).
2. Warm up the machine until the engine coolant
temperature reaches 50 C (122 F) or more, and
hydraulic oil is 50 5 C (122 9 F).
1
SM5401
IMPORTANT - Never attempt to the readjust stopper

(1).
T4-3-2
EX255-EX285
ENGINE TEST
Measurement:
1. No Load Engine Speed
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 below.
1-3. Start measurement from the slow idle
speed.
1-4. Measure while changing the engine control
dial, E mode switch, and HP mode switch.
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
AutoIdle
Switch
Work
Mode
Switch
Slow Idle
OFF
OFF
OFF
General
Purpose
Mode
Fast Idle
(Normal
Mode)
OFF
OFF
OFF
General
Purpose
Mode
Fast Idle
(E Mode)
ON
OFF
OFF
General
Purpose
Mode
Fast Idle
(HP Mode)
OFF
ON
OFF
General
Purpose
Mode
E Mode
Switch
HP Mode
Switch
Engine
Control Dial
SM0631
2. No Load Auto-Idle Speed

2-1. Select the switch positions as shown below.
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
AutoIdle
Switch
Work
Mode
Switch
Fast
Idle
OFF
OFF
ON
General
Purpose
Mode
2-2.
2-3.
Start the engine and operate the bucket

lever.
Return the lever to the neutral position.
Wait approx. 4 seconds until the engine
speed is automatically reduced. Then,
measure the reduced engine speed.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Auto-Idle
Switch
Work Mode
Switch
SM0612
EX255-EX285
T4-3-3
ENGINE TEST
ENGINE CHECK AND ADJUSTMENT
To perform the compression pressure 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.
T4-3-4
EX255-EX285
ENGINE TEST
NOTES
EX255-EX285
T4-4-1
EXCAVATOR TEST
TRAVEL SPEED
Summary:
Measure the time required for the excavator to travel
a 20 m (65.6 ft) test track.
Preparation:
1. Adjust the track sag on both side tracks equally.
2. Prepare a flat and solid test track 20 m (65.6 ft) in
length with extra length of 3 to 5 m (9.8 to 16 ft) on
both ends for machine acceleration and deceleration.
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the
ground with the arm and bucket rolled-in.
4. Maintain hydraulic oil temperature at 50 5 C
(122 9 F).
Arm Rolled-In, Bucket Rolled-In
End
Bucket Height: 0.3 to 0.5 m

Start
20 m
Acceleration
Zone
3 to 5 m
Deceleration
Zone
3 to 5 m
SM0138
Measurement:
1. Measure both the slow and fast speeds of the
machine.
2. Select the following switch positions:
Travel
Mode
Switch
Engine E Mode HP Mode Work Auto-Idle

Control Switch Switch
Mode Switch
Dial
Switch
Slow
Mode
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
Fast
Mode
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
3. Start traveling the machine in the acceleration

zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6 ft).
5. After measuring the forward travel speed, turn the
upperstructure 180 and measure the reverse
travel speed.
6. Repeat steps 4. to 5. three times in each direction
and calculate the average values.
Evaluation:
T4-2.
T4-4-2
EX255-EX285
EXCAVATOR TEST
TRACK REVOLUTION SPEED
Summary:
Measure the track revolution cycle time with the track
raised off ground.
Preparation:
1. Adjust the track sag of both side tracks to be
equal.
2. On the track to be measured, mark one shoe with
chalk.
3. Swing the upperstructure 90 and lower the
bucket to raise the track off ground. Keep the
boom-arm angle between 90 to 110 as shown.
Place blocks under the machine frame.
Mark
SM0139
WARNING
Securely support the raised track using wooden
blocks.
4. Maintain the hydraulic oil temperature at 50 5 C

(122 9 F).
Measurement:
Travel
Mode
Switch
90 110

Mode Switch
Dial
Switch
Slow
Mode
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
Fast
Mode
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
2. Operate the travel control lever of the raised track

to full stroke.
3. Measure the time required for 3 revolutions in both
directions after a constant track revolution speed
is obtained.
4. Raise the other side and repeat the above procedures.
5. Repeat steps 2. to 4. three times and calculate the
average values.
Evaluation:
T4-2.
NOTE - The measurement data obtained through the
raised track revolution test may have wide variations.
Therefore, the evaluation based on the results obtained from the 20 m travel speed check described
before is more recommendable.
EX255-EX285
T4-4-3
EXCAVATOR TEST
MISTRACK CHECK
Summary:
1. Allow the machine to travel 20 m (65.5 ft). Measure the maximum tread deviation from the tread
chord line drawn between the travel start and end
points to check the performance equilibrium between both sides of the travel device systems
(from the main pump to the travel motor).
2. If measured on a concrete surface, the tread
deviation has a trend to decrease.
Maximum Distance
Acceleration
Zone:
3 to 5 m
20 m
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.5 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and deceleration.
ground with the arm and bucket rolled in.
(122 9 F).
Measurement:
1. Measure the amount of mistracking in both fast,
and slow travel speeds.
Travel
Mode
Switch

Mode Switch
Dial
Switch
Slow
Mode
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
Fast
Mode
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
3. Start traveling the machine in the acceleration

zone with the travel levers at full stroke.
4. Measure the maximum distance between a
straight 20 m (65.5 ft) tread chord line and the
tread made by the machine.
5. After measuring the tracking in forward travel, turn
the upperstructure 180 and measure in reverse
travel.
average values.
Evaluation:
T4-2.
SM0140
T4-4-4
EX255-EX285
EXCAVATOR TEST
TRAVEL PARKING FUNCTION CHECK
Summary:
To measure the parking brake function on a specified
slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20% (11.31).
2. Mark a white line on the travel device cover.
ground with the arm and bucket fully rolled in.
(122 9 F).
0,2 0,3 m
SM0141
Measurement:
1. Measure in the fast travel mode.
Travel
Mode
Switch
Fast
Mode

Mode Switch
Dial
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
3. Measure the displacement (revolution angle) of

the travel device cover until the parking brake is
applied.
3-1. Climb the slope and place the travel levers in
neutral.
3-2. Measure the displacement from the mark
position on the travel device cover when the
levers are placed in neutral to that position
when the machine stops moving.
4. Measure the travel parking brake slip amount
while parked.
4-1. Climb the slope and place the travel levers in
neutral.
4-2. Stop the engine.
4-3. After the machine stops, put alignment
marks on a track link or shoe, and the track
side frame.
4-4. After 5 minutes, measure the distance between the marks on the track link or shoe and
the track side frame.
Evaluation:
T4-2.
Position where the machine

Position when the travel
comes to a stop
levers are in neutral
Displacement
(Revolution Angle)
Mark
SM0142
Alignment marks on the track

side frame and shoe when the
machine comes to a stop
Displacement measured
after 5 minutes
SM0143
EX255-EX285
T4-4-5
EXCAVATOR TEST
SWING SPEED
Summary:
Measure the time required to swing three complete
turns.
Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on
slopes.
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty.
(122 9 F).
WARNING
Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of the
swing area before starting the measurement.
Measurement:
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
AutoIdle
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
2. Operate swing control lever fully.

3. Measure the time required to swing 3 turns in one
direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
average values.
Evaluation:
T4-2.
The same height as the

boom foot pin height
SM0144
T4-4-6
EX255-EX285
EXCAVATOR TEST
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer circumference when stopping after a 180 full-speed swing.
Preparation:
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on a
slope.
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180.
(122 9 F).
Two chalk marks

SM0145
WARNING
the area is clear and that coworkers are out of the
Measurement:
SM0146
Measure difference between marks
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
AutoIdle
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
Marking on the Track Frame
Marking on the Swing Bearing
2. Operate the swing control lever fully and return it

to the neutral position when the mark on the
upperstructure aligns with that on the track frame
after swinging 180.
3. Measure the distance between the two marks.
4. Align the marks again, swing 180, then test in the
opposite direction.
5. Repeat steps 3. to 5. three times each and calculate the average values.
Evaluation:
T4-2.
SM0147
EX255-EX285
T4-4-7
EXCAVATOR TEST
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 %.
3. Load bucket fully. In lieu of loading the bucket,
weight (W: tons) of the following specification can
be used.
W = M x 1.5
where: M = Bucket heaped capacity (m3)
1.5 = Soil specific gravity
4. With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90 to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as illustrated.
(122 9 F).
SM0148
Measurement:
1. Select the following switch position:
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
AutoIdle
Switch
OFF
OFF
General
Purpose
Mode
OFF
2. Maintain the engine at slow idle. After five minutes, measure the difference between the marks
along the swing bearing periphery and the track
frame.
3. Perform the measurement in both right and left
swing directions.
4. Perform the measurement three times in each
direction and calculate the average values.
Evaluation:
T4-2.
Measure difference between marks
Marking on the Track Frame

Marking on the Swing Bearing
SM0147
T4-4-8
EX255-EX285
EXCAVATOR TEST
SWING BEARING PLAY
Summary:
Measure the swing bearing play using a dial gauge to
check the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolts for looseness.
2. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown,
using a magnetic base.
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
SM0149
Measurement:
the same as the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to raise
the front idler 0.5 m (20 in). Record the dial gauge
reading (h2).
3. Calculate bearing play (H) from this data (h1 and
h2) as follows:
H=h2-h1
SM0150
Measurement: (h2)
Measurement: (h1)
The same height as the

SM0144
Evaluation:
T4-2.
SM0152
EX255-EX285
T4-4-9
EXCAVATOR TEST
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
With the upperstructure swung 90 to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
be used.
W = M x 1.5
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the arm top
pin to the position flush with the boom foot pin
height.
4. Climb a slope and swing the upperstructure 90 to
the slope.
(122 9 F).
Measurement:
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
AutoIdle
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
2. Operate the swing lever to full stroke to swing the

upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle and repeat steps 2. and
3. Check both clockwise and counterclockwise.
5. Perform the measurement three times.
Evaluation:
T4-2.
SM0148
T4-4-10
EX255-EX285
EXCAVATOR TEST
HYDRAULIC CYLINDER CYCLE TIME
Measure the cycle time of the boom, positioning, arm,
and bucket cylinders.
Preparation:
1. To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket
rolled in, lower the bucket to the ground, as
shown.
2. To measure the cycle time of the positioning
cylinder (triple articulation)
With the empty bucket rolled in and arm rolled out,
raise the boom to the maximum height.
3. To measure the cycle time of the arm cylinder:
With the empty bucket rolled in, position the arm
so that it is vertical to the ground. Lower the boom
until the bucket is 0.5 m (20 in) above the ground.
4. To measure the cycle time of the bucket cylinder:
The empty bucket should be positioned at midstroke between roll-in and roll-out, so that the
sideplate edges are vertical to the ground.
(122 9 F).
SM0153
0.5 m
Measurement:
SM0154
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
AutoIdle
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
SM0155
EX255-EX285
T4-4-11
EXCAVATOR TEST
2. To measure cylinder cycle times:
(Cylinder full stroke includes cylinder cushioning
zone)
Boom cylinders:
Measure the time it takes to raise the boom, and
the time it takes to lower the boom. To do so,
position the boom at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
Positioning cylinder (triple articulation):
Measure the time it takes to extend and retract
the positioning cylinder. To do so, position the
cylinder at one stroke end, then move the
control pedal to the other stroke end as quickly
as possible.
Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so,
position the arm at one stroke end, then move
the control lever to the other stroke end as
Bucket cylinder:
Measure the time it takes to roll in the bucket,
and the time it takes to roll out the bucket. To do
so, position the bucket at one stroke end, then
move the control lever to the other stroke end as
3. Repeat each measurement three times and calculate the average values.
Evaluation:
T4-2.
T4-4-12
EX255-EX285
EXCAVATOR TEST
DIG FUNCTION DRIFT CHECK
Summary:
Measure dig function drift, which can be caused by oil
leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.
Extended
Distance
Retracted
Distance
Retracted
Distance
Same Height
NOTE - When testing the dig function drift just after

cylinder replacement, slowly operate each cylinder to
its stroke end to purge air.
Bucket Bottom
SM0156
Preparation:
be used.
W = M x 1.5
2. Position the arm cylinder with the rod 50 mm (2 in)
extended from the fully retracted position.
3. Position the positioning cylinder (triple articulation) with the rod 50 mm (2 in) extended from the
fully retracted position.
4. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
5. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket pin
is the same as the boom foot pin.
(122 9 F).
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, positioning
(triple articulation), arm and bucket cylinders.
3. Repeat step 2. three times and calculate the
average values.
Evalution:
T4-2.
Arm Cylinder Extension (and positioning cylinder for

triple articulation)
Mark
SM0157
Boom and Bucket Cylinder Retraction

Mark
Mark
SM0158
EX255-EX285
T4-4-13
EXCAVATOR TEST
CONTROL LEVER OPERATING FORCE
Summary:
Use a spring scale to measure the maximum resistance of each control lever as illustrated.
Preparation:
Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
Measurement:
1. Start the engine.
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
AutoIdle
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
SM0159
WARNING
3. Operate each boom, arm, bucket and swing lever

to at full stroke and measure the maximum operating force for each.
4. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating force
required. When finished, lower the track and then
jack-up the other track.
average values.
Evaluation:
T4-2.
SM0160
T4-4-14
EX255-EX285
EXCAVATOR TEST
Summary:
Measure each lever stroke at the lever top using a
ruler.
NOTE - When the lever has play, take a half of this

value and add it to the measured stroke.
Preparation:
Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
SM0161
Measurement:
1. Stop the engine.
2. Measure each lever stroke at the lever top from
neutral to the stroke end using a ruler.
3. Repeat step 2. three times and calculate the
average values.
Evaluation:
T4-2.
EX255-EX285
T4-4-15
EXCAVATOR TEST
COMBINED BOOM RAISE/SWING FUNCTION 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.
2. With the arm fully rolled out and bucket fully rolled
in, lower the bucket to the ground. The bucket
must be empty.
(122 9 F).
SM0162
WARNING
Measurement:
Engine
Control
Dial
E Mode
Switch
Fast
Idle
OFF
HP Mode
Switch
OFF
Work
Mode
Switch
AutoIdle
Switch
General
Purpose
Mode
OFF
SM0163
2. Raise the boom and swing simultaneously, both

at full stroke.
3. When the upperstructure rotates 90, release the
control levers to stop both functions. Measure the
time required to swing 90 and the height (H) of the
bucket teeth.
average values.
Evaluation:
T4-2.
SM0164
T4-4-16
EX255-EX285
EXCAVATOR TEST
NOTES
EX255-EX285
T4-5-1
COMPONENT TEST
PRIMARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the pilot pump delivery
port. Install adapter (75301519) and pressure
gauge (75301518) on the port.
: 6 mm
Plug
4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
(122 9 F).
SM0165
Measurement:
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
AutoIdle
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
Slow
Idle
OFF
OFF
General
Purpose
Mode
OFF
2. Measure the pilot pressure in each specified

setting above.
3. Repeat the measurement three times and calculate the average values.
Evaluation:
T4-2.
T4-5-2
EX255-EX285
COMPONENT TEST
Primary Pilot Pressure Adjustment
Adjustment:
Adjust the setting pressure of relief valve (1) (the
primary pilot pressure) as necessary.
1
: 36 mm
SM0166
1. Remove plug (3).

2. Install the estimated necessary number of shims
(2).
3. Tighten plug (3).
: 49 Nm (5 kgfm, 36 lbfft)
4. Check the relief pressure of relief valve (1).

3
Change in Relief Pressure
Shim Thickness (mm)

kPa
kgf/cm2
psi
0.25
78
0.8
11
0.5
157
1.6
23
1.0
304
3.1
44
SM2201
EX255-EX285
T4-5-3
COMPONENT TEST
SECONDARY PILOT PRESSURE
Preparation:
3. Install pressure gauge (75301518) and tee
(75301520) to the end of pilot line (1) at the
respective control valve spool end, as illustrated.
: 14 mm, 17 mm
(122 9 F).
Measurement:
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
AutoIdle
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
Slow
Idle
OFF
OFF
General
Purpose
Mode
OFF
SM0168
2. Measure the pilot pressure in each specified

setting above with the corresponding control lever
operated full stroke.
Evaluation:
T4-2.
SM0169
T4-5-4
EX255-EX285
COMPONENT TEST
SOLENOID VALVE SET PRESSURE
Measure solenoid valve set pressure with both the
Dr.EX and the pressure gauge.
Preparation:
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (75301482), tee
(75301521), adapter (75301522), and pressure
gauge (75301518) to the disconnected end at the
solenoid valve side, as illustrated.
: 17 mm, 19 mm, 22 mm
Connect Dr.EX to the machine for solenoid valve

set pressure monitoring.
(122 9 F).
SM0629
Solenoid Valve
Pressure Gauge
Measurement:
1
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
Travel
Mode
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
Fast
Speed
Mode
Hose
Tee
Adapter
SM0171
2. Operate as instructed below for each measuring

solenoid valve:
Solenoid Valve SG: Repeat pressing and releasing of the power boost switch.
Solenoid Valve SD: Perform a combined operation. Relieve both actuators.
Solenoid Valve SC: Perform a combined operation of boom raise and arm roll-in.
Solenoid Valve SI: Drive the machine, then stop
the machine.
3. Read the values on both Dr.EX and the pressure
gauge.
Evaluation:
The average value read on the pressure gauge shall
be within 0.2 MPa (2 kgf/cm2, 28 psi) of the value
indicated on Dr.EX.
EX255-EX285
T4-5-5
COMPONENT TEST
Solenoid Valve Set Pressure Adjustment Procedure
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

marker for the record of the original position.
(Take care not to touch any part of the screw
threads with the white marker).
2. Loosen lock nut (7). Turn adjusting screw (8) to
adjust the set pressure of the solenoid valve.
3. Retighten lock nut (7).
The distance between the

lock nut end and screw end
should be 4.0 mm (0.157 in)
or less.
SM0172
: 13 mm
: 4 mm
: 8.8 Nm (0.9 kgfm, 6.5 lbfft)
Reference: Standard Change in Pressure

Turns
1/4
1/2
3/4
kPa
98
196
294
392
kgf/cm2
psi
14
28
43
57
7
SM0173
Adjusting Screw
4. Check the set pressure of the solenoid valve.

Pressure
Increase
Pressure
Decrease
SM0174
T4-5-6
EX255-EX285
COMPONENT TEST
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be measured with Dr.EX.
Preparation:
3. Remove the plug from the main pump delivery
port. Install adapter (75301519), hose
(75301523) and pressure gauge (75301524) on
the port.
: 6 mm
Or connect Dr.EX to the machine for main pump
delivery pressure monitoring.
(122 9 F).
SM0175
Measurement:
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
AutoIdle
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
2. Measure the pressure with the control levers in

neutral.
Evaluation:
T4-2.
EX255-EX285
T4-5-7
COMPONENT TEST
MAIN RELIEF VALVE SET PRESSURE
Summary:
Measure the main relief valve setting pressure at the
main pump delivery port.
The main relief pressure can also be measured with
Dr.EX.
Preparation:
the port.
: 6 mm
Or connect Dr.EX to monitor the main pump
delivery pressure.
(122 9 F).
Measurement:
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
2. Relieve each actuator to measure main relief

pressures.
First, slowly operate bucket, arm, and boom control levers to the stroke end to relieve each function one at a time.
3. As for the swing function, secure the upperstructure so it is immovable. Slowly operate the swing
lever to relieve the swing function.
4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
travel levers to relieve the travel function.
Evaluation:
T4-2.
Reference:
If the measure pressures for all functions are lower
than the specified range, the probable cause is a
decrease of the main relief valve setting pressure.
If the relief pressure of a particular function is lower,
the probable cause is other than main relief valve.
SM0175
T4-5-8
EX255-EX285
COMPONENT TEST
Main Relief Pressure Setting Adjustment Procedure
Main Relief
Valve
Adjustment:
Adjust the pressure setting of the main relief valve
using plug (3) (for the low-side relief pressure setting)
and plug (5) (for the high-side relief pressure setting)
after loosening lock nut (1).
High-Side Relief Pressure Setting Adjustment Procedure
1. Loosen lock nut (1). Lightly tighten plug (3) until
the end of plug (3) comes into contact with
piston (2). Retighten lock nut (1).
: 27 mm
: Plug (3): 19.5 Nm (2 kgfm, 14.5 lbfft)
: Lock Nut (1):
68 to 78 Nm
(7 to 8 kgfm, 51 to 58 lbfft)
SM0168
2. Loosen lock nut (4). Turn plug (5) to adjust the

relief pressure setting referring to the table
below.
: 27 mm, 32 mm
: Lock Nut (4):
78 to 88 Nm
3
1
5
Low-Side Relief Pressure Setting Adjustment Procedure

3. Loosen lock nut (1). Turn plug (3) counter
clockwisely until the specified value is obtained
referring to the table below. Retighten lock nut
(1).
: 27 mm
: Lock Nut (1):
59 to 68 Nm
4
2
4. Recheck the set pressures.

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

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

Adjustment:
Adjust the pressure setting of the swing relief valve
using adjusting screw (1) after loosening lock nut (2).
1. Loosen lock nut (2).
2. Turn adjusting screw (1) adjust the pressure
setting referring to the table below.
4. Recheck the set pressure.
: 24 mm, 32 mm
: 177 Nm (18 kgfm, 130 lbfft)
SM0179
1
2
SM0180

1
Turns
MPa
kgf/cm2
psi
1/4
2.9
30
430
1/2
5.8
59.5
850
3/4
8.7
89
1270
1
11.7
119
1690
Pressure
Increase
Pressure
Decrease
SM0181
T4-5-10
EX255-EX285
COMPONENT TEST
Travel Relief Pressure Setting Adjustment Procedure
Adjustment:
Adjust the pressure setting of the travel relief valve
: 19 mm
: 6 mm
2. Turn adjusting screw (1) to adjust the pressure
Travel Relief
Pressure Valve
SM0182
1
2
SM0183

Turns
MPa
kgf/cm2
psi
1/4
2.9
30
430
1/2
5.9
60
850
3/4
8.8
90
1280
1
11.8
120
1710
Adjusting
screw
Pressure
Increase
Pressure
Decrease
SM0174
EX255-EX285
T4-5-11
COMPONENT TEST
OVERLOAD RELIEF VALVE SET PRESSURE
Summary:
Measuring the set pressure of the overload relief
valves on the machine is not recommended for the
following reasons:
1. The circuit pressure must be increased by 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.
2. Pressure setting of the overload relief valve must
be made at a specified oil flow rate normally far
smaller than the main pump delivery flow rate.
Accordingly, even if the main relief valve set
pressure can be reset higher than the overload
relief valve set pressure, the main pump supplies
too much oil to correctly measure the setting
pressure of the overload relief valve.
For this reason, in order to correctly measure the
set pressure of the overload relief valve, the
overload relief valve unit must be removed from
the machine and tested on a test stand.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload
relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
as follows:
Preparation:
the port.
: 6 mm
Or connect Dr.EX to the machine for main pump
delivery pressure monitoring.
(122 9 F).
SM0175
T4-5-12
EX255-EX285
COMPONENT TEST
Measurement:
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
2. Slowly operate bucket, arm, and boom control

levers to the stroke ends to relieve each function
one at a time.
3. Read the pressures on the pressure gauge while
releasing the front functions.
4. Perform the measurement for the bucket, arm,
and boom, in that order.
5. Repeat the measurement three times and calculate the average value for each front function.
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
within the specified value range.
Refer to the Performance Standard Table in
Group T4-2.
EX255-EX285
T4-5-13
COMPONENT TEST
Overload Relief Valve Set Pressure Adjusting
Procedure
NOTE - In principle, adjust the overload relief valve

set pressure on a test stand.
Adjustment:
Adjust the pressure setting of the overload relief valve
2. Turn adjusting screw (2) to adjust the pressure
SM0185
: 17 mm
: 6 mm
: 29.5 Nm (3.0 kgfm, 22 lbfft)
4. Recheck the set pressures.

Turns
MPa
kgf/cm2
psi
1/4
5.2
54
770
1/2
10.6
108
1540
3/4
15.9
162
2300
1
21.1
216
3070
Adjusting
Screw
Pressure
Increase
Pressure
Decrease
SM0174
T4-5-14
EX255-EX285
COMPONENT TEST
MAIN PUMPS FLOW TEST
Summary:
To test the performance of the main pumps, measure
the flow rate by connecting a portable flowmeter to
the main pump delivery connections.
Preparation:
1. Shut the engine. Press the air release valve on the
top of the hydraulic oil tank to discharge residual
pressures.
NOTE - Prior to starting the disconnection of the

pipings, check the primary piloting pressure, which
must fall within the required values.
2. Connect a vacuum pump to the oil filler neck on
the hydraulic oil tank.
NOTE - Operate the vacuum pump while the portable
flowmeter is connected to the main pumps.
3. Disconnect hoses A and B from the main pumps.

Connect test pipes (6) and (7) to hoses A and B
disconnected.
7. Disconnect the vacuum pump. Bleed the air from

the pump by loosening plug K on the pump, until oil
flows out the port of plug K.
8. Connect a pick-up of engine tachometer to the
engine injection pipes. Disconnect sensor N terminal. Fully open both loading regulation valves
(2) and (3).
9. Start the engine check the portable flow meter
connection for any leakage.
Measurement:
(122 9 F).
Engine
Control
Dial
E
Mode
Switch
HP
Mode
Switch
Work
Mode
Switch
Auto
Idle
Switch
A/I
Treavel
Mode
Switch
Fast
idle
OFF
OFF
Gen.
mode
OFF
Fast
mode
4. Connect test pipes (4) and (5) with the half flanges
and bolts to the main pumps. Connect portable
flowmeter kit (75298406) (1), (2) and (3) as illustrated in the figure. Eliminate as far as possible all
curves in the hoses and secure them appropriately to prevent all movements.
3. Gradually close the loading regulation pump relative to the pump involved by the test to obtain the
pressures specified in diagram P-Q and measure
the flow rate of the pump and the engine speed.
Repeat step 3. for all pressure points specified in
curve P-Q. To test the other pump, proceed in the
same manner with the other loading valve.
5. Disconnect hose SA (pump 1 control) from main

pump 1 regulator and plug the hose.
Disconnect hose SA (pump 2 control) from main
pump 2 regulator and plug the hose.
6. Disconnect hose PA from the pilot system pump

and install a T-joint between pilot pump and hose
PA.
To the free port of the T-joint, install another
T-joint to which two hoses have to be connected.
The other end of hoses have to be connected to
ports SA and SB on the pump regulators left free
when pipes SA and SB have been disconnected.
(This shall make the pumps operate at maximum
displacement angle).
EX255-EX285
T4-5-15
COMPONENT TEST
Evaluation:
1. Convert the measured pump flow rate into the one
for the rated pump speed using the following
formula.
2. Specified Pump Flow Rate

Refer to the Pump P-Q Diagram in Group T4-2.
Converted Pump Flow Rate:

Qc = Ns x Q / Ne
Where:
Qc: Converted Pump Flow Rate
Q : Measured Pump Flow Rate
Ns : Rated Engine Speed
EX255 = 2000 rpm
EX285 = 2050 rpm
Ne : Measured Engine Speed
K
B
4
SB
SA
5
1
3
PA
SB
Pilot pump
SA
T-joint
T-joint
To ports SA, SB
on pump
regulators
PA hose
SM5403
T4-5-16
EX255-EX285
COMPONENT TEST
Regulator Adjustment
4
6
5
1
2
9
3
10
7
8
SM0187
1
2
3
4
5
Lock Nut (For Minimum Flow Adjustment)

Adjusting Screw (For Minimum Flow Adjustment)
Lock Nut (For Maximum Flow Adjustment)
Adjusting Screw(For Maximum Flow Adjustment)
Lock Nut
(For Pilot Pressure Characteristic Adjustment)
- Adjusting Screw
(For Pilot Pressure Characteristic Adjustment)
7 - Lock Nut (For P-Q Line Adjustment)
8 - Adjusting Screw (For P-Q Line Adjustment)
9 - Lock Nut (For P-Q Line Adjustment)
10 - Adjusting Screw (For P-Q Line Adjustment)
EX255-EX285
T4-5-17
COMPONENT TEST
Adjustment Item
Adjustment Procedure
Remarks
1. Minimum Flow Rate
Loosen lock nut (1) and turn adjusting screw (2).

Rotating adjusting screw (2) 1/4
a turn clockwise increases the
minimum pump flow rate by 6.47
cm3/rev. (0.39 in3/rev).
1) Do not turn the adjusting screw

more than two turns.
2) Securely retighten lock nut (1)
after the adjustment.

a turn clockwise decreases the
maximum pump flow rate by 5.39
cm3/rev. (0.33 in3/rev).

more than two turns.
2) Do not increase the maximum
flow rate.
In other words, do not turn the
adjusting screw counterclockwise. Increasing the maximum
flow rate (turning the adjusting
screw counterclockwise), however, will be required after adjusting the pilot pressure characteristics.

a turn clockwise decreases the
flow rate by 10.77 cm3/rev.
(0.66 in3/rev).

more than one turn.
2) When adjusting screw (6) is
turned clockwise, the maximum flow rate will also be decreased.
To maintain the maximum flow
rate unchanged, turn adjusting
screw (4) counterclockwise
twice as much as adjusting
screw (6) is turned.
This ratio of 2 (adjusting screw
(4) counter clockwise turn) to 1
(adjusting screw (6) clockwise
turn) is to counterbalance.
A: Loosen lock nut (7) and turn

adjusting screw (8). Rotating
adjusting screw (8) 1/4 a turn
clockwise increases the
maximum pump flow rate by
10.77 cm3/rev. (0.66 in3/rev.).
B: Loosen lock nut (9) and turn
adjusting screw (10). Rotating adjusting screw (10) 1/4 a
turn clockwise increases the
maximum pump flow rate by
2.60 cm3/rev. (0.16 in3/rev).
1) Do not turn the adjusting

screws more than one turn.
2) Rotate the adjusting screws
watching the engine performance.
or (9) after the adjustment.
Pi
2. Maximum Flow Rate
Q
Pd
3. Pilot Pressure Characteristics (Pi-Q Line)
Q
Pi
4. P-Q Line
(Torque Adjustment)
Q
B
Pd
T4-5-18
EX255-EX285
COMPONENT TEST
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 5 C
(122 9 F).
WARNING
Also, take care not to fall off the machine while the
measurement.
Preparation:
(122 9 F). Rotate the swing motor to warm the
inside of the motor.
2. Properly shut down the engine. Press the air
release valve (1) on top of the hydraulic oil tank to
release any remaining pressure.
OM0400
3. Disconnect the swing motor drain hose (2) at the

hydraulic oil tank end. Install plug (75301529) to
the disconnected end on the hydraulic oil tank.
: 22 mm
Preconditions for Measurement:

Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
AutoIdle
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
SM0189
EX255-EX285
T4-5-19
COMPONENT TEST
Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the
arm tip pin height is the same as the boom foot
pin height. Be sure that the bucket is empty.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil measurement after the swing speed reaches a constant maximum speed. The measuring time
should be more than 45 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise directions, and calculate the average values.
2. Amount of Oil Drained While Relieving Swing
Motor Circuit
(1) Thrust the bucket teeth into the ground as
illustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
hose end. The measuring time should be
more than 45 seconds.
in both clockwise and counterclockwise directions, and calculate the average values.
The same height as

SM0144
SM0190
Evaluation:
T4-2.
* Conversion of the amount of drain oil measured into
the per-minute value
First measure the amount of drain oil using a calibrated container. Then, convert the measured drain
oil into the per-minute value using the formula below:
Q = 60 x q / t
Where:
Q : Amount of drain oil per minute (L/min)
t
: Time measured (seconds)
q
: Total amount of drain oil (L)
SM0191
T4-5-20
EX255-EX285
COMPONENT TEST
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.
Maintain hydraulic oil temperature at 50 5 C
(122 9 F).
Preparation:
(122 9 F). Rotate the travel motor to warm the
inside of the motor.
2. Properly shut down the engine. Press the air
release valve (1) on top of the hydraulic oil tank to
release any remaining pressure.
3. Disconnect the travel motor drain hose (2) at the
travel motor end. Install plug (75301525) to the
disconnected end. Connect the drain hose (3/416UN) to the travel motor.
OM0400
: 22 mm, 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
Preconditions for Measurement:
Engine
Control
Dial
E Mode
Switch
HP Mode
Switch
Work
Mode
Switch
AutoIdle
Switch
Fast
Idle
OFF
OFF
General
Purpose
Mode
OFF
SM0182
EX255-EX285
T4-5-21
COMPONENT TEST
Measurement:
1. Amount of oil drained while travel motor is rotating
(1) Start the engine. Jack up the measuring side
track using the front attachment, as illustrated.
90 110
WARNING
Securely support the raised track using wooden
blocks.
SM0139
(2) Rotate the raised track with the travel lever

operated full stroke. Start drain oil measurement after the track rotation speed reaches a
constant maximum speed. The measuring
time should be more than 45 seconds.
in both forward and reverse directions, and
calculate the average values.
Evaluation:
T4-2.
* Conversion of the amount of drain oil measured into
the per-minute value
SM0193
First measure the amount of drain oil using a calibrated container. Then, convert the measured drain
oil into the per-minute value using the formula below:
Q = 60 x q / t
Where:
Q : Amount of drain oil per minute (L/min)
t
: Time measured (sec.)
q
: Total amount of drain oil (L)
T4-5-22
EX255-EX285
COMPONENT TEST
NOTES
SECTION 5
EX255-EX285
TROUBLESHOOTING
INDEX
Group 1 -
Diagnosing Procedure
Group 4 -
Troubleshooting B
Introduction ........................................... T5-1-1
Troubleshooting B Procedure .................. T5-4-1
Diagnosing Procedure ......................... T5-1-2
Relationship between Machine Trouble
Dr.EX .................................................... T5-1-4

Dr.EX Start-Up Procedure ................... T5-1-4
Symptoms and Parts in Trouble ........ T5-4-2

Correlation between Trouble
Dr.EX Fault Code ................................. T5-1-5
Symptoms and Part Failures .......... T5-4-12
Dr.EX Monitoring Function ................... T5-1-6
Engine Troubleshooting ...................... T5-4-18
Dr.EX Special Function
Actuator Control System
(Service Mode) ................................. T5-1-7

Adjustable Data List ........................... T5-1-14
Troubleshooting ............................... T5-4-32

Front Attachment Control System
Troubleshooting ............................... T5-4-38
Swing System Troubleshooting ........... T5-4-50
Group 2 -
Component Layout
Travel System Troubleshooting ........... T5-4-53
Main Components ................................ T5-2-1
Troubleshooting for Other Functions .. T5-4-58
Electrical System (Overall System) ..... T5-2-2
Engine Speed Adjustment and
Electrical System (Cab) ........................... T5-2-3

Electrical System
(Monitor and Switch Panels) .............. T5-2-5
Pump and Related Parts ........................ T5-2-6
Engine Learning ............................. T5-4-60

Exchange Inspection Method ............... T5-4-61
Boom Lowering Method
when Engine Stalls ........................... T5-4-63
Other Components ................................. T5-2-7
Group 5 -
Troubleshooting C
Troubleshooting C Procedure ............... T5-5-1
Group 3 -
Troubleshooting A
Malfunction of Coolant
Troubleshooting A Procedure .............. T5-3-1
Temperature Gauge .......................... T5-5-2
Fault Codes .......................................... T5-3-2
Malfunction of Fuel Gauge ................... T5-5-4
Fault Code 01 ....................................... T5-3-4
Malfunction of Fuel Level
Fault Code 02, 03 ................................. T5-3-5

Fault Code 04, 05 ................................. T5-3-6
Indicator ............................................ T5-5-6

Malfunction of Indicator Light
Fault Code 06 ....................................... T5-3-7
Check System ................................... T5-5-8
Fault Code 07 ....................................... T5-3-8
Malfunction of Level Check Switch ....... T5-5-8
Sensor Operating Range List .............. T5-3-9
Malfunction of Engine Oil Level

Indicator .......................................... T5-5-10
INDEX
Malfunction of Coolant Level
Indicator ........................................... T5-5-12
Malfunction of Hydraulic Oil Level
Indicator .......................................... T5-5-14
Malfunction of Alternator Indicator .... T5-5-16
Malfunction of Engine Oil Pressure
Indicator .......................................... T5-5-18
Malfunction of Overheat
Indicator .......................................... T5-5-20
Malfunction of Air Filter Restriction
Indicator .......................................... T5-5-22
Malfunction of Buzzer ........................ T5-5-24
Malfunction of Hour Meter ................. T5-5-26
Group 6 -
Electrical System Inspection
Precautions for Inspection and

Maintenance ..................................... T5-6-1
Instructions for Disconnecting
Connectors ....................................... T5-6-3
Fuse Continuity Test ............................. T5-6-4
Inspection and Replacement of Maxi
Fusible Links .................................... T5-6-5
Battery Voltage Check ........................... T5-6-6
How to Troubleshoot Alternator
Malfunctions ...................................... T5-6-7
Continuity Check ................................... T5-6-8
Voltage and Current Check .................. T5-6-10
Wiper Controller .................................... T5-6-14
Replacement of Relay ......................... T5-6-16
Relay Box ............................................. T5-6-18
Replacement of QOS
Controller .......................................... T5-6-20
Replacement of Power Outlet ................ T5-6-21
Group 7 -
Harness Check
Circuit Check .......................................... T5-7-1
EX255-EX285
T5-1-1
DIAGNOSING PROCEDURE
INTRODUCTION
Each troubleshooting section group is presented in an
orderly fashion so as to make the inspecting and
troubleshooting procedures easy to follow. Use the
troubleshooting section to guide you in locating the
source of any problems that may arise.
The troubleshooting section consists of 6 groups: the
component layout, the troubleshooting A (using fault
codes), troubleshooting B (starting with symptoms),
troubleshooting C (gauges and indicators), the electrical system inspection procedures, and harness check
groups.
Component Layout Diagrams
Troubleshooting A (using fault codes)
Use these charts when the self-diagnosing function
of Dr.EX shows any fault codes.
(The controller automatically diagnoses and memorizes malfunctions that have occurred in the signal
sending system.)
Example: Fault Code 01 EC Sensor Failure
Troubleshooting B (starting with symptoms)
Use these charts when the machine is exhibiting
trouble and when Dr.EX does not indicate any fault
codes.
Example: Even if engine control dial is operated,
engine speed does not change.
Troubleshooting C (Gauges and indicators)
Use these charts when any gauges or indicators
malfunction.
Example: The fuel gauge does not operate.
Electrical System Inspection Procedure
Refer to this group for precautions and inspection
procedures of the electrical system when or before
performing inspections on the electrical system.
Example: Fuse Inspection
Harness Check
Refer to this group for information about the test
harnesses.
Example: 75301706D
T5-1-2
EX255-EX285
These six basic steps are essential for efficient
troubleshooting:
1. Study the System
Study the machines technical manuals. Know the
system and how it works, and what the construction, functions and specifications of the system
components are.
2. Ask the operator

Before inspecting, get the full story of malfunctions
from your star witness the operator.
SM0600
(a) How is the machine being used? (Find out if the

machine is being operated correctly)
(b) When was the trouble noticed, and what types
of work the machine doing at that time?
(c) What are the details of the trouble? Is the
trouble getting worse, or did it appear suddenly
for the first time?
(d) Did the machine have any other troubles previously? If so, which parts were repaired before?
3. Inspect the machine

Before starting the troubleshooting procedure,
check the machines daily maintenance points, as
shown in the operators manual.
SM0601
Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the controllers, causing total operational failure of the machine.
Fuse failure is often caused by a fine crack in the
fuse, and such fine cracks are very hard to detect
by visual inspection.
SM0602
EX255-EX285
T5-1-3
4. Operate the machine yourself.
If the trouble cannot be confirmed, stop the engine
and obtain further details of the malfunction from the
operator.
Also, check for any incomplete connections of the
wire harnesses.
5. Perform troubleshooting
CAUTION
Never attempt to disconnect harnesses or hydraulic lines while the engine is running. The machine
may malfunction or pressurized oil may spout,
possibly resulting in personal injury. Be sure to
stop the engine before disconnecting harnesses
or hydraulic lines.
SM0603
Connect the diagnostic analyzer, Dr.EX, to the MC

(Main Controller) to obtain malfunction records.
If any fault codes are displayed on the monitor,
check sensing signal circuits, referring to Troubleshooting A.
SM0604
If no fault code is indicated on the monitor, go to the

troubleshooting B group.
Note that Dr.EX will be necessary in the troubleshooting B procedures for monitoring real time
component performance.
*Note that the fault codes displayed do not necessarily indicate machine trouble. The controller
stores even temporary electrical malfunctions,
such as a drop in battery output voltage or
disconnections of the switches, sensors, etc., for
inspections.
For this reason, the RETRIAL is required to erase
the accumulated fault codes from the controller
memory and to confirm if any fault codes are
indicated after the RETRIAL.
SM0605
6. Trace possible causes

Before reaching a conclusion, check the most likely
causes again. Try to identify the actual cause of the
trouble.
Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions.
SM0606
T5-1-4
EX255-EX285
Dr.EX
Dr.EX (75301336) is a handy micro computer used for
diagnosing malfunctions of the machine control system, including the MC (Main Controller).
When the Dr.EX is connected to the MC, malfunctions
recorded in the MC memory are indicated as fault
codes on the Dr.EX display.
(Self-Diagnosing Function)
Input signals from the sensors or switches that are
connected to the MC, or output signals from the MC to
solenoid valves can be monitored on a real-time basis
while the machine is being operated.
(Real-Time Monitoring Function)
Dr.EX START-UP PROCEDURE

1. Connect the harness of the Dr.EX to the diagnosing
connector of the MC, located near fuse box behind
the operators seat.
Start
NOTE - Only this connecting harness can be used to

connect the Dr.EX to the controller. Do not use any
other harness to connect Dr.EX to the controller.
Initial Screen
2. Turn the key switch to the ON position or start the

engine.
3. Turn the Dr.EX ON. After a few seconds, following
patterns will appear on the Dr.EX display:
3-1.
Initial Pattern
3-2.
Model Code Pattern

Example :
Model
: EX200-5
Ver
: XXXX
3-3.
Function Selection Pattern

F-1 : Self-diagnosing Results
F-2 : Monitor Data
F-3 : Special Functions
4. Select key F1 (Proceed according to the instructions that appear on the display.)
NOTE - For the operation procedure of the Dr.EX, refer
to the Dr.EX OPERATORS MANUAL.
Can not
communicate
with MC
Check MC
power source
and/or
communication
harness
Model Code
Confirmation
OK?
OK
SelfDiagnosing
Self-Diagnosing
Results
(Fault Code)
Retrial B
Self-Diagnosing
Results
(Fault Code)
Function
Selection
Record
Not OK
Dr. EX Other
Software
Monitor
Data
Special
Functions
Data Selecting
Pattern
Monitor
Data Display
EX255-EX285
T5-1-5
Dr.EX FAULT CODE
Fault Code
Trouble
Corrective Action
01
EC sensor failure
1) Perform Retrial B.
2) Check harness.
3) Replace EC sensor.
02
03
Pump 1 delivery pressure sensor failure

2) Check harness.
3) Replace the pump delivery pressure sensor.
04
05
Pump 1 control pressure sensor failure

2) Check harness.
3) Replace the pump control pressure sensor.
06
Arm roll-in pilot pressure sensor failure
2) Check harness.
3) Replace the arm roll-in pilot pressure sensor.
07
Engine control dial failure
2) Check harness.
3) Replace the engine control dial.
T5-1-6
EX255-EX285
Dr.EX MONITORING FUNCTION
Dr.EX has a function to monitor the command signals
from the MC and the input signals to the MC from
various switches and sensors.
Monitor Item
Description
Pump 1 Control Pressure
kgf/cm2
kgf/cm2
kgf/cm2
kgf/cm2
Input from the PC pressure sensor (5-spool side)
Input from the arm roll-in pilot pressure sensor
Input from the pump 2 delivery pressure sensor
Arm Roll-In Pilot Pressure
Input from the pump 1 delivery pressure sensor
Pump 2 Delivery Pressure
Input Signal from EC Sensor
kgf/cm2
Input from the PC pressure sensor (4-spool side)
EC Angle
Display Unit and Form
Accelerator Angle
Dial Angle
Input from the engine control dial
Arm Regenerative Proportional

Solenoid Valve Output
S, G, P, A
EP
AI
HP
Pd
Lo. Hi
On/off state of the key switch
BmH, Fr, Tr
Selected travel mode
Key Switch
ON/off state of the power boost switch
Selected Travel Mode Switch
On/off state of the HP mode switch
Power Boost Switch
On/off state of the auto-idle switch
HP Mode Switch
rpm
On/off state of the E mode switch
Auto-Idle Switch
rpm
Selected work mode
E Mode Switch
kgf/cm2
On/off state of the pressure switches
Selected Work Mode Switch
step
Pressure Switch
kgf/cm2
EC Motor Position
kgf/cm2
Input from the N sensor
kgf/cm2
Target engine speed under loaded condition.

(Approx. 150 min-1 difference from engine speed
under no load.)
Actual Engine Speed
The value of the command signal to the solenoid

valve unit SG
Target Engine Speed

valve unit SD
Power Boost Pressure

valve unit SI
Pump Proportional Solenoid

Valve Output

valve unit SC
Travel Motor Displacement

Angle Change Pressure
Ky
Done, Undone, Aborted
EX255-EX285
T5-1-7
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
MC
3. Operation
How to Turn Dr.EX in the Service Mode
1) Turn the key switch OFF. Wait 10 seconds or
more.
2) Connect the Dr.EX.
3) Turn the learning switch to the Engine Learning
position.
4) Turn the key switch to the ON position. (Do not
start the engine.)
5) Turn on the switch on the Dr.EX.
On the following pages, the service mode panels on

the Dr.EX and the service mode operating procedure are shown.
T5-1-8
EX255-EX285
Dr.EX VER ****

F1 : Start
F10 : Model Menu
F1
Press
Model: XXXX-X
Ver
: XXXX
Is model correct ?
F1 : Correct
F5 : ESC
F1
Press
Service mode selected

In service mode, self diagnosis
operation and / or monitor display
will not be conducted.
F1 : Rechecked
F5 : ESC
F1
Press
Service mode related to Dr.EX screen panels, beginning with the start screen, are shown along with the
corresponding Dr.EX key operations.
However, Dr.EX screen panels which are not related
to the Dr.EX key operation are excluded.
EX255-EX285
T5-1-9
Select Functions
F3 : Special Functions
F5 : ESC
F3
Press
F5 : ESC
Press
F8
Press
F7
Select Functions
F6 :
F7 : Learning Data Display
F8 : Parameter Change
Select learning data to be displayed.

F6 : EC Motor Stop Position
F7 : EC Motor Maximum Speed
Position
F5 : ESC
F8
F6
Press
Press
F5
Press
Select Item
F6 : Li Speed
F7 : E Speed
F8 : P Speed
F3 : Next
EC Motor Stop Position

-XXXX digit
F5 : ESC
F3
Press
F5 : ESC
Learning
data is
displayed.
T5-1-10
EX255-EX285
Select Item
F6 : AI Speed Control
F8 : Crusher (L) Engine Speed
Control
F4 : Prev.
F5
An example of F7: Breaker Engine

Speed Control operation is shown on
the next page.
Press
F5 : ESC
F5
Press
(Press F4 to return to the previous screen.)
End
(Returns to panel (A) on the previous page.)
EX255-EX285
T5-1-11
F3 : Next F5 : ESC F7 : HELP
F5
Press
Breaker Engine Speed Control

HELP
Adjustable Range : -500 to+100 rpm
Initial : 0 rpm
Minimum Adjusting Deviation :
10 rpm
Press
Input the adjusting deviation you

want.
F7

adjustable range in HELP
F5 : ESC
F3
Press
Values
Adjusted
In Tens

123
0 rpm
12
12
12 rpm
F1 : Execute
F2 : Corr
F4 : Prev. F5 : ESC F7 : HELP
F7
Press
F5
Press
Current
:
Adjustment :
-100 is entered as an example here.

SFT
SFT
3
SFT
SFT
Press (123 on the upper right corner of the screen will change to ABC.)
Press (- will be displayed in the Adjustment field.)
Press (ABC on the upper right corner of the screen will change to 123.)
*
1
Press (-1 will be displayed in the Adjustment field.)
.
0
.
0

123
Current
: 0 rpm
Adjustment : -100 rpm
F1 : Execute
F2 : Corr
F4 : Prev. F5 : ESC F7 : HELP
F1
Press
NOTE - Confirm that 123 is displayed on the upper right

corner of the screen before pressing key
T5-1-12
EX255-EX285
Adjusting Deviation
Data Confirmation
Adjusting Deviation Data Name :
F3 : Next
F5 : ESC
F3
The value input on the previous page will be displayed again in the
Adjustment field.
Press
Current
: 0 rpm
F1 : Execute F4 : Prev. F5 : ESC
F1
Press
Adjustment was made as follows :

Adjusting Deviation Data Name :
F3 : Next
F3
The last screen for the Breaker Engine Speed Control will be
displayed.
Press
Current
: 0 rpm
F4 : Prev
Turn off Dr.EX.
End
F5 : ESC
EX255-EX285
T5-1-13
Check the engine performance (Check if the engine
speed has been changed), as follows:
IMPORTANT - Be sure to turn the learning switch to
the OFF (Neutral) position before checking the engine
performance. Because the MC does not perform the
engine, pump, and valve controls if the learning switch
is in the Engine Learning position, engine speed
change cannot be confirmed properly.
1) Turn the key switch OFF.
2) Wait 10 or more seconds.
3) Turn the learning switch to the OFF (Neutral) position.
4) Disconnect Dr.EX. (This step can be omitted if you
wish to monitor the engine speed on Dr.EX.)
5) Turn the key switch to the ON position.
6) Start the engine.
7) Operate the machine to check the engine performance.
T5-1-14
EX255-EX285
ADJUSTABLE DATA LIST
Adjustable Data
Values Adjusted In
Adjustable Range
Set Adjustment Value Before

Factory Shipment
Li Mode Speed
10s min-1 (rpm)
0 to 120 min-1 (rpm)
0 min-1 (rpm)
E Mode Speed
10s min-1 (rpm)
-120 to 120 min-1 (rpm)
0 min-1 (rpm)
-1
P Mode Speed
10s min (rpm)
-120 to 120 min (rpm)
0 min-1 (rpm)
AI Mode Speed
10s min-1 (rpm)
-120 to 100 min-1 (rpm)
0 min-1 (rpm)
-1
-1
-1
Breaker Engine Speed
10s min (rpm)
-500 to 100 min (rpm)
0 min-1 (rpm)
Crusher Engine Speed
10s min-1 (rpm)
-500 to 100 min-1 (rpm)
100 min-1 (rpm)
EX255-EX285
T5-2-1
COMPONENT LAYOUT
MAIN COMPONENTS
SM5601
1
2
3
4
5
6
7
8
9
10
11
Bucket Cylinder
Arm Cylinder
Boom Cylinder
Center Joint
Swing Bearing
Swing Device
Fuel Tank
Hydraulic Oil Tank
Control Valve
Pilot Filter, Pilot Relief Valve
Pump Device
12
13
14
15
16
17
18
19
20
21
Engine
Radiator
Oil Cooler
Intercooler
Battery
Travel Device
Shockless Valve
Travel Pilot Valve
Front/Swing Pilot Valve
T5-2-2
EX255-EX285
COMPONENT LAYOUT
ELECTRICAL SYSTEM (overall system)
SM5402
1 2 3 4 5 6 7,8 9 10 11 12 13 14 15 16 17 18 -
Wiper Motor
Monitor Panel
Relays, Relays box
Windshield
Horn
Work Light
Fuel Sensor with Low Fuel Level Switch
Solenoid Valve Unit
PC Pressure Sensor (Upper: 4-Spool Side)
PC Pressure Sensor(Lower: 5-Spool Side)
EC Motor
EC Sensor
N (Engine Speed) Sensor
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

Coolant Temperature Switch (Engine Preheat Circuit)
Engine Oil Level Switch (on oil pan)
Overheat Switch
Battery Relay
Battery
Starter Relay
Air Cleaner Restriction Switch
Pressure Switch (Boom Raise), Pressure Sensor
(Arm Roll-In)
Fuse Box
MC (Main Controller)
QOS Controller
EX255-EX285
T5-2-3
COMPONENT LAYOUT
SM5603
1
2
3
4
5
6
7
8
9
10
11
12
Relay box
Air conditioner relays (if installed)
Connection for cab light (ceiling)
WWES connection for wiper cut-off microswitch
Heater connection
Air conditoner connection
Loudspeakers connection
Cab ground
Main controller (MC)
Q.O.S. controller
Load momentum alarm buzzer provision
Load momentum alarm relay provision (R1)
13
14
15
16
17
18
19
20
21
22
23
24
Breaker relay (R2) variant provision

R.H. Rotation bucket relay (R3) variant provision
L.H. Rotation bucket relay (R4) variant provision
Cab light relay (R5)
Rear cab light relay (R6)
A, B, K junction connector
C, D juncton connector
E, F junction connector
G, H junction connector
Dr. EX. connector
Engine learning switch
Fuse box
T5-2-4
EX255-EX285
COMPONENT LAYOUT
SM5604
1
2
3
4
5
6
Connectors for monitor and switch panels

Cigarette lighter
Connectors to cab harness
Connectors not used
Windshield wiper controller
(1) connector for breaker switch
(2) connector for cab light switch
(3) connector for bucket rotation
(4) connector for load momentum alarm switch
(5) connector for rear cab light
7
8
- Connector not used

- Connector
EX255-EX285
T5-2-5
COMPONENT LAYOUT
ELECTRICAL SYSTEM (monitor and switch panels)
10
24
11
12
23
13
22
14
21
20
15
16
17
19
3
18
T157-07-02-001
SM0610
5
25
6
4
32
7
8
26
31
27
28
30
T157-01-01-009
SM0611
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Monitor Panel
Switch Panel
Power Boost Switch
Key Switch
Cigar Lighter
HP Mode Switch
E Mode Switch
Engine Control Dial
Air Conditioner Panel
Warm Up Complete Indicator
Fuel Gauge
E Mode Indicator
Auto-Idle Indicator
Hydraulic Oil Level Indicator
Preheat Indicator
Air Filter Restriction Indicator
29
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
T157-01-01-018
SM0612
Fuel Level Indicator

Overheat Indicator
Alternator Indicator
Engine Oil Pressure Indicator
Engine Oil Level Indicator
Coolant Level Indicator
HP Mode Indicator
Coolant Temperature Gauge
Work Light Switch
Wiper Switch
Travel Mode Switch
Work Mode Switch
Buzzer Stop Switch
Auto-Idle Switch
Washer Switch
Level Check Switch
T5-2-6
EX255-EX285
COMPONENT LAYOUT
PUMP AND RELATED PARTS
3-4
8
12
11
10
9
SM3004
1
2
3
4
5
6
Pilot Filter
Pilot Relief Valve
EC Motor
EC Sensor
Pilot Pump
Regulator (Pump 2)
7
8
9
10
11
12
N Sensor
Regulator (Pump 1)
Pump 1
Pump 2
EX255-EX285
T5-2-7
COMPONENT LAYOUT
OTHER COMPONENTS
Shockless Valve
Swing Device
9
8
6
7
SM0626
T157-01-01-011
Travel Device
SM0627
T157-07-03-018
Solenoid Valve Unit
FRONT
10
11
12
13
3
SM0628
T157-01-01-012
1
2
3
4
5
6
7
Swing Relief Valve

Travel Relief Valve
Shockless Valve
Check Valve
Shockless Valve
SM0629
W157-02-11-020
8
9
10
11
12
13
Check Valve
Pilot Pressure Sensor (Arm Roll-In)
Solenoid Valve Unit (SG)
T5-2-8
EX255-EX285
COMPONENT LAYOUT
Control valve
Right travel motor
Left travel motor
3
2
10
11
12
41
13
14
40
15
16
39
Bucket cylinder
38
37
36
35
34
Boom cylinder
17
18
Arm cylinder
33
32
31
19
20
30
29
21
22
23
26
27
28
24
25
Swing motor
1 - Hydraulic Timer
2 - Travel Flow Control Valve
3 - Load Check Valve (Travel Parallel Circuit)
4 - Check Valve
6 - Check Valve
7 - Check Valve
(Switch Valve A)
(Switch Valve B)
(Poppet Valve)
13 - Load Check Valve (Boom 1 Parallel Circuit)
14 - Load Check Valve (Boom 1 Tandem Circuit)
SM0037
15
16
17
18
19
20 21 22 23 24 25 26 27 28 -

Boom Anti-Drift Valve (Check
Valve)
Valve)
Check Valve
Side)
Check Valve
Restriction (4-Spool Side Parallel Circuit)
Circuit)
Restriction (Arm 1 Parallel Circuit)

Circuit)
30 - Check Valve
32 - Check Valve
37 - Load Check Valve (Boom 2 Parallel
Circuit)
39 - Check Valve
40 - Load Check Valve (Travel Tandem
Circuit)
41 - Pump Control Valve (5-Spool Side)
EX255-EX285
T5-2-9
COMPONENT LAYOUT
Section A
H
B
C
D
E
F
41
SM0036
SM0038
Section C
Bucket
Auxiliary
15
12
11
39
Section D
9
Boom 2
16
Section B
Boom 1
SM0040
L. Travel
R. Travel
38
17
37
3
2
20
21
19
13
14
40
10
18
SM0039
SM0041
T5-2-10
EX255-EX285
COMPONENT LAYOUT
Left travel motor
3
2
10
Right travel motor
11
12
41
13
14
40
15
16
39
38
37
36
35
34
Bucket cylinder
Boom cylinder
17
18
Arm cylinder
33
32
31
19
20
30
29
21
22
23
26
27
28
24
25
Swing motor
SM0037
1 - Hydraulic Timer
2 - Travel Flow Control Valve
3 - Load Check Valve (Travel Parallel Circuit)
4 - Check Valve
6 - Check Valve
7 - Check Valve
(Switch Valve A)
(Switch Valve B)
(Poppet Valve)
13 - Load Check Valve (Boom 1 Parallel Circuit)
14 - Load Check Valve (Boom 1 Tandem Circuit)
15
16
17
18
19
20 21 22 23 24 25 26 27 28 -

Boom Anti-Drift Valve (Check
Valve)
Valve)
Check Valve
Side)
Check Valve
Restriction (4-Spool Side Parallel Circuit)
Circuit)
Restriction (Arm 1 Parallel Circuit)

Circuit)
30 - Check Valve
32 - Check Valve
37 - Load Check Valve (Boom 2 Parallel
Circuit)
39 - Check Valve
40 - Load Check Valve (Travel Tandem
Circuit)
41 - Pump Control Valve (5-Spool Side)
EX255-EX285
T5-2-11
COMPONENT LAYOUT
Arm 1
Section E (2)
Arm 2
31
32
Section E (1)
Arm 1
Section F
Arm 2
Swing
SM0042
36
34
35
28
24
26
25
27
29
23
22
33
30
SM0045
SM0043
Section H
Section G
1
SM0044
SM0046
T5-2-12
EX255-EX285
COMPONENT LAYOUT
NOTE:
EX255-EX285
T5-3-1
TROUBLESHOOTING A
TROUBLESHOOTING A PROCEDURE
Use troubleshooting A procedure when fault codes are shown on Dr.EX.
How to Read the Troubleshoting Flow Charts
YES(OK)
(2)
After checking or measuring item (1), select either Yes (OK) or No (NOT
OK) and proceed to item (2) or (3), as appropriate.
(1)
(3)
NO(NG)
Key switch: ON
Special instructions or reference item are indicated in the spaces under the box. Incorrect
measuring or checking methods will render troubleshooting impossible, and may damage
components as well.
Explanation of how to use lamp harness kit required. Refer to Harness Check Group (Group
T5-7) in this section.
Use the Dr. EX troubleshooting/monitor function for the description in a double line box.
Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes
can be seen without going through the flow chart.
NOTE - For all connector drawings illustrated in this

group, harness end connector terminals seen from the
open end side are shown.
SM0630
T5-3-2
EX255-EX285
TROUBLESHOOTING A
FAULT CODES
FAULT CODE
TROUBLE
CORRECTIVE ACTION
01
EC sensor failure
2) Check harness.
3) Replace EC sensor.
02
03

2) Check harness.
3) Replace the pump delivery pressure sensor.
04
05

2) Check harness.
3) Replace the pump control pressure sensor.
06
Arm roll-in pilot pressure sensor failure
2) Check harness.
3) Replace the arm roll-in pilot pressure sensor.
07
Engine control dial failure
2) Check harness.
3) Replace the engine control dial.
EX255-EX285
T5-3-3
TROUBLESHOOTING A
T5-3-4
EX255-EX285
TROUBLESHOOTING A
FAULT CODE 01 (EC SENSOR FAILURE)
NO
YES
YES
Disconnect EC sensor
connector. Check if
resistance between EC
sensor side connector
terminals No.1 and No.3
is 1.7 0.4 k.
Connect test harness
between EC sensor
connector halves. Turn
engine control dial and
check if voltage
changes as specified.
Check if breakage or
short circuit exists
between MC 22P
connector terminal
No.D15 and EC
sensor terminal No. 2.
Disconnect EC
sensor connector.
Check if voltage
between harness end
connector terminals
No.1 and No.3 is
5 0.5 V.
Key switch: ON
After replacement,
refer to page T5-4-60.
YES
YES
Check if voltage
between harness end
connector terminals
NO No.1 and vehicle
frame is 5 0.5 V.
Key switch: ON
5 0.5 V for the voltage
change standard
values.
Harness failure
between MC and EC
sensor.
Harness breakage
between MC and EC
sensor terminal No.3.
Harness breakage
between MC and EC
NO sensor terminal
No.1.
NO
Test harness: 75301706D

Refer to page T5-3-9 for
the voltage change standard values.
Faulty MC
Faulty EC sensor
After replacement,
Connector (harness end connector terminals seen from the open end side)
Main Controller (22P): D is added for each terminal number in the text.
1 2 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
EC Sensor
1
EX255-EX285
T5-3-5
TROUBLESHOOTING A
FAULT CODE 02
(PUMP 1 DELIVERY PRESSURE SENSOR
FAILURE)
FAULT CODE 03
(PUMP 2 DELIVERY PRESSURE SENSOR
FAILURE)
Checking Instruction:
It is unlikely for both pump delivery pressure sensors (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.
YES
Disconnect the pump
delivery pressure
sensor connector.
Check if voltage
between harness end
connector terminals
No.1 and No.3 is
5 0.5 V.
NO
Switch pump delivery

pressure sensors
(for pumps 1 and 2)
with each other.
Perform RETRIAL.
Check if indicated
fault code changes
to the one for the
other pump delivery
pressure sensor.
Key switch: ON
between MC 22P
connector terminal
No. D16 (pump 1)/
No. D17 (pump 2)
and pump delivery
pressure sensor terminal No.2.
YES
Faulty EC sensor
NO
After replacement,
YES
Check if voltage
between harness end
connector terminals
NO No.1 and vehicle
frame is 5 0.5 V.
Key switch: ON
change standard
values.
Harness failure
between MC and
pump delivery
pressure sensor.
Harness failure between MC and pump

delivery pressure

NO delivery pressure
Faulty pump delivery

pressure sensor.
YES
1 2 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Pump Delivery Pressure Sensor
T5-3-6
EX255-EX285
TROUBLESHOOTING A
FAULT CODE 04
(PUMP 1 CONTROL PRESSURE SENSOR
FAILURE)
FAULT CODE 05
(PUMP 2 CONTROL PRESSURE SENSOR
FAILURE)
Checking Instruction:
It is unlikely for both pump control pressure sensors
(ones in 4-spool side and in 5-spool side control
valves) to fail simultaneously. For this reason, if
faults codes 04 and 05 are indicated, the probable
cause is harness failure.
YES
Disconnect pump
control pressure
sensor connector.
Check if voltage
between harness end
connector terminals
No.1 and No.3 is
5 0.5 V.
NO
Switch pump control

pressure sensors (ones
in 4-spool side and in 5spool side control
valves) with each other.
Perform RETRIAL.
Check if the indicated
fault code changes to
the one for the other
pump control pressure
sensor.
Key switch: ON
between MC 22P
connector terminal
No. D14 (4-spool
side)/No. D19
(5-spool side) and
pump control pressure sensor terminal
No.2.
YES
Faulty MC
NO
After replacement,
YES
Check if voltage
between harness end
connector terminals
NO No.1 and vehicle
frame is 5 0.5 V.
Key switch: ON
5 0.5 V for the voltage change standard
values.

control pressure sensor.
Harness breakage
between MC and
pump control pressure sensor terminal
No.3.
Harness breakage
between MC and
NO pump delivery pressure sensor terminal.
Faulty pump control
pressure sensor.
YES
1 2 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Pump Control Pressure Sensor
3
2
EX255-EX285
T5-3-7
TROUBLESHOOTING A
FAULT CODE 06
(ARM ROLL-IN PILOT PRESSURE
SENSOR FAILURE)
YES
YES
Disconnect pilot
pressure sensor
connector. Check if
voltage between harness end connector
terminals No.1 and
No.3 is 5 0.5 V.
NO
Key switch: ON
Replace pilot pressure

sensor with pump control pressure sensor.
Perform RETRIAL.
Check if fault code disappears.
between MC 22P
connector terminal
No.D18 and pilot
Harness failure between MC and pilot

pressure sensor.
Faulty MC
NO
After replacement,
YES
Check if voltage
between harness end
connector terminals
NO No.1 and vehicle
frame is 5 0.5 V.
Key switch: ON
5 0.5 V for the voltage change standard
values.
Harness breakage
between MC and pilot
Harness breakage
between MC and pilot
NO pressure sensor terminal No.1.
YES
Faulty pilot pressure

sensor (arm roll-in).
1 2 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Pilot Pressure Sensor
1
2
T5-3-8
EX255-EX285
TROUBLESHOOTING A
FAULT CODE 07
(ENGINE CONTROL DIAL FAILURE)
YES
YES
Disconnect engine
control dial connector. Check if voltage
between harness end
connector terminals
No.5 and No.7 i
5 0.5 V.
NO
Disconnect engine control dial connector.
Check if resistance between engine control dial
side terminals No.5 and
No.7 is 5 0.5 k.
With the engine control
dial connected, insert
test probe from back of
engine control dial. Turn
engine control dial and
check if voltage changes
as specified.
Key switch: ON
between MC 22P
connector terminal
No.D21 and engine
control dial terminal
No.6.
Faulty MC
NO
After replacement,
YES
Check if voltage
between harness end
connector terminals
NO No.5 and vehicle
frame is 5 0.5 V.
Key switch: ON
change standard
values.
Refer to page T5-3-9 for

the voltage change standard values.
Harness failure between MC and engine

control dial.
Harness breakage
between MC and engine control dial terminal No.7.
Harness breakage
between MC and enNO gine control dial terminal No.5.
Faulty engine control
dial.
YES
1 2 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Engine Control Dial

4 3
5 6
7 8
2 1
9
EX255-EX285
T5-3-9
TROUBLESHOOTING A
SENSOR OPERATING RANGE LIST
1. Preconditions for measurement
Hydraulic Oil Temperature: 50 5 C (122 9 F)
Unless otherwise instructed, set the switches as
follows:
Engine
Control Dial
E Mode
Switch/HP
Mode Switch
Work
Mode
Switch
Auto-Idle
Switch
Max.
Position
OFF
General
Purpose
Mode
OFF
Monitor using the Dr.EX.
SM0631
2. Sensor Operating Range

Item
Engine Control Dial
Required Control/Switch Operation

At minimum speed position
0.3 to 1.0 V
At maximum speed position
4.0 to 4.7 V
Engine control dial at Min. position
2.5 to 2.7 V
Engine control dial at Max. position with HP mode

switch turned OFF
3.3 to 3.7 V
EC Sensor
Engine control dial at Max. position with HP mode
switch turned ON
Control Levers: Neutral

Pump Delivery Pressure
Sensor
Boom Raised to stroke end and main relief

valve relieved
2
25+15
-7 kgf/cm
2
350+20
-5 kgf/cm

Pilot Control Shut-Off Lever:
Locked Position
0 to 1.0 kgf/cm2
Control Lever: Full Stroke

Pilot Control Shut-Off Lever:
Unlocked Position
34 to 40 kgf/cm2

Pump Control Pressure
Sensor
0.2 V or more larger than the voltage

obtained above (with the engine
control dial at Max. position with HP
mode switch turned OFF)
One Track Jacked-Up Travel Lever (Raised track

side): Full Stroke
NOTE - 1 kgf/cm2 = 0,09807 MPa
10 to 16 kgf/cm2
30 to 40 kgf/cm2
T5-3-10
EX255-EX285
TROUBLESHOOTING A
EX255-EX285
T5-4-1
TROUBLESHOOTING B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the Dr.EX although the machines
operation is abnormal.
On the front section pages of this group T5-4, are
tables indicating the relationship between machine
trouble symptoms and related parts which may cause
such trouble if failed.
Start the troubleshooting with more probable causes

selected by referring to these tables.
How to Read the Troubleshooting Flow Charts
YES (OK)
(2)
After checking or measuring item (1), select either Yes (OK) or No

(NOT OK) and proceed to item (2) or (3), as appropriate.
(1)
(3)
NO(NG)
Key switch: ON
components as well.
Explanation of how to use lamp harness kit required. Refer to Harness Check Group
(Group 7) in this section.
Use the Dr. EX troubleshooting/monitor function for the description in a double line box.
Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-2
EX255-EX285
TROUBLESHOOTING B
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND PARTS IN
TROUBLE
Part Name
Part function
Control System
Trouble
Machine Symptoms
Trouble
shooting
Procedures
This table indicates the probable machine trouble

symptoms by part item when each part is failed and
procedures to determine if the part has failed.
EC Motor
EC Sensor
To operate governor lever.
To detect the slow-idle speed

governor lever position (2.5 V).
To instruct the engine

target speed governor lever
position.
Governor lever does not

move.
Whenever key switch is ON,

governor lever position is learned
as in the slow idle speed position
differing from the correct position.
Accordingly, engine speed is
controlled afterward with the
discrepancy which occurred at this
time.
Even if engine control dial

is operated, engine speed
is unchanged.
If harness to engine control
dial is broken, target speed
1600 min-1 is used as the
backup value
Even if engine control dial is If the discrepancy occurred to the

Engine speed is constantly
operated, engine speed does
slower side, engine speed is
held at 1600 min-1.
changed by engine control dial.
not increase from slow
(Auto-idle function
However, engine speed control
speed range.
operates, and engine can
range stays slower than normal.
be stopped by turning key
Starter rotates but engine
(Note: If the discrepancy occurred
switch.)
fails to start occasionally.
to the faster side, when engine
While engine is running at a
control dial is turned to the fastest
faster than specific speed, if position, EC motor continues
harness to EC motor is bromoving. However, EC motor is a
ken, engine stalls.
worm gear type so that governor
While engine is running at a
lever is kept holding at the full
stroke position. If engine control dial
slower than specific speed, if
is turned to the slowest position,
harness to EC motor is brogovernor lever returns to the slow
ken, engine becomes unconidle position.)
trollable.
When engine is started, engine
speed fluctuates.
Engine start may become difficult
-
By Dr.EX SelfDiagnosing
Function
By Dr.EX Monitor
Function
Fault code 01 is displayed.
Monitor Item: EC Angle
Monitor item:
Target Engine Speed
By Lamp Harness Install test harness

Check
(75301706B). Then, check
output signal from EC and
check if harness is normal
-
By Other Check/
Measurements
Note
Descriptions in
(Operational Principle)
Technical Manual
Engine Control Dial
Engine is stopped by
EC motor.
No engine stop
is provided. However, a
fuel shut-off cable is installed
T2-1
If EC sensor is failed, engine

learning operation becomes
impossible.
T2-1
T2-1
EX255-EX285
T5-4-3
TROUBLESHOOTING B
Pump Control
Pressure Sensor
Pump Delivery
Pressure Sensor
N Sensor
To detect pump control valve

pressure in control valve to
control the travel motor
swash angle.
To detect both right and left

pump delivery pressures to
control speed sensing system,
HP mode circuit, arm regenerative circuit, and travel motor
swash angle.
To detect engine speed to

control speed sensing system.
To increase relief setting

pressure temporarily.
Sensor output is reduced

to zero and travel motor
swash angle is held to the
maximum angle.
When pump delivery pressure

sensor output is 0 V or 5 V, the
following symptoms appear.
Speed sensing system does

not function.
If solenoid valve unit (SG)

is not energized, pilot pressure at port SG is 0 MPa
(0 kgf/cm2).
Even if travel mode switch is

turned to the fast mode
position, travel speed does
not change to the fast
range.
Travel speed is changed to the

slow speed range. However,
automatic up shifting to the
fast speed range from slow
speed range is impossible.
HP mode does not work.
When combined operation is
made, arm speed is slow
(when delivery pressure
sensor for pump 2 has
failed).
Engine stalls when the

machine is operated at a high
altitude or under heavy operating
conditions.
Main relief pressure set is

unchanged from the
standard setting pressure
of 34 MPa (350 kgf/cm2).
Even if the power boost
switch is depressed, main
relief pressure does not
increase. Digging force
does not increase.
Fault codes 04 and 05 are

displayed.
Fault codes 02 and 03 are

displayed.
Monitor items:
Install lamp harness

(75301514). Then, check
output signal from MC and
check if harness is normal.
Proportional solenoid
valve is used for the ONOFF valve so that whether
the power boost switch is
depressed or not, as long
as an output signal from
MC is measure by means
of test harness, the control
of solenoid valve unit is
normal. If any output signal
is detected, a broken wire
harness may be a cause.
See NOTE at the end of
TABLE.
Evaluation by Dr.EX
0.25 V or Less: Discontinuity
4.75 V or More: Short Circuit
T2-1
T2-1
Monitor item:
Actual Engine Speed
Solenoid Valve Unit

(SG)
T2-1
Monitor item:
Power boost pressure
T2-1
T5-4-4
EX255-EX285
TROUBLESHOOTING B
Part Name
Part function
Control System
Trouble
Machine Symptoms
To reduce pump swash

angle by guiding pilot
pressure to regulator to operate the speed sensing
control system.
When arm is rolled in, arm

speed is increased by guiding
return oil from arm cylinder rod
side to bottom side.
To increase travel speed

by decreasing travel motor
swash angle when fast
travel mode is selected
and pump delivery
pressure is low.
Pilot pressure is not fed to

regulator.
If solenoid valve unit (SC) is not

energized, pilot pressure at port
SC is 0 MPa (0 kgf/cm2).
Thereby, arm regenerative
function does not work.
Travel speed is held in

slow speed range.
Engine may stall under

heavy conditions such as
operation at a high altitude.
When leveling, arm speed

becomes very slow.
Travel speed does not

increase even if travel
mode switch is turned to
the fast travel speed
position.
Function
Trouble
shooting
Procedures
By Dr.EX Monitor
Function
Monitor item:
Pump proportional
Solenoid valve output
Monitor item:
Arm regenerative proportional
solenoid valve output
Monitor item:
Travel motor displacement
angle change pressure
By Lamp Harness
Check
Install test harness

(75301514). Then, check

(75301514). Then, check output
signal from MC and check if
harness is normal.

(75301514). Then, check
By Other Check/
Measurements
Note
Descriptions in
(Operational
Principle)Technical
Manual
Output signal MC must be

measured with the
solenoid valve connected.
table.
T2-1

measured with the
table.

measured with the
table.
T2-1
T2-1
EX255-EX285
T5-4-5
TROUBLESHOOTING B
To detect that travel spool

is operated (for auto-idle
operation and travel motor
swash angle control).
To detect that front and/or

swing spool is operated (for
auto-idle operation).
To detect boom raise pilot

pressure (for arm
regenerative control).
To detect arm roll-in pilot

pressure (for HP mode
control and arm regenerative control).
No signal is sent to MC.
Even if machine is traveled

with auto-idle switch ON,
engine speed does not
increase.
When traveling on a flat
area in the fast travel
mode, travel speed is
slow.
Even if either front or swing

control lever is operated with
auto-idle switch ON, engine
speed does not increase.
As arm regenerative function

does not work, when boom is
raised and arm is rolled in,
arm speed is slower than
normal (difficult to discern).
When beginning to level a
ground surface, bucket is
slightly lowered into the
ground.
When the combined operation of swing and arm roll-in

is made, arm regenerative
function does not work so
that arm speed is slow
when starting to roll in (difficult to discern).
Arm speed is slow when
leveling.
HP mode does not function
when arm is rolled in.
Monitor item: Pressure Switch

While operating front or swing
function, monitor to check if
pressure switch is ON or
OFF.
Monitor item: Pressure Switch.

While raising boom, monitor to check
if pressure switch is ON or OFF
Monitor item:
Arm Roll-In Pilot Pressure
It is possible to check if
pressure switch has failed
or if a port is clogged by
switching the pressure
switch with an adjacent one
(for front).
It is possible to check if
pressure switch has failed or
if a port is clogged by
switching the pressure
switch with an adjacent one
(for travel).
T2-1
T2-1
Monitor item: Pressure

Switch
While traveling, monitor to
check if pressure switch is
ON or OFF.
Pressure Switch
(Boom Raise)
T2-1

(Arm Roll-In)
T2-1
T5-4-6
EX255-EX285
TROUBLESHOOTING B
Part Name
Part function
Learning Switch
To start learning engine control
ON: 0 V Learning
OFF: 5 V Normal Control
Control System
Trouble
Machine Symptoms
By Dr.EX Monitor
Function
To operate power boost function

ON: 0 V Boost function works.
OFF: 5 V Boost function does
not work.
HP Mode Switch
To control HP mode
operation
ON: 0 V HP Mode.
OFF: 5 V Standard Mode.
Engine learning does not

function.
Breaking of Wire: Boost function

does not work.
Short Circuit: Boost function
works for 8 seconds after key
switch is turned ON, but becomes
inoperative afterwards.
If trouble is caused by circuit discontinuity, engine

control system operates
normally. (Only engine
learning function fails.)
If trouble is caused by a
short circuit, the learning
mode operates when key
switch is turned ON. Therefore, engine may stall 5 seconds after engine starts.
Power boost function does not

work if whether a wire is broken
or short circuit occurs.
Broken Wire: Even if HP

mode switch is
depressed, HP mode does
not operate.
Short Circuit: Even if HP
mode switch is turned
OFF, HP mode is not
deactivated.
Function
Trouble
shooting
Procedures
Power Boost Switch
Monitor item:
Monitor item: Power Boost Switch
Monitor item: HP Mode

Switch
By Lamp Harness Check
By Other Check/
Measurements
Note
Descriptions in
(Operational
Principle)Technical
Manual
T2-1
T2-1
T2-1
EX255-EX285
T5-4-7
TROUBLESHOOTING B
E Mode Switch
To select E mode.
ON: 0 V E Mode
OFF: 5 V Standard Mode
Travel Mode Switch
MC
Pump Control
Valve
To change travel speed at two

stages.
To control engine, pump, and

valve operations.
To develop pump control

pressure in response to the
oil flow rate passing through
the center bypass passage
in the control valve.
Fast Travel Mode:

0 V Traveling at fast
speed
Slow Travel Mode: 5 V
Discontinuity in Switch:
Travel speed is kept in slow
range (5 V).
Problems may differ depending

on the trouble. (Machine
troubles shown below signify
that the logic circuit in MC has
some faults.)
If the pump control valve

spool is seized, or the
spring is broken, pump control pressure does not
change.
Broken Wire: Even if E

mode switch is depressed,
engine runs at full speed.
Short Circuit: Engine
speed is not increased up
to full speed.
Even if travel mode switch is

turned to the fast travel
mode position, travel speed
is un-changed.
Even if key switch is turned to

the ON position, EC motor
does not rotate to the start
position so that engine cannot
start. Or, even if engine is
started, engine speed does not
increase.
Pump swash angle is held to a
minimum, all function speeds
are slow.
When the 5-spool side

pump control valve is faulty:
1.Left track travel speed
only
is slow.
2.Swing function is also slow.
3.Arm speed is slow when
leveling.
4.Single operation of bucket,
boom, or arm is almost
normally performed.
When 4-spool side pump
control valve is faulty:
1.Bucket single operation
speed is very slow.
2.Boom is not raised when
leveling.
3.Right track travel speed
only is slow.
4.Single operation of boom,
arm, or swing is almost
normally performed.
Procedures may differ depending

on the locations of failures.
Monitor item:
Selected Travel Mode Switch
Before suspecting a failure in MC,

check the fuse in this control circuit.
Monitor item:
E Mode Switch
T2-1
T2-1
Monitor items:
T3-3
T5-4-8
EX255-EX285
TROUBLESHOOTING B
Part Name
Part function
Control System
Trouble
Machine Symptoms
Trouble
shooting
Procedures
Flow Combiner Valve
Restriction in Arm 1
Parallel Passage
Check Valve and Restriction in

4-Spool Side Parallel Circuit
To supply hydraulic oil to

both right and left travel
spools from pump 1 when
the combined operation of
travel and
front/swing is made.
To ensure lateral thrust force of

the front by swing function.
To supply hydraulic oil from

pump 1 to arm 1 spool in
pump 2 side.
When the combined operation of travel and front/swing

is made, hydraulic oil is not
supplied to the left travel
spool, or oil flow to the left
travel spool is insufficient.
If the restriction is clogged,

hydraulic oil does not flow
through the arm 1 parallel
circuit.
If the check valve is seized

and kept closed, or the
restriction is clogged,
hydraulic oil does not flow
from pump 1 to arm 1
spool.
If the check valve is seized
and kept opened, hydraulic
oil from pump 2 flows to the
pump 1 side.
While traveling straight, the

machine mistrack when the
swing lever is operated.

leveling.
When check valve is kept

closed, or restriction is
clogged:
leveling.
When check valve is kept
opened:
Left travel speed is slow.
Function
By Dr.EX Monitor Function
By Lamp Harness
Check
By Other Check/
Measurements
Note
Descriptions in
(Operational Principle)
Technical Manual
T3-3
T3-3
T3-3
EX255-EX285
T5-4-9
TROUBLESHOOTING B
Arm Regenerative
Control Valve
Travel Flow Control Valve
To increase arm speed by

allowing the return oil from the
arm cylinder rod side to flow
into the arm cylinder bottom side when the valve is
switched by pilot pressure
oil led from solenoid valve
unit (SC)
To reduce the shock load

developed when single travel
operation is switched to the
combined operation of travel
and front by gradually
restricting oil flow in the
travel parallel circuit.
To ensure the boom lower

force when the combined
operation of travel and boom
lower is made.
To prevent the arm drift

caused by inner leakage
of hydraulic oil in control
valve. Only when arm rollin operation is made, antidrift valve (check valve) in
the arm cylinder return
circuit is forcibly opened
so that the arm is rolled in.
Arm regenerative function

does not operate.
Oil flow is not restricted

properly.
Boom 2 spool does not move

when the combined operation
of travel and boom lower is
made.
Boom 2 spool is moved even if
the single operation of boom
lower is made.
Check valve does not

open if the changeover
valve is seized.
Arm speed is very slow

when leveling.
When fully closed:

Great shock is felt when
changed from travel single
operation to travel combined
operation.
When fully opened:
The boom is not raised
when the combined operation of travel down a slope
and boom raise with the
bucket loaded is made.
(Boom is raised when boom
single operation is
performed.)
When fully opened:

Boom lower speed is very fast.
With swing lever fully stroked,
swing speed is slow when the
combined operation of swing
and boom lower is made.
When fully closed:
With the front lowered while
traveling, the track of the base
machine is not raised off the
ground.
If check valve does not

open fully, arm roll-in
speed is slow.
If check valve is kept
opened, arm drift
increases due to the
control valve inner leakage.
According to the degree of
seizure in check valve,
arm roll-in operation
becomes jerky, or slower.
T3-3
Travel and Boom Lower

Selector Valve
Arm Anti-Drift Valve
T3-3
T3-3
T3-3
T5-4-10
EX255-EX285
TROUBLESHOOTING B
Part Name
Boom Anti-Drift Valve
Part function
To prevent the boom drift

caused by inner leakage of
hydraulic oil in control valve.
Only when boom lower
operation is made, anti-drift
valve (check valve) in the
boom cylinder return circuit
is forcibly opened so that
boom is lowered.
To prevent boom hesitation when

lowering boom by allowing the
return oil from the boom cylinder
bottom side to flow into the boom
cylinder rod side.
To restrict the bucket

circuit to assist boom to
raise when the combined
operation of bucket, arm
roll-in, and boom raise is
made.
Control System
Trouble
Check valve does not open

if the switch valve is seized.
With check valve kept closed,

boom lower speed becomes slow.
With check valve kept opened,
the track of the base machine is
not raised off the ground by
lowering the boom.
Bucket circuit is always

restricted if the switch
valve is seized.
Machine Symptoms
If check valve does not

open, boom is not lowered.
If check valve is kept
opened, boom drift
increases due to the control
valve inner leakage.
According to the degree of
seizure in check valve,
boom lower operation
becomes jerky, or slower.
Same as described in the above

column.
Bucket speed is slow if

poppet valve is seized and
kept closed, or switch valve is seized so that the
poppet valve is closed.
Boom is not raised when
the combined operation of
bucket, arm roll-in, and
boom raise is made with
poppet valve fully opened,
or if the switch valve is
seized so that the poppet
valve is fully opened.
Trouble
shooting
Procedures
Bucket Flow Control

Valve
Function
By Dr.EX Monitor
Function
By Lamp Harness
Check
By Other Check/
Measurements
Note
Descriptions in
(Operational
Principle)Technical
Manual
T3-3
T3-3
T3-3
EX255-EX285
T5-4-11
TROUBLESHOOTING B
NOTE - The measurement of the control voltage of proportional solenoid valves SG,
SI, SD and SC, must be performed with test harness (75301514) meaning
that the main controller (MC) output must be connected to the load of the
solenoid valve. Under this test configuration, the normal control voltage
changes from 5 through 10 Volt.
On the other hand, when measuring the control voltage directly on the
connector disconnected from the solenoid valve (harness side) the voltage
measured is always 24 Volt and this is irrelevant in troubleshooting the
solenoid valve.
T5-4-12
EX255-EX285
TROUBLESHOOTING B
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
Engine Control
Trouble Symptom
EC
EC
Motor Sensor
Pump / Valve Control
Eng. Coolant QOS Sol. Pump Pump

N
Cont. Temp. Con- Valve Deliv. Deliv. SenDial
Sw.
troller Unit Press. Press. sor
(PreSD Sensor Sensor
heat
Pump Pump
Circuit)
2
1
Arm
Roll
In
Sensor
Switch Panel
Press. Press. AutoSw.
Sw.
Idle
Travel Front Sw.
Act.
Learning
Sw.
HP
Mode
Sw.
E-1 Starter does not rotate

E-2 Although starter rotates,
engine does not start.
E-3 Engine runs slower than
normal at all operation
speeds.
Slow idle speed is faster or
slower than normal.
E-4 Even if engine control dial is
turned, engine speed is
unchanged.
E-5 Even if HP mode switch is
depressed, HP mode does
not operate.
E-6 Engine does not stop even
if key switch is turned OFF.
E-7 Auto-idle function does not
function.
E-8 Engine speed does not
change, even if E mode is
depressed.
E-9 Engine stalls several seconds after engine starts.
E-10 Engine stalls when machine is operated at high
altitude or under adverse
conditions.
E-11 Engine is hard to start at
low ambient temperature.
A-1. All actuators speeds are
slow
A-2. When single travel operation is made, left side track
slow but right side track is
normal. Single swing operation is slow. Bucket operation is normal. Arm
speed is slow when leveling. (All above symptoms
occurred at the same time).
A-3. When single travel operation is made, right side
track is slow but left side
track is normal. Single
swing operation is normal.
Boom hardly raises when
leveling. (All the above
symptoms occurred at the
same time).
A-4. Actuator does not stop,
even after control lever is in
the neutral position.
NOTE - The above table shows the correlation between machine operation trouble and related parts
which may cause trouble. However, the correlations in
this table are described based on the condition supposing that each occurs independently.
If any other trouble occur at the same time, find out the
faulty parts causing the trouble by checking all suspected parts in each symptom.
EX255-EX285
T5-4-13
TROUBLESHOOTING B
Switch Panel
E
Mode
Sw.
Key
Sw.
MC
(Main
Contr.)
Engine
Eng.
Elec.
Parts
Eng.
Unit
Pump
Governor
Main
Pump
Unit
Pilot
Pump
Control Valve
Spool
Pump
Cont.
Valve
5Spool
Side
Pump
Cont.
Valve
4Spool
Side
Other
Main
Relief
Valve
Pilot
Valve
Pilot
Relief
Valve
Note
Check battery
Check fuel system
Check fuel shut-off
handle. Check engine
control cable. Be sure to
operate engine learning
whenever engine is
replaced.
Check engine control
cable.
Check if fuel system

is clogged
: being linked closely. Checking the part is required.

: being linked, but if this parts is faulty another type of
trouble will be prominent. Therefore this part may not be
the main cause of the trouble.
T5-4-14
EX255-EX285
TROUBLESHOOTING B
Pump/Valve Control
Sw.
Sol.
Sol.
Pump
Arm
Press.
Valve
Valve Deliv. Roll in
Sw.
Unit SG Unit SC Press. Sensor Boom
Sensor
Raise
Pump 2
Power
Boost
Sw.
Control valve
Spool
Main
Relief
Valve
Overload
Relief
Valve
Load
Check
Valve
Boom
ReCheck
RestricValve
genertion
& Reative Arm 1
stric.
Valve Parallel 4-Spool
Parallel
F-1 All front attachment

functions are weak.
F-2 Digging force is not
increased even if
power boost switch is
depressed.
F-3 Some cylinders do
not move or speeds
are slow.
F-4 Boom lower single
operation is fast.
F-5 Arm speed is slow in
a combined operation.
Arm speed is slow in
leveling operation.
F-6 Bucket digging single
operation is slightly
slow.
Bucket digging single
operation is jerky.
F-7 Arm starting speed is
slow during
combined operations.
Arm operation is
jerky.
During arm roll-in
single operation, arm
starting speed is
slightly slow which often
occurs at low temperature.
F-8 Boom starting speed
is slow during
combined operations.
Boom operation is jerky.
Boom starting speed
is slightly slow during
boom lower single
operation.
F-9 When operating the
control lever to raise
boom or to roll-out
arm, boom or arm
starts to move after
slightly moving in the
reverse direction.
F-10 Front attachment
cylinders drift is large.
S-1 Swing speed is slow or
swing function does
not operate.
S-2 Swing speed is slow
during combined
operation with boom
lower.
this table are described based on the condition sup-
posing that each occurs independently.If any other

trouble occur at the same time, find out the faulty parts
causing the trouble by checking all suspected parts in
each symptom.
EX255-EX285
T5-4-15
TROUBLESHOOTING B
Control valve
Arm
Regenerative
Valve
Travel
Boom
Lower
Select.
Valve
Arm
Anti
Drift
Valve
Boom
Anti
Drift
Valve
Others
Bucket Swing ShockFlow Device less
Cont.
Valve
Valve
Pilot Cylinder
Valve
Note
Check the work mode switch position

Take care not to confuse power boost
operation with HP mode
Check the work mode switch position

T5-4-16
EX255-EX285
TROUBLESHOOTING B
Pump/Valve Control
Trouble Symptom
Sol.
PC
PC
Valve Press. Press.
Unit Sensor Sensor
SI
5 Spool 4 Spool
Side
Side
Pump Pump. Press

Deliv. Deliv.
Sw.
Press. Press. Travel
Sensor Sensor
Pump Pump
2
1
T-1 Both right and left

side tracks do not
move or move
slowly.
T-2 When a single
travel operation is
shifted to a
combined operation
with front functions,
a shock load is felt.
T-3 One side track does
not move or moves
slowly. Or the
machine cannot
travel straight
(mistracks).
T-4 During a combined
operation of travel
and front
attachment
function, the
machine mistracks.
T-5 Steering power and
gradeability are insufficient in the fast
travel mode.
T-6 Travel mode does
not change to the
fast speed range.
O-1 The wiper does not
operate, or will not
retract.
this table are described based on the condition supposing that each occurs independently.
If any other trouble occur at the same time, find out the
faulty parts causing the trouble by checking all suspected parts in each symptom.
Sw.
Travel Spool
Mode
Switch
Control valve
Load
Check
Valve
Flow Travel
Comb. Boom
Valve Lower
Select
Valve
Others
Travel
Device
Center
Joint
.
EX255-EX285
T5-4-17
TROUBLESHOOTING B
Others
Pilot
valve
Remarks
.
Refer to A1.
Refert to T-6.
Refer to the troubleshooting section.

T5-4-18
EX255-EX285
TROUBLESHOOTING B
ENGINE TROUBLESHOOTING
E-1 Starter Does Not Rotate.
Faulty starter or
disconnected starter ground
line.
YES
Related Fault Code: None

Checking Instructions
Measure each voltage by referring to the tables
below.
Electronic system such as MC has nothing to do
with the trouble obstructing the rotation of starter.
YES
Key switch:
ONSTART
Check if each terminal

voltage on starter is normal
with key switch turned to the
positions in the following
table.
Key
switch
Terminal
With key switch

positioned at
START, voltage at
terminal C does
not increase to 24
volts.
ON
ON
(Engine START (Engine
not
running)
running)
24
24
24
24
24
Starter Relay Terminal Voltage Unit: Volt
NO
Key
switch
Terminal
Voltage:
24 volts or more
Density:
1.26 or more
NO
With key switch

positioned as shown
in the following table,
check if each
terminal voltage is
normal.
Unit: Volt
Starter Terminal Voltage
Check if battery
voltage and
electrolyte density
are normal.
Regardless of key switch

position ON or START,
voltage at terminal B is 0
(zero).
ON
ON
(Engine START (Engine
not
running)
running)
24
24
24
12
24
With key switch

positioned at
START, voltage at
terminal S does
not increase to 24
volts.
Faulty Battery
24
Faulty starter or
disconnected
starter ground line.
(When key switch is turned to START, in

case voltage at terminal B is 18 V or lower,
battery is faulty.)
Starter Terminal Voltage Check.
Starter Relay Voltage Check.
(Seen from the back of the connector.)

SM5401
SM6117
EX255-EX285
T5-4-19
TROUBLESHOOTING B
YES
Faulty harness between

battery relay and starter.
Check if battery relay clicks

when key switch is turned
OFF from the ON position.
Key switch: ONOFF
Faulty battery relay

NO
YES
With key switch in

START, voltage at
terminal S does not
increase to 24 V.
Terminal No.1
voltage: 0 V
Measure voltage
at key switch
terminals No. 1
and No. 6.
Check if fusible link

(40 A) has blown.
NO
Key switch: START

fusible link and key switch.
Blown fusible link 1 (40A).
Terminal No.1 voltage: 24 V

Faulty key switch.

Voltage at terminal B is 0 V.
Faulty harness between key

switch terminal No. 6 and
starter relay terminal S.
Broken harness between
both terminals B on starter
and starter relay.
With key switch in START, voltage at

terminal C is 0 V but voltage at starter
relay terminal C is 24 V.
Broken harness between

both terminals C on starter
and starter relay.
With key switch in START, voltage at all

terminals other than C is normal. Voltage at
terminal C does not increase to 24 V.
Faulty starter relay.
Key Switch Voltage Check

NOTE - Remove the key switch from the console.
View A
SM0633
T5-4-20
EX255-EX285
TROUBLESHOOTING B
E-2
Although Starter Rotates, Engine Does Not

Start.

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 system may be faulty.
YES
Faulty engine.
Refer to engine Section.
With key switch ON, check if

governor lever moves to the
starting position.
Key switch : ON
Check EC motor activating
circuit.
NO
Governor Lever and Fuel Shut-Off Lever
1
SM5402
1 - Governor Control Cable

(From EC Motor)
2 - Fuel Shut-Off Cable
[Handle (Emergency Engine
Stop)]
3 - Fuel Shut-Off Lever
4 - Governor Lever
EX255-EX285
T5-4-21
TROUBLESHOOTING B
Governor Lever Position
AB-
Key Switch OFF (Engine Stop Position)

Key Switch ON (Engine Start Position)
B
FULL
STOP
P
STO
L
FUL
SM5404
Fuel Shut-Off Lever

AB-
Fuel Cut Handle Pulled Position

Fuel Cut Handle Returned Position
SM5405
T5-4-22
EX255-EX285
TROUBLESHOOTING B
E-3
Engine Runs Slower than Normal at

All Operation Speeds.
Slow Idle Speed is Faster or Slower
than Normal.
Related Fault Code: 01

Before the engine learning operation is carried out,
or when the engine learning operation is made in a
wrong procedure, the engine may run slower at all
operation speeds.
If the EC sensor is faulty, the governor lever
position which is located when the key switch is
turned ON, is learned as the idle position. Then, the
engine is controlled based on this engine learning
operation. Accordingly, the engine runs with discrepancy from the standard control speed. Further
more, this trouble may not reemerge as the extent
of discrepancy in the governor lever position differs
each time when the key switch is turned ON.
Refer to the Control System Group titled Engine
Learning Control in the SYSTEM Section in the
Operational Principle book (Technical Manual).
Even if the EC motor control becomes abnormal,
the governor lever position is constantly kept at the
full stroke end since the EC motor is a worm gear
type. Accordingly, the engine does not stall.
NO
Check governor
lever or EC motor
cable for proper
operation.
Restore governor
lever or EC motor
cable to correct
operation.
YES
YES
Faulty EC sensor.
After replacement,
refer to T5-4-60.
Check if fault
code 01 is
displayed.
NO
Check if the
trouble is
reconditioned
after engine
learning operation
is conducted.
Refer to T5-4-60.
YES
NO
End.
Monitor the
engine learning
operation.
Monitor item:
Engine Learning
Control
EX255-EX285
T5-4-23
TROUBLESHOOTING B
OK
Check if governor
lever comes in
contact with the
stopper when
conducting
engine learning
operation.
YES
NO
Faulty engine or
fuel system.
Faulty control
cable. Faulty
engine governor
lever adjustment.
Refer to T5-4-60.
NOT OK
Failure in MC.
Faulty learning
switch, or
harness between
learning switch
and MC.
After replacement,
refer to T5-4-60.
T5-4-24
EX255-EX285
TROUBLESHOOTING B
E-4
Even If Engine Control Dial is Turned, Engine Speed is Unchanged.
Related Fault Code: 07

Refer to the Control System group titled Engine
Learning Control in the SYSTEM Section in the
YES
Faulty engine control dial or

broken harness between
engine control dial and MC.
YES
Check if fault code 07 is

displayed.
NO
Connect Lamp Harness

(75301706B) to EC motor.
Check if the lamp comes
ON when engine control dial
is turned.
Faulty EC motor.
After replacement, refer to
T5-4-60.
NO
Failure in MC or broken
harness between MC and EC
motor.
After replacement, refer to
T5-4-60.
EX255-EX285
T5-4-25
TROUBLESHOOTING B
E-5
Even If HP Switch is Depressed, HP Mode

Does NOT Operate.
(Standard Mode Operates Normally.)
Related Fault Codes: 02, 03, and 06

The pressure switches check if the HP mode is
requested so that if these pressure switches fail,
the HP mode does not operate.
Refer to the Control System group titled HP Mode
Control in the SYSTEM Section on the Operational
Principle book (Technical Manual).
Faulty HP mode
switch, or broken
harness between
HP mode switch
and MC.
NO
NO
Check if fault
code is displayed.
Monitor HP mode
switch. Check if
indication of HP
is displayed or
deleted on Dr. EX
screen by
operating the HP
mode switch on
the right console
ON or OFF.
Monitor item:
HP Mode Switch
YES
YES
Faulty sensors, or
broken harness
between MC and
sensors.
Fault codes:
Pump 1 delivery pressure sensor: 02
Pump 2 delivery pressure sensor: 03
Pilot pressure sensor (arm roll-in): 06
Check if governor
lever comes into
contact with fullspeed side stopper
when hydraulic oil
pressure is relieved by arm rollin operation.
YES
Faulty engine or
poor quality fuel.
Failure in MC.
NO
After replacement,
refer to T5-4-60.
T5-4-26
EX255-EX285
TROUBLESHOOTING B
E-6
Engine Does Not Stop Even If Key Switch is

Turned OFF.
(When the engine does not stop, be sure to
start checking after stopping the engine by
pulling the engine stop handle located under the seat stand).
Related Fault Codes: 01 and 07

Checking Instruction
Trouble symptoms such as Engine runs slower
than normal at all operation speed or Even if
engine control dial is turned, engine speed is unchanged are sure to exist at the same time.
Perform the troubleshooting of all symptoms.
E-7
Auto-Idle Function Does Not Function.

When trouble corresponding to E-1 to E-6 exist,
perform the troubleshooting of them beforehand.

Refer to the Control System group titled Auto-Idle
Control in the SYSTEM Section in the Operational

NO
YES
Monitor auto-idle switch.

Check if indication of AI
is displayed or deleted on
Dr.EX screen by
operating the auto-idle
switch on the right panel
ON or OFF.
Monitor item:
Auto-Idle Switch
Monitor pressure switches

(travel and front
attachment).
Check if indication of Tr
and Fr is displayed or
deleted on Dr.EX screen by
operating each of the travel
and front control levers.
Faulty pressure switches

(travel, and front attachment).
MC and pressure switches.
Filter in the pilot signal circuit is clogged.
NOTE - Pressure switches

(travel, and front attachment)
are installed on the control
valve.
Monitor item:
Pressure Switch
Failure in MC
YES
After replacement,
refer to T5-4-60.
NO
Faulty auto-idle switch, or

broken harness between
auto-idle switch and MC.
EX255-EX285
T5-4-27
TROUBLESHOOTING B
E-8
Engine Speed Does Not Change Even If

E Mode Switch is Depressed.

If trouble corresponding to E-1 to E-7 exist, perform
the troubleshooting of them beforehand.
Refer to the Control System group titled E Mode
Control in the SYSTEM Section in the Operational
Monitor E mode
switch. Check if
indication of E or
P is displayed
alternately on Dr.EX
screen by operating
the E mode switch
on the right console
ON or OFF.
E-9
Faulty E mode
switch, or broken
harness between E
mode switch and
MC.
NO
Failure in MC.
YES
After replacement
refer to T5-4-60.
Engine Stalls Several Seconds After Engine

Starts.

Refer to the Control System group titled Engine
Learning Control in the SYSTEM Section on the
If engine learning switch is set to the engine learning
side, engine comes to a stop 5 seconds after engine
is started.
YES
Check if engine
learning switch is
turned ON.
NO
Return the switch

to neutral.
End.
Faulty learning
switch, or short
circuit of harness
between learning
switch and MC.
Or, check if the
fuel system is
clogged.
SM0108
T5-4-28
EX255-EX285
TROUBLESHOOTING B
E-10
Engine Stalls When Machine is Operated

at High Altitude, or under Adverse Conditions.

If speed sensing control does not function, engine
may stall under adverse operating conditions.
NO
NO
Check if fault
code is displayed.
Monitor engine
speed. Check if
engine runs at
abnormal speed.
Monitor item:
Pump Proportional
Solenoid Valve Output
Refer to Operational
Performance Test
section.
Monitor item:
Actual Engine Speed
YES
Referring to the
displayed fault
code, check
suspectable
parts.
Monitor output
signal from
solenoid valve
unit (SD). With
a pressure gauge
installed to port
SD, compare the
pressure gauge
reading with the
monitored
pressure by
Dr.EX. Check if
pressure values
indicated on both
the pressure
gauge and the
Dr.EX vary
identically.
YES
Faulty N sensor
or faulty harness
between N
sensor and MC.
NO
YES
Disconnect harness from solenoid valve unit

(SD) and
connect test harness (75301514)
between solenoid
valve unit (SD)
and the disconnected harness.
Check if the solenoid valve control
voltage is
present.
Disassemble and
check regulator.
EX255-EX285
T5-4-29
TROUBLESHOOTING B
YES
NO
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. Under this test configuration, the normal control voltage changes from
5 through 10 Volt.
On the other hand, when measuring the control voltage directly on the connector disconnected from the
solenoid valve (harness side) the voltage measured is always 24 Volt and this is irrelevant in
troubleshooting the solenoid valve.
T5-4-30
EX255-EX285
TROUBLESHOOTING B
E-11 Engine is Hard to Start at Low Ambient
Temperature.
(Even if preheated, engine is hard to start or
does not start at a low ambient temperature
or in a cold climate district.)

Check if electricity is conducted to glow plugs and
glow plugs are normal.
YES
Faulty engine coolant temperature switch.
Disconnect engine coolant

temperature switch. Check if
voltage at glow plug is 20 to
24 V.
YES
Key switch: ON
NO
With engine coolant temperature switch

disconnected, ground glow
relay terminal No.4 to vehicle
frame. Check if voltage at
glow plug is 20 to 24 V.
Key switch : ON
Without removing connector,
ground the terminal to vehicle
frame using a jumper wire,
like a clip, from the reverse
side of the connector.
NO
Faulty QOS controller.
With engine coolant

temperature switch, and glow
relay disconnected, check if
voltage at glow relay harness
end connector terminal No.1
and No.3 is 20 to 24 V.
Measurement of Glow Plug Voltage and Resistance
Remove
Copper
Plates.
Standard: 20 to 24 V
Standard: 10 or Less
SM4049
SM4050
EX255-EX285
T5-4-31
TROUBLESHOOTING B
YES
Faulty glow relay.
10 or less
NO
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
plug resistance.
Faulty engine.
Replace glow plug.
T5-4-32
EX255-EX285
TROUBLESHOOTING B
OVERALL ACTUATOR SYSTEM TROUBLESHOOTING
A-1 All Actuator Speeds are Slow.
In case the speed is normal without power, main
relief valve may be faulty (F-1). If speed is extremely slow, the pump control system may have
malfunction (A-2, or A-3) or the pilot system may be
faulty.
If N sensor fails, only an abnormal value like
0 min-1 (rpm) is displayed.
Normal. Select
general purpose
mode
YES
Check if precision
work mode is
selected.
NO
NO
NO
Check if any
fault codes are
displayed.
YES
Arm: Fully rolled in.

Monitor item:
Arm roll-in pilot
pressure
Monitor actual
engine speed.
Check if abnormal
speed is
monitored.
Monitor item:
Actual Engine Speed
Check if
secondary pilot
pressure is normal.
YES
Faulty N sensor
or broken
harness in N
sensor circuit.
Referring to the
displayed fault
code, check
faulty parts.
EX255-EX285
T5-4-33
TROUBLESHOOTING B
NO
YES
NO
End
YES
Faulty pilot pump

or clogged pilot
filter.
After
disassembling,
cleaning, and
adjusting
pilot relief valve,
check if an
abnormal
condition still
remains.
Trace the causes

of trouble by
checking other
symptoms.
T5-4-34
EX255-EX285
TROUBLESHOOTING B
A-2
When Single Travel Operation is Made, Left

Side Track is Slow But Right Side Track is
Normal. Single Swing Operation is Slow.
Single Bucket Operation is Normal.
Arm Speed is Slow When Leveling.
(All above symptoms occurred at the same
time.)

Due to some reasons, pump 2 delivery rate is
reduced to the minimum (approx. 20 L/min). Accordingly, left side track and swing function speeds
are too slow as they are actuated by pressure oil
from pump 2.
Arm and boom cylinders are also actuated by
pressure oil from pump 1 so that arm and boom
speed is slightly reduced when the single operation
of arm or boom is made. However, when the level
crowding operation is made, oil flow to boom cylinders has priority over arm cylinder. Then, almost no
oil flow is supplied to arm cylinder, reducing arm
speed.
Refer to Control Valve and Pump Device groups
in COMPONENT OPERATION Section in the Operational Principle book (Technical Manual).
YES
NO
Check if pump
control pipe lines
are correctly
connected.
NO
Check if fault
code is displayed.
YES
Reconnect
correctly.
Referring to the
displayed fault
code, check
suspected parts.
NO
Monitor pump
control pressure
by operating
control lever.
Check if pump
control pressure
increases.
Swing or travel left
Monitor item:
YES
Faulty pump
control valve
(5 spool side).
Check regulator
for pump 2.
EX255-EX285
T5-4-35
TROUBLESHOOTING B
A-3
When Single Travel Operation is Made,

Right Side Track is Slow But Left Side Track
is Normal.
Single Bucket Operation is Slow. Single
Swing Operation is Normal.
Boom Hardly Raises When Leveling.
(All the above symptoms occurred at the
same time.)

Due to some reasons, pump 1 delivery rate is
reduced to the minimum (approx. 20 L/min). Accordingly, right side track and bucket function
speeds are too slow as they are actuated by
pressure oil from pump 1.
Arm and boom cylinders are also actuated by
pressure oil from pump 2 so that arm and boom
speed is slightly reduced when the single operation
of arm or boom is made. However, when the level
crowding operation is made, oil flow to arm cylinder
has priority over boom cylinders. Then, almost no
oil flow is supplied to boom cylinders, causing boom
to become immovable.
Refer to Control Valve and Pump Device groups
in COMPONENT OPERATION Section in the Operational Principle book (Technical Manual).
YES
NO
Check if pump
control pipe lines
are correctly
connected.
NO
Check if fault
code is displayed.
YES
Reconnect
correctly.
Referring to the
displayed fault
code, check
suspected parts.
NO
Monitor pump
control pressure
by operating
control lever.
Check if pump
control pressure
increases.
Bucket or travel right.
Monitor item:
YES
Faulty pump
control valve (4
spool side).
Check regulator
for pump 1.
T5-4-36
EX255-EX285
TROUBLESHOOTING B
A-4
Actuator Does Not Stop Even After

Control Lever is Returned to Neutral.

Sticking of pilot valve spool or control valve main
spool may be the cause of the trouble.
YES
Faulty Pilot Valve.

When control lever is in
neutral, pilot pressure is
guided to control valve
spool.
Check if actuator stops when

pilot control shut-off lever is
raised.
Faulty Control Valve.

NO
Pilot pressure is not
guided to control valve
spool. However, control
valve is kept open as
spool is stuck.
EX255-EX285
T5-4-37
TROUBLESHOOTING B
T5-4-38
EX255-EX285
TROUBLESHOOTING B
FRONT ATTACHMENT CONTROL SYSTEM TROUBLESHOOTING
F-1
All Front Cylinder Functions are Weak.

If motion speed is normal and power is weak, main
relief valve may be faulty (F-1). If motion speed is
too slow, pump control system may have malfunction (A-2, or A-3) and pilot system also may be
faulty.
NOTE - 1 kgf/cm2=98.07 kPa
350 to 370 kgf/cm2

Monitor pump 1
and 2 delivery
pressures.
Monitor item:
Relieve boom, arm, or
bucket.
F-2
E mode switch: OFF

HP mode switch: OFF
Work mode: General
purpose mode.
Less than 350 kgf/cm2
Main Relief Valve

is normal. Trace
the cause of the
trouble by
checking other
symptoms.
Adjust main relief
valve.
Digging Force is Not Increased Even If

Power Boost Switch is Depressed.

Refer to the Control System Group titled Power
Boost in the SYSTEM Section in the Operational
Pressure increases from less than
350 kgf/cm2 to 370 kgf/cm2.
Monitor the
delivery
pressures from
pumps 1 and 2.
Monitor items:
Pump 1 Delivery
Pressure
Pump 2 Delivery
Pressure
With power
boost switch
depressed,
check the pump
delivery pressure.
Pressure does
not increase.
Monitor power
boost switch.
Check if the
indication of Pd
is displayed or
deleted on Dr.EX
by operating
power boost
switch.
Monitor items:
Power Boost Switch
NO
YES
Faulty power
boost switch, or
broken harness
between power
boost switch and
MC.
Measure oil
pressure at the
port of solenoid
valve unit (SG).
With power boost
switch depressed,
check pressure
change.
Refer to Operational
Performance Test
section
Normal
(HP mode
operation might
have been
mistaken for
Power Boost
operation.)
EX255-EX285
T5-4-39
TROUBLESHOOTING B
5 through 10 Volt.
NOTE - 1 kgf/cm2=98.07 kPa
Pressure does
not change.
Disconnect harness
from solenoid valve
unit (SG) and
connect test
harness (75301514)
between solenoid
valve unit (SG)
and the
disconnected
harness. Check
when the switch is
actuating if the
solenoid valve
control voltage is
present.
Power boost switch: ON
Pressure increases
from less than 5
kgf/cm2 up to 10
kgf/cm2.
Faulty main relief

valve.
YES
NO
Faulty solenoid
valve unit (SG).
Faulty harness
between solenoid
valve and MC.
T5-4-40
EX255-EX285
TROUBLESHOOTING B
F-3
Some Cylinders Do Not Move or Speeds

are Slow.

Discriminate whether the cause of the trouble is in
the pilot system or in the main circuit system.
If other functions (travel, swing) are normal, the pilot
pump is considered to be normal.
If bucket single operation speed is slow, refer to
F-6 as well.
If arm roll-in single operation speed is slow, refer to
F-7 as well.
If boom lower single operation speed is slow, refer
to F-8 as well.
YES
YES
Check if the pilot
valve delivery
pressure is
normal by
monitoring or
measuring.
Pilot valve delivery
pressure: Refer to
Operational
Performance Test
section.
Monitor Item:
Arm Roll-In Pilot
Pressure
When measuring the
pilot valve delivery
pressure for boom
raise or lower, bucket
roll-in or roll-out, or
arm roll-out, install a
pressure gauge to the
control valve pilot oil
port.
Monitor pump
control pressure
by slowly
operating the
control lever.
Check if the
control pressure
changes
smoothly.
NO
Monitor item:
Pump 1 Control
Pressure
Pump 2 Control
Pressure
NO
Check if overload
relief pressure is
normal.
YES
Check if the pilot

valve delivery
pressure is
correct at the inlet
port of the
shockless valve.
Control valve
spool is sticking.
NO
Faulty pilot valve
YES
Shockless valve
spool sticking
Only when
operating arm
roll-out or boom
raise.
2 1
1
2
3
4
5
6
7
8
6
7
SM0634
Faulty overload
relief valve
NO
Shockless Valve
Faulty cylinder
(Seal kits are
faulty.)
From swing left pilot valve

From swing right pilot valve
From bucket roll-out pilot valve
From bucket roll-in pilot valve
From boom raise pilot valve
From boom lower pilot valve
From arm roll-out pilot valve
From arm roll-in pilot valve
EX255-EX285
T5-4-41
TROUBLESHOOTING B
F-4
Boom Lower Single Operation Speed is

Fast.

When the speed is too fast, travel/boom lower
selector valve may be sticking.
NO
Trace the cause of the trouble by checking other types

of trouble.
Check if travel/boom lower

selector valve is scored or
stuck.
YES
Faulty travel/boom lower

selector valve.
T5-4-42
EX255-EX285
TROUBLESHOOTING B
F-5
Arm Speed is Slow in a Combined Operation.

Arm Speed is Slow in leveling Operation.
Related Fault Codes: 03 or 06

Refer to the Control System Group titled Arm
Regenerative Control in the SYSTEM section in
the Operational Principle book (Technical Manual).
When arm speed is slow in only a combined operation with boom lowering, travel/boom lower selector
valve may be faulty.
Refer to the Control Valve group in the COMPONENT OPERATION section in the Operational
NOTE - When the grading mode is selected, arm

regenerative control does not function so that arm
speed becomes slow.
NO
Check if any fault
codes
are displayed.
Fault codes:
Pump delivery
pressure sensor
(Pump 2): 03
(Arm roll-in): 06
Monitor the output

signal from
solenoid valve unit
(SC). Install a
pressure gauge to
port SC and compare the
monitored
pressures by Dr.
EX with the gauge
readings. Check if
both pressures
vary identically.
Monitor Item:
Arm Regenerative
Proportional Solenoid
Perform a combined
operation of boom raise
and arm roll-in.
Measurement: Refer to
Operational Performance
Test section.
NOTE - If other fault

codes are displayed,
check the suspected parts
referring to the displayed
fault code.
YES
NO
Disconnect
harness from
solenoid valve
unit (SC).
Connect test
harness
(75301514)
between solenoid
valve unit (SC)
and the
disconnected
harness. Check
when a combined
operation is
performed, the
solenoid valve
control voltage is
present.
YES
NO
Faulty solenoid
valve unit (SC)
Broken harness
between solenoid
valve and MC.
Perform the combined

operation of boom
raise and arm roll-in.
YES
Faulty sensor or
broken harness
between MC and
sensors.
EX255-EX285
T5-4-43
TROUBLESHOOTING B
5 through 10 Volt.
Faulty arm
regenerative
valve
YES
Check if arm
regenerative
valve on 5-spool
control valve is
seized or stuck.
Faulty check
valve or
restriction
(in 4-spool control
valve).
YES
NO
Check if check
valve or
restriction in the
parallel passage
in the 4-spool
control valve is
seized, bound, or
clogged.
YES
NO
Check if the
restriction in
arm 1 parallel
passage in 5spool control
valve is clogged.
NO
Faulty restriction
(in 5-spool control
valve)
Trace the cause

of the trouble by
checking other
types of trouble.
T5-4-44
EX255-EX285
TROUBLESHOOTING B
F-6 Bucket Digging Single Operation is
Slightly Slow.
Bucket Digging Single Operation is
Jerky.
Refer to A-3.
Refer to Control Valve group in the COMPONENT
OPERATION section in the Operational Principle
book (Technical Manual).
NO
Check if bucket flow control
valve in control valve is
seized or bound.
YES
F-7
Trace the cause of the

trouble by checking other
types of trouble.
Cleaning or replacement of
bucket flow control valve.
Arm Starting Speed is Slow during

Combined Operations. Arm Operation
is Jerky.
During Arm Roll-in Single Operation,
Arm Starting Speed is Slightly Slow
which Often Occurs at Low Temperature.


NO

types of trouble.
Check if anti-drift valve is

seized or bound.
YES
anti-drift valve.
EX255-EX285
T5-4-45
TROUBLESHOOTING B
F-8
Boom Starting Speed is Slow during Combined Operations. Boom Operation is Jerky.
Boom Starting Speed is Slightly Slow during Boom Lower Single Operation.


NO
NO
Check if boom anti-drift

valve is seized or stuck.
YES
Check if boom anti-drift

valve is seized or stuck.
YES

symptoms.
boom regenerative valve.
boom anti-drift valve.
T5-4-46
EX255-EX285
TROUBLESHOOTING B
F-9
When Operating the Control Lever to Raise

Boom or to Roll-out Arm, Boom or Arm
Starts to Move after Slightly Moving in the
Reverse Direction.
YES
YES
Faulty anti-drift valve
Check if anti-drift valve for

arm or boom is sized or
bound.
Cylinder internal leakage
NO
Check if load check valve in

control valve operates
correctly.
Disassemble and visually
check.
Faulty load check valve

NO
EX255-EX285
T5-4-47
TROUBLESHOOTING B
NOTE - 1. During the initial stage of operation, oil
pressure and flow rate from the pump is
low. Therefore, if the load check valve is
malfunctioning, the oil in the bottom side of
the boom cylinder flows back into the
circuit through the load check valve, causing the boom cylinder to temporarily retract.
2. If the clearance between the piston and the
cylinder barrel is poor, oil pressure in the
bottom side (A) leaks to rod side (B). As oil
pressure and flow rate from the pump is
low during the initial stage of operation,
and if the amount of oil leaking through the
gap between the piston and the barrel is
large, the cylinder is temporarily retracted.
In addition, cylinder force is reduced. In
this case, the cylinder drift is also increased.
(B)
When the load check valve

is malfunctioning:
(A)
SM0635
T5-4-48
EX255-EX285
TROUBLESHOOTING B
F-10
Front Attachment Cylinder Drift is Large.
YES
Normal
Check if each front

attachment
cylinder drift is
within the specified
value.
NO
NO
NO
Check if the
cylinder drift is
reduced when pilot
shut-off
valve is closed.
Check if manual
boom lowering
valve in boom
section in 4-spool
control valve is
correctly
adjusted.
YES
Correctly adjust
manual boom
lowering valve
and lock it up.
Check if the
symptom is
deleted when the
overload valve is
temporarily
switched with one
in an other
cylinder circuit.
Faulty pilot valve

YES
Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the arm

cylinder slightly extended from the fully retracted
position, lower the bucket tooth tips onto the
ground.
2. Disconnect hoses to the boom cylinder rod side.
Then, drain oil from hoses and cylinders. (Plug the
disconnected hose ports.)
3. Retract the arm cylinder to lift the bucket above the
ground.
At this time, if oil flows out of the pipes from which
the hoses were disconnected and the boom cylinder
is retracted, internal leakage in the boom cylinder
exists.
If no oil flows out of the pipes from which the hoses
were disconnected but the boom cylinder is retracted, internal leakage in the control valve exists.
SM0636
EX255-EX285
T5-4-49
TROUBLESHOOTING B
Manual Boom Lowering Valve
1
2
NO
NO
Check if internal
leakage in cylinder exists.
SM0637
YES
YES
Control valve
spool is scored,
spring is
damaged, or spool
end is loose.
Faulty cylinder
(replace seal kit.)
Adjustment Procedure:
Tighten (1). Then, tighten (2).
Faulty overload
relief valve.
Tightening Torque:
(1)- 7 Nm (0.7 kgfm)
(2)- 13 Nm (1.3 kgfm)
T5-4-50
EX255-EX285
TROUBLESHOOTING B
SWING SYSTEM TROUBLESHOOTING
S-1
Swing Speed is Slow or Swing Function

Does not Operate.

Check whether the pilot system is malfunctioning or
the main hydraulic system is malfunctioning.

If other functions (front attachment or travel) ope-
rate normally, the pilot pump is considered to be

normal. If the pilot system is malfunctioning, the
cause of the trouble may exist in the pilot system
after the pilot valve.
When the left travel speed is also slow, refer to
A-2.
YES
YES
YES
Check if the pilot

secondary
pressure is
normal.
Specification: Refer
to Operational
Performance Test
section.
Monitor the pump

control pressure.
While slowly
operating the
control lever,
check if the pump
control pressure
changes
smoothly.
Monitor item:
NO
Measurement:
Refer to
Operational
Performance Test
section.
Check if swing
relief pressure is
normal.
Monitor item: Pump 2
Delivery Pressure
Specification: Refer to
Operational
Performance Test
section.
Check if swing
motor oil drain
amount is
normal.
NO
Faulty swing
relief valve
Seized control
valve spool
Faulty pilot valve

NO
EX255-EX285
T5-4-51
TROUBLESHOOTING B
NO
YES
Check if swing
motor parking
brake release
valve is stuck or
seized.
YES
NO
Faulty swing
reduction device
Faulty swing
motor parking
brake release
valve
Faulty swing
motor
T5-4-52
EX255-EX285
TROUBLESHOOTING B
S-2
Swing Speed is Slow during Swing Combined Operation with Boom Lower.

YES
Clean or replace
travel/boom lower selector
valve.
Check if travel/boom lower

selector valve is stuck.
NO
Trace the cause of the trouble

by checking other symptoms.
EX255-EX285
T5-4-53
TROUBLESHOOTING B
TRAVEL SYSTEM TROUBLESHOOTING
T-1
Both Right and Left Travel Side Tracks Do

Not Move or Move Slowly.

Pilot valves, travel motors, control valve spools in
both right and left travel systems are unlikely to be
faulty at the same time.
If both travel systems do not operate, the pilot
system, which is applied to both side travel motors,
may be faulty. If the pilot pump delivery pressure is
lower than specification, the front attachment does
not operate as well. Refer to A-1.
T-2
When a Single Travel Operation is Shifted to

a Combined Operation with Front Functions, a Shock Load is Felt.

Travel flow control valve might be seized.

T5-4-54
EX255-EX285
TROUBLESHOOTING B
T-3
One Side Track does not Move or Move

Slowly, or the Machine cannot Travel
Straight (Mistracks).

If one side system only does not operate, pilot
valve, control valve, travel motor, or center joint
might be faulty.
If a symptom such as bucket or swing function
speed is slow, or arm roll-in or boom raise speed is
slow during a leveling operation is recognized at the
same time, refer to A-2 and A-3.
YES
Check if travel
pilot secondary
pressure is
normal.
YES
NO
Relieve travel
system.
Monitor Item:
Pump 1 Delivery
Pressure
Pump 2 Delivery
Pressure
Specification: Refer
to Operational
Performance Test
section.
Check if the
symptom is
reversed when
right and left
travel line hoses
connected to top
of center joint are
switched with
each other.
Measurement: Refer
Operational
Performance Test
section
Check if travel
relief pressure in
slow speed side
system is normal.
NO
Check if travel
motor oil drain
amount is normal.
Switch rear and
front or right and
left travel relief
valves with each
other. Check if
symptom is
reversed.
Seized control
valve spool
YES
Faulty pilot valve

NO
Relation between Faulty Seal Position and
Mistrack Direction
Seal No.
Traveling
Pivot Turn
External oil leakage
Seal Position
1
3
4
Left Travel
(Reverse)
Left Travel
(Forward)
4
5
6
7
External oil leakage
Right Travel
(Reverse)
Right Travel
(Forward)
SM0638
EX255-EX285
T5-4-55
TROUBLESHOOTING B
NO
Faulty travel
motor
YES
YES
YES
Faulty travel
reduction device
Disassemble and
clean travel motor
servo piston.
Check if same
symptom arises.
Disassemble and
clean travel motor
counterbalance
valve. Then,
recheck if same
symptom arises.
Faulty travel
motor servo
piston
NO
Faulty
counterbalance
NO
NO
Faulty center joint
Faulty travel relief

valve
YES
Piping Location
Front
1
2
3
4
5
6
Left Travel (Forward)

Right Travel (Forward)
Pilot
Right Travel (Reverse)
Left Travel (Reverse)
Drain
SM0639
T5-4-56
EX255-EX285
TROUBLESHOOTING B
T-4
During a Combined Operation of Travel and

Front Function, the Machine Mis-tracks.
YES
Faulty load check valve

NO
Check if load check valve is

normal.
NO

Check if flow combiner valve

is normal.
Faulty flow combiner valve
YES
T-5
Steering Power and Gradeability are

Insufficient in the Fast Travel Mode. (Normal
in the Slow Travel Mode)
Related Fault Codes: None

Monitor travel motor swash
angle. After installing a pressure gauge to solenoid valve
unit (SI) port, repeat traveling
and travel pressure relief operation. Check if the pressure
value displayed on Dr.EX
equals is to the pressure
gauge reading and vary identically.
T-6

YES
Monitor item:
Travel Motor Displacement
Angle Change Pressure
Travel mode: Fast
Measurement: Refer to
Operational Performance
Test section.
Seized solenoid valve unit (SI)

NO
Travel Mode Does Not Change to the Fast

Speed Range.
Related Fault Codes: 02, 03, 04, and 05

Refer to the Control group titled Travel Motor
Swash Angle Control in the SYSTEM section in the
NO
Check if any fault

codes are
displayed.
Monitor travel
mode switch.
Check if Lo or
Hi, displayed on
Dr.EX, changes
alternately each
time the travel
switch is
operated.
Monitor item:
Selected Travel Mode
Switch
YES
Faulty sensor or
broken harness
between sensors
and MC.
NO
YES
Monitor travel
pressure switch.
Check if the
display Tr is
indicated or
deleted on Dr.Ex
screen each time
travel lever is
operated or
released.
Faulty travel
mode switch or
broken harness
between travel
mode switch and
MC.
Monitor item:
Pressure Switch
Fault code:
Pump delivery pressure sensor (Pump 1): 02
Pump delivery pressure sensor (Pump 2): 03
Pump control pressure sensor (4-Spool Side): 04
Pump control pressure sensor (5-Spool Side): 05
NOTE - If any other fault codes are displayed,

check suspected parts referring to the displayed fault codes.
EX255-EX285
T5-4-57
TROUBLESHOOTING B
5 through 10 Volt.
Faulty travel
pressure switch,
broken harness
between travel
pressure switch
and MC, or
clogged filter in
travel pilot signal
circuit.
NO
YES
Monitor travel motor

swash angle. After
installing a pressure
gauge to solenoid
valve unit (SI) port,
repeat traveling and
stopping. Check if the
pressure value
displayed on Dr. EX
equals to the pressure
gauge reading and that
both vary identically.
Monitor item: Travel motor swash

angle control pressure
Travel mode: Fast
Measurement: Refer to Operational
Performance Test section.
NO
Disconnect
harness from
solenoid valve
unit (SI). Connect
test harness
(75301514)
between solenoid
valve unit (SI)
and the
disconnected
harness. Check
when travel
mode selector is
actuated, the
solenoid valve
control voltage is
present.
Travel mode: Fast
YES
YES
NO
Faulty solenoid
valve unit (SI).
Broken harness
between solenoid
valve and MC.
Faulty travel
motor or travel
reduction gear.
T5-4-58
EX255-EX285
TROUBLESHOOTING B
TROUBLESHOOTING FOR OTHER FUNCTIONS
O-1
Wiper Does Not Operate, or Retract.

The wiper is controlled by a wiper box in which the
relay circuit are operated by the monitor panel.
When the wiper does not work, check first that the
motor and the relevant linkage are operative, using
an auxiliary power source and the test herness.
If the wiper motor works properly when is powered
throught the test harness, check the upper latch of
front window and wiper cut-off switch for proper
operation.
The windshield wiper motor and washer pump con-
trol relays are moulded inside the wiper controller

and cannot be replaced. The wiper controller must
be considered as an assembly.
YES
YES
As illustrated to the
right, connect test
harness
(75301706C)
between power
outlet and wiper
motor. Check if
wiper operates.
Remove the test

harness and
reconnect the
disconnected
harness to the
original position.
Key switch: ON
NO
Faulty wiper box.
YES
End
NO
Faulty cab
harness
Replace the
monitor assembly.
Check if wiper
operates.
Key switch: ON
NO, or lamp
does not light
normally.
NOTE - When the wiper motor is

normal, lamp S comes ON while
the wiper is moving within the
operating range. Then, only when
the wiper reaches the intermittent
stop position, both lamps B and S
light for a moment at the same
time.
YES
Faulty wiper
motor or link
Check correct
operation of wiper
cut-off switch.
NO
Faulty wiper cutoff switch.
EX255-EX285
T5-4-59
TROUBLESHOOTING B
Electrical Circuit When Test Harness is Connected.
Power outlet
Lamp S
Wiper Motor
Lamp B
Ground
SM0640
Wipers Operating Range
Intermittent Stop Position

Retracted Position
Wiper Range
SM0641
Test Harness Connection
Lamp B
Lamp S
Wiper Motor
Power outlet
Test Harness
SM5618
T5-4-60
EX255-EX285
TROUBLESHOOTING B
ENGINE SPEED ADJUSTMENT AND
ENGINE LEARNING
When the following repair or inspection is made, or
when engine speeds deviate from the specifications,
perform the engine speed adjustment and engine
learning.
When the engine, engine control cable, or EC motor
is removed.
When MC is replaced.
Engine Speed Adjustment:
1. Turn the key switch to START and run the engine.
(Note: Turn the air-conditioner switch OFF.)
2. Turn the engine control dial to the minimum speed
position. (EC sensor voltage is set to
2.5 V.)
3. Loosen the bolt tightening the control lever to the EC
motor output axis.
4. While checking the engine actual speed with Dr.EX
or a tachometer, adjust the control lever to conform
the slow idle speed specification.
Specification: Refer to Operational Performance
Test section.
5. Tighten the bolt to secure the control lever to the EC
motor output axis.
Bolt
Tightening
Control Lever
SM0643
: 13 Nm (1.3 kgfm, 9.4 lbfft)

NOTE - Take care not to allow oil or grease to stick to
the motor output axis.
6. Perform engine learning.
Engine Learning :
Rear cover
1. Turn the key switch OFF.

NOTE - If the engine does not stop with the key switch
OFF, pull the fuel shut-off handle under the operator's
seat to stop the engine
2.
3.
4.
5.
6.
7.
Remove Dr.EX. Wait for 5 seconds.

Turn the engine learning switch ON.
Turn the key switch ON. Wait for 5 seconds.
Turn the key switch OFF. Wait for 5 seconds.
Turn the engine learning switch OFF.
Check the engine speed.
Fuse box
Engine
Learning
switch
Engine
Learning
side
Neutral position (OFF)

SM0108
EX255-EX285
T5-4-61
TROUBLESHOOTING B
EXCHANGE INSPECTION METHOD
Exchange inspection method is used to check if a part
and/or a component is normal by replacing or switching the part/component with one being identical in
performance characteristics.
Pump 2
(5-Spool
Side)
Some of sensors and solenoid valves used on this

machine are identical in performance characteristics.
Accordingly, the exchange inspection method is effective to find out if a part/component or harness is
normal.
PP2
Pump 1
(4-spool
Side)
PP1
Example: Abnormal Pump 1 Delivery Pressure Sensor Failure (Fault Code: 02)
Check :
1. Switch two delivery sensor connectors from the
position shown in Fig.1 to Fig.2.
2. Retry troubleshooting.
Fig. 1
SM0644
Result :
If pump 2 delivery pressure is shown as abnormal
(Fault Code: 03), the pump 1 delivery pressure
sensor is faulty.
Pump 2
(5-Spool
Side)
If pump 1 delivery pressure is shown as abnormal

(Fault Code: 02), the harness which was connected
to the pump 1 delivery pressure sensor is faulty.
PP1
Pump 1
(4-spool
Side)
PP2
Fig. 2
SM0645
T5-4-62
EX255-EX285
TROUBLESHOOTING B
Exchange Inspection Method Application
Fault Code
Trouble
Application
01
EC Sensor Failure
Not Applicable
02
03
Pump 1 Delivery Pressure Sensor Failure

Pump 2 Delivery Pressure Sensor Failure
Applicable
Applicable
04
05
Pump 1 Control Pressure Sensor Failure

Pump 2 Control Pressure Sensor Failure
Applicable
Applicable
06
Arm Roll-In Pilot Pressure Sensor Failure
Applicable (Pump Control Pressure Sensor)
07
Engine Control Dial Failure
Not Applicable
EX255-EX285
T5-4-63
TROUBLESHOOTING B
BOOM LOWERING METHOD WHEN ENGINE STALLS
Excavator not equipped with hose rupture protection valve
In case the engine has stalled and is difficult to restart
while the boom is raised above the ground, lower the
boom in the following method.
WARNING
Ensure that nobody stands under or near the front
equipment prior to beginning the boom lowering
procedure.
1. Loosen lock nut (1) and loosen screw (2) half turn.
The boom will start lowering. The lowering speed
can be slightly adjusted by loosening a bit more
screw (2).
NOTE: never loosen screw (2) more than 2 turns, since

it could come out.
2. After lowering the bucket to the ground, tighten

screw (2) then lock nut (1) to the torques here
below:
Lock nut (1)
- Wrench:
13 mm
- Tightening torque:
1.3 daNm
Screw (2)
- Allen wrench:
4 mm
- Tightening torque:
0.7 daNm
NOTE: in the event the screw and the lock nut are not
adequately tightened, excessive leakages could occur.
Make sure that screw and lock nut are tightened to the
specified torque.
S0014
T5-4-64
EX255-EX285
TROUBLESHOOTING B
Excavator equipped with hose rupture protection valve
In case the engine has stalled and it is difficult to
restart while the boom is raised above the ground,
lower the boom with the following method.
WARNING
Ensure that nobody stands under or near the front
equipment prior to beginning the boom lowering
procedure.
1. Remove protection cap (1) from the relief valve of

the hose rupture protection valve located on the
boom right cylinder.
3
2
2. Make a reference mark on the relief valve and the

lock nut, in correspondence with the hole on the
setting screw.
4. Loosen, very slowly, setting screw (3) to lower the
front equipment to the ground.
5. Return the setting screw and the relevant lock nut
into their original position, making reference to the
mark made as per point 2.
NOTE: it is sufficient to perform the procedure explained above on one hose rupture protection valve
only.
OM0416
EX255-EX285
T5-5-1
TROUBLESHOOTING C
TROUBLESHOOTING C
(TROUBLESHOOTING FOR MONITOR)
PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators malfunction.
How to Read Troubleshooting Flow Charts
YES(OK)
(2)
After checking or measuring item (1), select either Yes (OK) or No (NOT
(1)
OK) and proceed to item (2) or (3), as appropriate.

(3)
NO(NG)
Key switch: ON
components as well.
Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes
can be seen without going through the flow chart.
NOTE - For all connector drawings illustrated in this

group, harness end connector terminals seen from the
open end side are shown.
Wire Harness Side
Open End
Side
Harness End Connector
SM0646
T5-5-2
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF COOLANT
TEMPERATURE GAUGE
Providing that:
Be sure to inspect wiring connections prior to
troubleshooting.
YES
Gauge pointer does not
move at all. (It does not rise
from zero.)
Remove coolant
temperature sensor terminal,
ground harness side terminal
to vehicle. Does pointer
swing to the (H) side?
NO
Key switch : ON
With sensor terminal disconnected, remove 20P connector from monitor, and check
continuity between terminal
No.47 and sensor terminal.
YES
Gauge pointer swings over
scale.
When removing coolant temperature sensor, does

pointer swing back to
zero?
Key switch : ON
NOT OK
(Continuity)
NO
With sensor terminal disconnected, remove 20P connector of monitor, and check
continuity between harness
side terminal and ground.
OK
(No continuity)
Gauge pointer swings

unstably.
Remove coolant
temperature sensor terminal,
and ground harness side terminal to vehicle. Does the
pointer swing to [H] side, and
stably?
Key switch : ON
YES
NO
EX255-EX285
T5-5-3
TROUBLESHOOTING C
Approximate Temperature on Coolant Temperature
Gauge
105 C (221 F)
95 C (203 F)
Faulty coolant temperature

sensor.
OK
(Continuity)
NOT OK
(No continuity)
70 C (158 F)
Failure in monitor.
Faulty harness (breakage)

between monitor and sensor.
SM0647

sensor.
Faulty harness (short circuit)
between monitor and sensor.
Failure in monitor.
Coolant
Temperature
Resistance
(50 C)
(122 F)
(153.9 )
80 C
(176 F)
51.910
100 C
(212 F)
27.44
(120 C)
(248 F)
(16.1 )
NOTE - The value indicated in parentheses is only

a reference value.
sensor.
Failure in monitor.
Connector (harness end connector terminals seen

from the open end side)
Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
T5-5-4
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION FUEL GAUGE
Providing that:
troubleshooting.
YES
Gauge pointer does not
swing. (It does not rise from
zero.)
Remove connector of fuel

sensor, short-circuit terminals C and A of harness side
connector by using a jumper
wire. Does pointer swing to
(FULL) side?
NO
Key switch : ON
With sensor connector disconnected, remove 20P connector of monitor, and check
continuity between terminal
No.46 of monitor and terminal
C of fuel sensor.
YES
Gauge pointer swings over
scale.
When fuel sensor

connector is removed,
does pointer swing back to
zero?
Key switch : ON
Gauge pointer swings

unstably.
NO
Remove connector of fuel

sensor, and short-circuit terminals C and A of harness
side connector by using
jumper wire. Does pointer
swing to [FULL] side, and
stably?
Key switch : ON
With sensor connector disconnected, remove the 20P

connector of monitor, and
check continuity between terminal C of harness side connector and ground.
YES
NO
NOT OK
(Continuity)
OK
(No continuity)
EX255-EX285
T5-5-5
TROUBLESHOOTING C
Fuel Sensor
1 mm=0.03937 in
Float
FULL
257 mm
3/4
138.6 mm
Faulty fuel sensor.

OK
(Continuity)
22
R370
33
70.5 mm
1/2
Failure in monitor.
228 mm
27
28
Resistance
1/4
292 mm
NOT OK
(No continuity)
Faulty harness (breakage)

between monitor and fuel
sensor.
Reserve
338 mm
EMPTY
SM0648
Faulty fuel sensor.

Faulty harness (short- circuit) between monitor and
fuel sensor.
Float
Resistance ()
FULL
10+0
-4
3/4
26
1/2
385
1/4
53
EMPTY
90+10
0
Failure in monitor.

Faulty fuel sensor.
Monitor (20P)
Fuel Sensor
Failure in monitor.
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
C B A
C
B
A
Level signal
Reserve signal
Ground
T5-5-6
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF FUEL LEVEL INDICATOR (RESERVE)
Providing that:
troubleshooting.
YES
YES
Although fuel
gauge pointer
shows E, the indicator does not
come ON.
Check if indicator
comes ON when
key witch is
turned ON
With fuel sensor

connector removed, short circuit terminals B
and A of harness
side connector
by using a jumper
wire. Does indicator light?
Key switch : ON
Key switch : ON
NO
Reconnect fuel
level sensor connector
Remove 12P
connector of
monitor, and
check continuity
between terminal
No.2 of connector and vehicle
ground.
NO
YES
Even if fuel is in
tank, the indicator
comes ON.
Check if indicator
goes OFF when
fuel level sensor
connector is removed.
Key switch : ON
NO
Disconnect fuel
level sensor connector and 12P
connector of
monitor, and
check continuity
between terminal
No.2 of connector and vehicle
ground.
NOT OK (Continuity)
OK (No Continuity)
EX255-EX285
T5-5-7
TROUBLESHOOTING C
Faulty fuel level

sensor.
YES
NO
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.

Monitor (12P)
1 2
7 8
3 4 5 6
9 10 11 12
T5-5-8
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
YES
Indicator does not come ON

when indicator light check
switch is turned ON.
Check if all indicators do not

come ON.
NO
Check power line.

Fuse
Disconnect 20P monitor
connector. Then, check
side terminal No.30 and
fuse terminal No.6.
Perform troubleshooting for the

individual indicator which does
not come ON.

Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
MALFUNCTION OF LEVEL CHECK SWITCH

Process to be taken:
This troubleshooting is applied when only the level
check switch malfunctions.
If power is not supplied at all when key switch is
turned ON, or indicator does not come ON when
indicator light check is conducted, perform troubleshooting for these failures first.
Required Condition:
Park the machine on level surface.
YES
YES
Check if indicator
does not come
ON when level
check switch is
depressed.
Check if all indicators do not

come ON.
Check if oil and

coolant levels are
correct.
NO
NO
Faulty level
switch or harness
(breakage).
Refill engine oil,

hydraulic oil, or
coolant.
Perform troubleshooting for individual indicator

which does not
come ON.
EX255-EX285
T5-5-9
TROUBLESHOOTING C
MALFUNCTION OF PREHEAT INDICATOR
Providing that:
troubleshooting.
Reference:
The preheat system operates when the coolant
temperature is 10 C (50 F) or lower.
During preheat operation, the preheat indicator
stays ON for 8 seconds.
YES
Preheat indicator
comes ON even if
preheat system is
not in operation.
Faulty QOS controller
Check if preheat
indicator goes OFF
when QOS controller
is disconnected.
With QOS controller

disconnected, remove
20P connector from
monitor. Check for
continuity between
monitor harness end
connector terminal
No.43 and vehicle
frame.
Key switch : ON
NO
YES
NO
YES
Preheat indicator
does not come ON
during preheat operation.
With QOS controller

disconnected, remove
20P connector from
monitor. Check for
continuity between
monitor harness end
connector terminal
No.43 and vehicle
frame.
NO
Without disconnecting
the connector, insert a
jumper wire such as a
clip into the back of the
connector and ground
to the vehicle frame.

Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
Q.O.S. Controller
3 2
6 5
1
4
Faulty monitor.
Faulty QOS controller
With QOS controller

disconnected, ground
harness end connector terminal No.6
to vehicle frame.
Check if preheat indicator comes ON.
Key switch : ON
Short-circuited harness between QOS controller and

monitor.
YES
NO
Broken harness between QOS controller and monitor.
Faulty monitor.
T5-5-10
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF ENGINE OIL LEVEL INDICATOR
Providing that:
Indicator light is not burned out.
Other indicators work correctly.
The machine is parked on a level surface.
troubleshooting.
YES
Indicator does not
come ON even if the
level check switch is
depressed.
With engine oil level

switch disconnected,
check continuity between engine oil level
switch connector and
vehicle frame.
Reconnect engine oil

level switch. Disconnect 12 P connector
from monitor. Check
for continuity between harness end
terminal No. 7 and vehicle frame.
YES
NO
NO
YES
Lower than 3.5 mm
below LOW level
Indicator comes ON
even if oil level is
lower than the specified level when level
check switch is depressed.
Check oil level with oil

level gauge.
Higher than 3.5 mm

below LOW level
Disconnect engine
oil level switch.
Check if indicator
comes ON when
level check switch is
depressed.
NO
With engine oil level

switch disconnected,
disconnect 12P connector from monitor.
Check for continuity
between harness
end terminal No.7
and vehicle frame.
EX255-EX285
T5-5-11
TROUBLESHOOTING C
Engine Oil Level Switch
1 mm=0.03937 in
Oil Level Gauge
Engine Oil
Level Switch
ON
Indicator ON
Indicator
OFF
Faulty in monitor.
OFF
A : 3,5 mm
SM6130
Broken harness between engine oil level

switch and monitor.
Faulty engine oil level

switch.

Monitor (12P)
YES
Short-circuited harness
between engine oil level
switch and monitor.
Faulty monitor.
NO
Faulty engine oil level

switch.
Normal.
1 2
7 8
3 4 5 6
9 10 11 12
T5-5-12
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF COOLANT LEVEL INDICATOR
Providing that:
troubleshooting.
YES
Indicator does not

come ON even if
level check switch
is depressed.
With coolant level

switch disconnected, check
continuity between terminals
on level switch 2P
connector.
Reconnect coolant level switch.

Disconnect 12 P
connector of
monitor. Check
side terminal No.8
and vehicle
ground.
YES
NO
NO
YES
YES
Indicator comes
ON even if coolant level is lower
than specified
level when level
check switch is
depressed.
Check coolant
level at coolant
reservoir. Check
if coolant level is
lower than LOW
mark.
Disconnect coolant level switch.

Check if indicator
comes ON
when level check
switch is depressed.
NO
NO
Leave coolant
level switch disconnected.
Disconnect 12 P
connector of
monitor. Check
side terminal No.8
and vehicle
ground.
EX255-EX285
T5-5-13
TROUBLESHOOTING C

Coolant Reservoir
ON
FULL
LOW
Failure
in monitor.
Radiator
OFF
SM0649
Faulty harness.
(breakage)

Faulty coolant
level switch.
Monitor (12P)
1 2
7 8
YES
NO
Faulty harness.
(short circuit)
Failure in
monitor.
Faulty coolant
level switch.
Normal
3 4 5 6
9 10 11 12
T5-5-14
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF HYDRAULIC OIL LEVEL
INDICATOR
Providing that:
troubleshooting.
YES
Indicator does not

come ON even if
level check switch
is depressed.
With hydraulic oil

level switch disconnected,
check continuity
between level
switch 2P connector.
Disconnect 12P
connector of
monitor. Check
side terminal No.9
and vehicle
ground.
YES
NO
NO
YES
YES
Indicator comes
ON even if oil
level is lower than
the specified level
when level check
Check oil level

with level gauge.
Check if oil can
be seen at level
gauge.
Disconnect oil
level switch.
Check if indicator
comes ON when
level check switch
is depressed.
NO
NO
Leave hydraulic
oil level switch
disconnected.
Disconnect 12P
connector of
monitor. Check
side terminal No.9
and vehicle
ground.
EX255-EX285
T5-5-15
TROUBLESHOOTING C

1 mm=0.03937 in
ON
6.2 mm
Failure
in monitor.
OFF
Faulty harness.
(breakage)
Faulty hydraulic
oil level switch.
SM0650

Monitor (12P)
YES
NO
Faulty harness.
(short circuit)
Failure in
monitor.
Faulty hydraulic
oil level switch.
Normal
1 2
7 8
3 4 5 6
9 10 11 12
T5-5-16
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF ALTERNATOR INDICATOR
Providing that:
troubleshooting.
NOTE - (*) Regulator terminals L is water-resistance

type connectors so that it is not practical to measure
voltage at these terminals. Measure voltage at starter
relay terminal R.
Before measuring voltage, check continuity between
the starter relay terminal R and regulator terminal L.
13 V or higher
13 V or
higher
Alternator indicator does not go off

after engine is
started.
Measure voltage at
monitor 20 P connector terminal
No.42.
Engine: Running
Measure voltage
at regulator terminal L.
Less than 13 V
Engine: Running
Less than
13 V
Less than 10 V.
YES
Although alternator output is low,

alternator indicator does not
come on.
Check voltage at
regulator terminal L
(*).
Key switch: ON
Engine: Stopped
Check if indicator
comes on when
key switch is
turned to ON position.
10 V or more
Key switch: ON
NO
EX255-EX285
T5-5-17
TROUBLESHOOTING C
Faulty monitor.

Starter Relay
Harness breakage
between regulator
terminal L and
monitor terminal
No.42.
E
S
Monitor (20P)
Faulty regulator or
faulty alternator.
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
Faulty monitor.
Faulty regulator.
Blown indicator bulb.
T5-5-18
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR
Providing that:
troubleshooting.
YES
YES
Although engine
oil pressure is
lower than specification, indicator
does not come
ON
Key switch: ON
Engine: Stopped
Check if indicator
comes ON when
key switch is
turned to ON position.
Key switch: ON
Key switch: ON
NO
YES
Indicator stays
ON after engine
is started.
Check if oil filter is
clogged or not.
Check if indicator
goes OFF when
engine oil pressure switch is disconnected.
Key switch: ON
Engine: Stopped
With engine oil pressure switch disconnected, check if indicator comes ON

when terminal
of wire number 33 is
grounded to vehicle.
NO
NO
EX255-EX285
T5-5-19
TROUBLESHOOTING C

Pressure
Faulty engine oil

pressure switch.
Reconnect engine oil

pressure switch.
Check if indicator
comes ON when
monitor terminal
No.10 is grounded to
vehicle.
Key switch: ON
Without disconnecting,
ground connector to
vehicle using a clip from
the back of connector.
YES
Broken harness
between monitor
and engine oil
pressure switch.
Approx.
98 kPa (1.0 kgf/cm2,
14.2 psi) or Less
ON
More than Approx.

98 kPa (1.0 kgf/cm2,
14.2 psi)
OFF

Monitor (12P)
NO
Faulty
monitor.
Faulty engine oil

pressure switch,
faulty engine oil
lubrication system, or clogged
oil filter.
With engine oil pressure switch connected, remove 12P

connector from monitor. Check for continuity between harness end connector
terminal No.10 and
vehicle frame.
Indicator
YES
NO
Short-circuited
harness between
monitor and engine oil pressure
switch.
Faulty monitor.
1 2
7 8
3 4 5 6
9 10 11 12
T5-5-20
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF OVERHEAT INDICATOR
Providing that:
troubleshooting.
YES
YES
Indicator does not
come ON even if
engine overheats.
Check if indicator
comes ON when
key switch is
turned to HEAT
position.
With overheat
switch connector
disconnected,
check if indicator
comes ON when
terminal of wire
number 201 is
NO
Key switch: ON
Key switch: ON
NO
YES
Indicator comes
ON even if coolant
temperature is
low.
Check if indicator
goes OFF when
overheat switch
connector is disconnected.
Key switch: ON
Engine: stopped
NO
Disconnect overheat switch connector and 12P

connector of
monitor. Check if
continuity between 12P connector terminal
No.1 and vehicle.
YES
NO
EX255-EX285
T5-5-21
TROUBLESHOOTING C
Overheat Switch
Coolant Temperature
Faulty overheat
switch.
Lower than 105 C

(221 F)
OFF
105 C (221 F)
or more
Reconnect overheat
switch connector.
Check if indicator
comes ON when
monitor 12P connector terminal No.1 is
Key switch: ON
Without disconnecting,
ground connector to
vehicle using a clip from
the reverse side of the
connector.
YES
Faulty harness.
(breakage)
ON

Monitor (12P)
NO
Failure in
monitor.
Faulty overheat
switch.
Faulty harness
(short circuit) between monitor
and overheat
switch.
Failure in
monitor.
Indicator
1 2
7 8
3 4 5 6
9 10 11 12
T5-5-22
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR
Providing that:
troubleshooting.
YES
YES
When air filter is
clogged, indicator
does not light.
When key switch

is returned to
HEAT position,
does indicator
light?
When restriction
switch is disconnected, and harness side terminal of wire
number 203 is
grounded to vehicle, does indicator light?
NO
Key switch: ON
Key switch: ON
NO
YES
Although air filter

is not clogged,
indicator lights.
Disassembled and
visual check
Confirm that air filter
is not moist.
When air filter restriction switch is

disconnected,
does the indicator
go out?
Key switch: ON
NO
Disconnect air
filter restriction
switch connector
and 12P connector of
monitor, and
check continuity
between terminal
No.3 of connector
and vehicle
ground.
YES
NO
Reconnect restriction switch.

Disconnect 12P
connector of
monitor, and
check continuity
between terminal
No.3 of connector
and vehicle
ground.
EX255-EX285
T5-5-23
TROUBLESHOOTING C
Air Restriction Switch

Pressure
Faulty air restriction switch.
YES
Failure in
monitor.
Indicator
62 6 mbar (6.2 0.6 kPa)

(635 58 mmH2O)
or Less
OFF
More than 62 6 mbar

(6.2 0.6 kPa)
(635 58 mmH2O)
ON

Monitor (12P)
NO
Faulty harness
(breakage) between monitor
and air restriction
switch.
Faulty air restriction switch.
Faulty harness
(short circuit) between monitor
and air restriction
switch.
Failure in
monitor.
1 2
7 8
3 4 5 6
9 10 11 12
T5-5-24
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF BUZZER
relay terminal R.
13 V or more
Faulty regulator.
Buzzer keeps
sounding when
key switch is
turned ON.
Check voltage at
monitor terminal
No.42.
Key switch: ON
(Engine is stopped.)
Less than 13 V
Failure in engine
oil pressure system.
YES
Buzzer keeps
sounding when
engine is started.
Check if engine
oil pressure indicator is ON.
YES
NO
YES
Check if engine is
running at 1000
min-1 (rpm) or
faster.
Check if buzzer
stops when
buzzer stop
Normal
NO
NO
Overheat of engine.
Check if overheat
indicator is ON.
NO
Buzzer does not

sound even if engine oil pressure
indicator or overheat indicator
comes ON.
Failure in
monitor.
Normal
Check if alternator indicator is

ON.
YES
Check voltage at
alternator terminal L.
Engine speed:
1000 min-1 (rpm) or
faster.
EX255-EX285
T5-5-25
TROUBLESHOOTING C
Monitor (20P)
Starter Relay
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
YES
Normal
Failure in monitor.
NO
Less than 13 V
13 V or more
Faulty regulator or
alternator.
Check voltage at
monitor 20P connector terminal
No.42.
Engine speed:
1000 min-1 (rpm) or
faster.
Less than 13 V
Faulty harness
(breakage) between
alternator terminal L
and monitor terminal
No.42.
Failure in monitor.
13 V or more
T5-5-26
EX255-EX285
TROUBLESHOOTING C
MALFUNCTION OF HOUR METER
Providing that:
troubleshooting.

relay terminal R.
Broken harness
between monitor
terminal No.29
and No.6 fuse.
0V
NO
Check voltage at
No.29.
24 V
Hour meter
does not count
operating
hours when
engine is running.
Failure in
monitor.
Check if alternator indicator is

ON.
Less than 13 V
Faulty regulator
or alternator.
Engine : Running
YES
Check voltage at
alternator terminal L
(*).
Engine speed:
1 000 min-1 (rpm) or
faster
13 to 14.5 V
or more
Check voltage at
No.42.
13 V or more

Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
Starter Relay
E
S
Less than
13 V
Failure in
monitor.
Broken harness
between alternator terminal L and
monitor terminal
No.42.
EX255-EX285
T5-6-1
ELECTRICAL SYSTEM INSPECTION

PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
A
0511
0511
0511
20 30 mm
C
2,5 R 0679
0511
0511
1. Disconnect the power source.

Be sure to remove the negative terminals from the
batteries first when taking wire harnesses and
connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
2. Wire harnesses identification.
The wire harnesses used on electrical system of the
machine are of three colours: red, white and brown.
The wire harnesses red coloured are used for
the main power supply distribution and for direct
connection to the positive not controlled by key
switch.
The wire harnesses white coloured are used for
the all other functions.
The wire harnesses brown coloured are used for
ground connection.
Each wire is identified by a four digit numerical
coding printed on the whole lenght every 20 to 30
mm (A).
This coding is also shown on the wiring diagrams of
electrical system (B).
On the general electrical system diagram attached,
numbers and letters are shown before the four digit
coding.
Numbers mean the wire section shown in mm2.
The following letters indicate the wire colours;
where W stands for white, R for Red and Br for
Brown. See detail (C).
3. Precautions for connecting and disconnecting terminal connectors.
1) When disconnecting harnesses, grasp them by
their connectors. Do not pull on the wire itself.
Be sure to release the lock first before attempting to separate connectors, if a lock is provided.
(Refer to Instructions for Disconnecting Connector on page T5-6-3.)
2) Water-resistant connectors keep water out so
that if water enters them, water will not easily
drain from them. When checking water-resistant connectors, take extra care not to allow
water to enter the connectors. In case water
should enter the connectors, reconnect only
after the connectors are thoroughly dried.
3) Before connecting terminal connectors, check
that no terminals are bent or coming off. In
addition, as most connectors are made of
brass, check that no terminals are rusting.
4) When connecting terminal connectors provided
with a lock, be sure to insert them together until
the lock clicks.
Right
Wrong
SM0651
Right
Rust
Wrong
(deformation)
Wrong
(Separation)
SM0652
T5-6-2
EX255-EX285

4. Precaution for using a circuit tester.
1) Before using a circuit tester, refer to the instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to
be measured, voltage range and current polarity.
2) Before starting the connector test, always
check the connector terminal numbers, referring to the circuit diagram.
When the connector size is very small, and the
standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or
a pin around the probe to make the test easier.
Wind a Piece of Wire
Tester Probe
Sharpen the end of the Wire

SM0653
EX255-EX285
T5-6-3

INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
Push the lock to disconnect.
NOTE - 1) Connectors may not be separated if the
lock is pushed while the connectors are
pulled. Be sure to push the lock first before
pulling the connectors.
2) The lock is provide on the female connector (harness side).
SM0654
Locations of This Type Connector

Fuel Gauge
Horn
Cab Harness
Pressure Switch
Washer
Pilot Pressure Switch
EC Motor
EC Sensor
Pump Delivery Pressure Sensor
N Sensor
Engine Oil Level Sensor
Key Switch
Engine Control Dial
Radio
Speaker
Learning Switch
Wiper
Monitor
Pull up the lock to disconnect.

Pump Control Pressure Sensor
Rel avviamento
Pull to disconnect.
Solenoid Valve Unit
Dr.EX
SM0656
T5-6-4
EX255-EX285

FUSE CONTINUITY TEST
Fuse failure is often caused by a fine crack in the fuse,
and such fine cracks are very hard to detect by visual
inspection.
Checking fuse continuity with a tester is far superior to
sight inspection.
NOTE - All the inside terminals of the fuses in the

fuse box are connected to the power source,
while the outside terminals are connected to
the accessories.
Test all fuses using the same method.
(1) Turn the key switch ON

In doing so, the battery relay is activated by the
current from terminal M of the key switch, and
electric power is supplied to all circuit, except the
glow relay circuit.
(2) Remove the fuse box cover and set the correct
voltage measurement range of the tester.
(Measurement range: 0 to 30 V)
(3) Connect the negative probe to the vehicle ground,
and touch the outside terminal of each fuse with the
positive probe of the tester.
When normal continuity of a fuse is intact, the
tester will indicate 20 to 25 volts.
Accessory (Outside)
SM0657
Glow relay
Power Source (Inside)

Accessory (Outside)
EX255-EX285
T5-6-5

INSPECTION AND REPLACEMENT OF
MAXI FUSIBLE LINKS
Inspection
1. Remove the negative cable from the battery.
2. Loose the wing nut fixing the protection panel and
open it by rotating forward to gain the access.
3. Withdraw the front cover of the maxi fusible link box
and visually inspect the maxi fusible link inside.
Replacement
1. Make sure that the negative cable is removed from
the battery.
2. Loose the wing nut fixing the protection panel and
open it by rotating forward to gain the access.
OM5633
3. Withdraw the front cover of the maxi fusible link box.

4. Take out the maxi fusible link and replace it.
Front cover
5. Reinstall the front cover to maxi fusible link box.

6. Reconnect the negative cable to the battery.
Maxi fusible
Body
Bottom cover
SM3032
T5-6-6
EX255-EX285

BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle frame.
Normal Voltage: 24 V
NOTE - If voltage is abnormal, recharge or replace the
battery.
2. Start the engine. Check voltage between the battery
positive terminal and the vehicle frame.
V
Normal Voltage: 26 to 28 V
NOTE - If voltage is abnormal, check the charging
system.
SM3034
EX255-EX285
T5-6-7

HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
Terminal R
Terminal L
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

1. Stop the engine. Turn the key switch to the ON
position. Confirm that the alternator indicator
comes on.
2. Measure the voltage between the B and E terminals
of the alternator. If the measured voltage is around
24 V, the alternator circuit can be consi-dered
normal. If the measured voltage is low, a shortage
in battery capacity or looseness of the wire connectors of the alternator circuit might be the cause of
the malfunction. When the voltage is 0 V, the wiring
between the fuse box and alternator might be loose
or disconnected.
Also, the alternator cannot generate electricity if the
ground line is disconnect.
3. Next, start the engine and measure the voltage
generated while as the alternator rotates.
As described above, measure the voltage between
terminals B and E on the side of the alternator. If the
voltage is around 28 V, the alternator is operating
normally.
If the rated voltage is not being generated, there is
some trouble with the alternator or the regulator.
Terminal E
SM6122
T5-6-8
EX255-EX285

CONTINUITY CHECK
Harness
Single-line continuity check

Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is:
0 = Continuity
= Discontinuity
NOTE - When the one end connector is far apart from
the other, connect one end of connector (A) to the
machine chassis using a clip. Then, check continuity
of the harness through the vehicle frame as illustrated.
0 = Continuity
= Discontinuity
Connect to the
machine
chassis.
Connect to the
machine
chassis.
Single-line short-circuit check

Disconnect both end connectors of the harness and
check continuity between one end connector of the
harness and the vehicle frame:
0 = Short circuit is present.
= No short circuit is present.
Multi-line continuity check
Disconnect both end connectors of the harness, and
short-circuit two terminals, (A) and (B), at one end
connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If
the ohm-meter reading is , either line (A) - (a), or
(B) - (b) is in discontinuity. To find out which line is
discontinued, conduct the single line continuity check
on both lines individually, or, after changing the shortcircuit terminals from (A) - (B) to (A) - (C), check
continuity once more between terminals (a) and (c).
Short-circuit
between the
harness and
the vehicle
frame
SM0660
First short-circuit
a
b
c
A
B
C
Second short-circuit
NOTE - By conducting the multi-line continuity check

twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check
continuity between terminals (a) and (c).
0 = Line (B) - (b) has discontinuity.
= Line (A) - (a) has discontinuity.
Multi-line short-circuit check
Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or (C).
0 = Short-circuit exists between the lines.
= No short-circuit exists between the lines.
SM0661
Short-circuit between harnesses.
a
b
c
A
B
C
SM0662
EX255-EX285
T5-6-9
T5-6-10
EX255-EX285

VOLTAGE AND CURRENT CHECK
Turn switch ON so that the specified voltage (current)
is applied to the point to be measured. Then start
measuring either voltage or current. Judge if the
specified voltage is applied.
Engine
Key
Switch
24 Voltage Circuit
Start checking in order up to the point where voltage is
measured from either power source or actuator side.
Thereby, the faulty location in the circuit will be found.
Black Probe (Minus) of Tester : To ground (vehicle
frame).
Red Probe (Plus) of Tester
: To location to be
measured.
Check Point
Standard
Power Source Circuit

Stopped
Stopped
Stopped
Stopped
Stopped
Stopped
OFF
OFF
OFF
OFF
OFF
OFF
Between (2) and (1): One Battery

Between (3) and (2): One Battery
Between (3) and (1): Two Batteries
Between (4) and Ground: Power Source
Between (5) and Ground: Fusible Link
Between (1) and Ground: Backup Current (*)
10 to 12.5 V
10 to 12.5 V
20 to 25 V
20 to 25 V
20 to 25 V
6 mA
Preheat Circuit
Stopped
Stopped
Stopped
ON
ON
ON
Between (6) and Ground: Key Switch

Between (7) and Ground: Glow plugs
Between (20) and Ground: QOS Controller power supply
20 to 25 V
20 to 25 V
20 to 25 V
Starting Circuit
Started
Started
Started
Started
Started
Started
START
START
START
START
START
START
Between (8) and Ground: Key Switch

Between (9) and Ground: Battery Relay (Coil)
Between (10) and Ground: Battery Relay (Switch)
Between (11) and Ground: Starter (B)
Between (12) and Ground: Starter (C)
Between (13) and Ground: Starter Relay (S)
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
Charging Circuit
Fast Speed
Fast Speed
Fast Speed
Fast Speed
Fast Speed
ON
ON
ON
ON
ON
Between (14) and Ground: Alternator Generating Voltage (B)

Between (10) and Ground: Alternator Generating Voltage
Between (15) and Ground: Alternator Generating Voltage
Between (16) and Ground: Alternator Generating Voltage (L)
Between (17) and Ground: Monitor
26 to 30 V
26 to 30 V
26 to 30 V
13 to 30 V
13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idling
Slow Idling
Slow Idling
Slow Idling
ON
ON
ON
ON
Between (14) and Ground: Alternator (B)

Between (16) and Ground: Alternator (L)
Between (18) and Ground: Anti Load Dump Relay
Between (10) and Ground: Battery Relay
26 to 30 V
13 to 30 V
26 to 30 V
26 to 30 V
Accessory Circuit
Stopped
Stopped
Stopped
Stopped
ON
ON
ON
ON
Between (19) and Ground: Air Conditioning

Between (21) and Ground: Horn
Between (22) and Ground: Lighter
Between (23) and Ground: Radio
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
(*) After disconnection the minus cable to the battery, start measuring.
EX255-EX285
T5-6-11
QOS Controller
Battery
Battery
Relay
Starter
Key Switch
Fuse
box
Starter Relay
Glow
Relay
Fuse
box
Alternator
Monitor
Glow Plugs
SM5619
Relay box
SM3036
T5-6-12
EX255-EX285

5 Voltage Circuit
Voltage between terminal No.1 and the vehicle
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.
Two polarities
Signal or
ground
Power source
1
Key switch position: ON

Tester black terminal (negative):
Connected to the vehicle (ground)
Tester red terminal (positive):
Connected to terminal No.1
SM0664
Ground
Power source
1
Three polarities
Evaluation:
If the measuring voltage is within 50.5 volts, the
circuit up to terminal No.1 is normal.
Voltage between terminal No.1 and the ground

terminal
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the ground
terminal (terminal No.2 for two polarities, or terminal
No.3 for three polarities) under the following conditions.
SM0665
Two polarities
1
Key switch position: ON

Tester black terminal (negative):
Connected to the ground terminal

(terminal No.2 or 3)
Tester red terminal (positive):
Connected to terminal No.1
SM0666
Three polarities
1
Evaluation:
If the measuring voltage is within 50.5 volts, the
circuit up to terminal No.1 or the ground terminal is
normal.
V
SM0667
EX255-EX285
T5-6-13

Check Using False Signal
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, controllers and fuses to burn due to current overload.
Two polarities

sensor connector.
Short-circuit terminal No.1 (power source) and No.2
(signal) on the machine harness side connector and
supply the power source voltage as a false signal to
the controller. Check the controller under this condition, using the Dr.EX monitor function.
Evaluation:
Except for the pressure switch circuits, if the maximum value is displayed, the MC (Main Controller) and
the circuits up to the machine harness side connector
are normal. When the pressure switch circuits are
normal, the Dr.EX monitor displays ON.
(Pressure switch)
(N sensor)
Short circuit
SM0668
Three polarities
(EC sensor)
(Pilot pressure sensor)
(Pump control pressure
sensor)
(Pump delivery pressure
sensor)
Short circuit
SM0669
T5-6-14
EX255-EX285

WIPER CONTROLLER
2
SMW0465
3
5
To wiper
motor
To washer
pump
SMW0466
1
2
3
4
Connector
Box
Diode 1n5408 (q.ty 3)
Relay
5
6
7
- Board
- Diode 1N4007
- Wiper controller connector, harness side
EX255-EX285
T5-6-15

Replacement of wiper controller
1. Remove screw (1) under the right console to detach
cover (2).
2. Remove bolt (3) and turn the console around pin (4).
Then, take out lock pin (5). Push pin (4) to the seat
side, then remove spacer (6).
: 17 mm
3. Move the console to the seat side.
4. Using a sharp-pointed tool, remove cap (9) from
cover (7) and duct cover (8) located under the
monitor.
13
SM5620
5. Remove cover (7) and duct cover (8).
6. Remove ashtray (10) and the ashtray screw.

Remove aux. switch panel (11).
7. Remove wiper controller cover (12).

a
8. Replace the wiper controller (13).
5
4
1
SM0670
View a
11
10
SM0671
1
2
3
4
5
Screw
Cover
Bolt
Pin
Lock Pin
6
7
8
9
10
Spacer
Cover
Duct Cover
Cap
Ashtray
12
11 - Aux. Switch Panel

12 - Wiper controller cover
13 - Wiper controller
T5-6-16
EX255-EX285

REPLACEMENT OF RELAY
(R1, R2, R3, R4, R5, R6)
1. Remove the rear cover (1) by loosen the 3 bolts (3)
and the four bolts (2).
: 13 mm
2. Remove the bolt (4 and 5) fixing the support (6)

: 13 mm
R1-R2-R3-R4-R5-R6
SM5621
3. Lift the support (6).
3
SM1126
4. Lift the protection sheet (7).

6
SM3039
EX255-EX285
T5-6-17

5. Identify the relay on the terminal board.
SM5622
6. Replace the relay.
T5-6-18
EX255-EX285

RELAY BOX
SM5623
- Relay box
- Relay box connector harness side
SM5624
- Diodes
d1, d2, d3, d4 : Diode IN4007
D1, D2, D3, D4, D5, D6 : Diode IN5408
- Relay
R1:
R2:
R3:
R4:
Anti Load Dump

Horn
Light 2
Light 1
EX255-EX285
T5-6-19

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).
SM1126
A
4. Disconnect the connector (6).
5. Remove the relay box (4).

SM3039
View from A
5
6. Install the new relay box (4).
4
7. Fix the relay box with hexagonal screw M6 and the

two washer (5).
8. Install the connector (6) on the relay box.

6
SM5625
9. Reinstall the rear cover by tightening the four bolts

(2) and the three bolts (3).
T5-6-20
EX255-EX285

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. Lift the protection sheet (7).

3
5. Remove the main controller (MC) (8) by loosening

the four bolts (9).
Do not disconnect the MC connectors.
SM1126
6. Remove the QOS controller (10) by loosening the

two bolts (11).
Disconnect the connector.
5
7. Install the new QOS controller (10) and secure by
tightening the two bolts (11). Properly route the
QOS controller cable tail and fix by tie-wrap.
Connect the connector.
SM3039
8. Reinstall main computer (MC) (8) by tightening the

four bolts (9), the protection sheet (7) and the
support (6).
9. Reinstall the rear cover by tightening the four bolts

(2) and the three bolts (3).
SM6127
10
11
SM6128A
EX255-EX285
T5-6-21

REPLACEMENT OF POWER OUTLET
1. Gain the access to the rear of panel and disconnect
the connector from power outlet.
2. Open the guard.
Power outlet
OM0376
3. Using the special plier (Fiat Auto code No.

1876044000) unlock the sleeve from the lock ring.
Panel
Power outlet
4. Withdraw the sleeve from the rear of the panel.
Guard
SM3041
5. Install the new power outlet inserting the sleeve

from the rear of the panel and pushing the lock ring
on the front of the panel.
SM3042
6. Reconnect the connector to the power outlet.
Special plier Fiat Auto Code No. 1876044000
T5-6-22
EX255-EX285

NOTES
EX255-EX285
T5-7-1
HARNESS CHECK
CIRCUIT INSPECTION
To inspect the circuits of the machine, a test harnesses kit 75301706 has been developed, including
dedicated harnesses for the inspection of the various
components of the machine, and the test harness
75301514.
The kit 75301706 includes harnesses for the check of
solenoid valves, harnesses for sensor check and
harness for wiper check.
The test harness 75301514 is used to check the

solenoid valves installed on solenoid valve unit.
To check the circuits, connect the appropriate harness
between the male and female connectors of the
component to be checked.
Then check the normal or abnormal operation of the
circuit, measuring with a tester, the power voltage on
the free connections.
Solenoid valve test harness

Two terminals test harness 75301706A.
Use this harness to check the circuit of solenoid
valve.
SM6732
Test harness 75301706A
Two-terminal test harness 75301514.

Use this harness to check the circuit of solenoid
valves SG, SI, SD, SC (installed on solenoid valve
unit). (Refer to pages T5-4-28, -39, -42 and -57).
SMW0491
Test harness 75301514
T5-7-2
EX255-EX285
HARNESS CHECK
EC motor test harness
Test harness 75301706B
Use this harness to check the circuit of the EC
motor.
(Refer to page T 5-4-24).
SM6733
Test harness 75301706B
Sensor test harness

Test harness 75301706D
Use this harness to measure the signal voltage of the
EC angle sensor circuit.
(Refer to page T5-3-4)
(Red)
(Blue)
(Black)
V
SM6734
Test harness 75301706D
Wiper circuit test harness

Test harness 75301706C
Use this harness to check the wiper circuit.
(Refer to page T5-4-58)
SM6735


Print No. 604.13.196 - VII - 2002

EXCAVATOR
WORKSHOP MANUAL
(Tier 2)
All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication.

ENGINEERING
EX255-EX285
IN-1
INTRODUCTION
TO THE READER
This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.

MACHINERY S.p.A.
Strada Settimo, 323
10099 ITALY
PRODUCT SUPPORT
Fax. ++39 011 6877357
Manual
- Parts Catalog

books:
- Workshop Manual

The Service Manual for EX255 andEX285 Excavators consists of the following book/print numbers:
- The Technical Manual -Troubleshooting includes

the technical information needed for operational
performance tests, and troubleshooting procedures.
BOOK
PRINT NUMBER
604.13.191
604.13.196
- Workshop Manual
604.13.201
IN-2
EX255-EX285
INTRODUCTION
PAGE NUMBER
Example: T 1-2-3
Section number
W : Workshop Manual
SYMBOLS

parts.
UNITS USED
Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
Quantity
To
convert
from (SI)
Into
(Others)
Multiply by
Quantity
To
convert
from (SI)
Into
(Others)
Multiply by
Lenght
mm
in
0.03937
Pressure
MPa
kgf/cm2
10.197
mm
ft
0.003281
MPa
psi
145.0
US gal
0.2642
kW
CV-PS
1.360
US qt
1.057
kW
HP
1.341
Volume
L
3
yd
kg
lb
m
Weight
Force
Torque
Power
1.308
Temperature
C x 1.8 + 32
2.205
Velocity
km/h
mph
0.6214
kgf
0.10197
lbf
0.2248
N.m
kgf.m
0.10197
N.m
lbf.ft
0.7375
min
Flow rate
-1
rpm
1.0
L/min
US gpm
0.2642
mL/rev
cc/rev
1.0
EX255-EX285
S-1
SAFETY PRECAUTIONS
RECOGNISE SAFETY INFORMATION
This is your SAFETY ALERT SYMBOL.
- When you see this symbol on your machine or in
this Manual, be alert of the potential for personal
injury.
- Follow recommended precautions and safe
operating practices.
S0021
UNDERSTAND SIGNAL WORDS

In this Manual you will find the following words:
- DANGER;
- WARNING;
- CAUTION.
referring to different hazard risks.
These words are always accompanied by the safety
alert symbol.
DANGER
WARNING
DANGER: indicates an imminent hazardous

situation which, if not avoided, will result in death or
serious injury.
CAUTION
WARNING: indicated a potential hazardous

situation which, if not avoided, could result in death or
serious injury.
IMPORTANT
CAUTION: indicates a potential hazardous situation

which, if not avoided, may result in minor or moderate
injury.
NOTE
IMPORTANT: indicates a situation which, if not

avoided, may cause damage to the machine.
NOTE: indicates an additional explanation for
information purposes.
ENVIRONMENTAL PROTECTION
This Manual also contains this symbol
accompanying instructions for correct behaviour
as regards environmental protection.
S0024
S-2
EX255-EX285
SAFETY PRECAUTIONS
FOLLOW SAFETY PRECAUTIONS
Carefully read and observe all safety signs on the
machine and read all safety precautions in this
Manual.
Safety signs should be installed, maintained, and
replaced when necessary.
- If a safety sign or this Manual are damaged or
missing, obtain a replacement from your FIAT
KOBELCO Dealer in the same way you order a
spare part (be sure to detail machine model and
serial number upon ordering).
Learn how to operate the machine and its controls
correctly and safely.
Allow only trained, qualified, authorised personnel
to operate the machine.
S0022
Keep the machine in proper working conditions.

- Unauthorised changes to the machine may
impair function and/or safety and affect machine
life.
Safety messages in this Chapter SAFETY
PRECAUTIONS, are intended to illustrate basic
safety procedures of the machine. However, it is
impossible for these safety messages to cover
every hazardous situation you may encounter. If
you have any doubts, consult your direct
supervisor prior to operating or servicing the
machine.
PREPARE FOR EMERGENCIES

Be prepared if a fire starts or an accident occurs.
- Keep the first-aid kit and fire extinguisher on hand.
- Thoroughly read and understand the label
attached to the fire extinguisher to use it properly.
- Establish emergency priority procedures to cope
with fires and accidents.
- Keep emergency numbers for doctors,
ambulance service, hospitals and fire
department posted near the telephone.
S0023
EX255-EX285
S-3
SAFETY PRECAUTIONS
WEAR PROTECTIVE CLOTHING
Wear close-fitting clothing and safety equipment
appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask.
Be sure to correctly wear equipment and clothing
for the job.
- Do not take any chances.
- Avoid wearing loose clothing, jewellery, or other
items that can catch on control levers or other
parts of the machine.
S0025
Operating equipment safely requires the full

attention of the operator. Do not wear radio or
music headphones while operating the machine.
PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause
impairment or loss of hearing.
- Wear a suitable hearing protection such as
earmuffs or earplugs to protect objectionable or
uncomfortably loud noise.
S0026
INSPECT THE MACHINE

Inspect the machine carefully every day or workshift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.
- In the walk-around inspection, be sure to cover all
points detailed in the Chapter "MAINTENANCE",
paragraph "EXTERNAL VISUAL INSPECTION"
of the OPERATION AND MAINTENANCE
INSTRUCTION MANUAL.
S0027
S-4
EX255-EX285
SAFETY PRECAUTIONS
USE HAND HOLDS AND STEPS
Falling is one of the major causes of personal injury.
- When you get on and off the machine, always
face the machine and maintain a three-point
contact with the steps and handrails.
- Do not use any control as a handhold.
- Never jump off the machine. Never get on and
off a moving machine.
- Be careful of slippery conditions of platforms,
steps, and handrails when leaving the machine.
S0028
ADJUST THE OPERATOR'S SEAT

A seat poorly adjusted for operator or work
requirements may quickly fatigue the operator
leading to improper operations.
- The seat should be adjusted whenever machine
operator changes.
- The operator should be able to fully press the
pedals and correctly move the control levers with
his back resting against the seat back.
- If not, move the seat fore and aft, and check again.
S0029
EX255-EX285
S-5
SAFETY PRECAUTIONS
FASTEN SEAT BELT
Should the machine overturn, the operator may
become injured and/or thrown from the cab. Not
only, the operator may be crushed by the
overturning machine resulting in serious injury or
even death.
- Prior to operating the machine, thoroughly
examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
S0030
- Be sure to remain seated with the seat belt

securely fastened at all times when the machine
is in operation to minimise injury hazard in case
of accident.
- After a significant accident, replace the seat belts
even though they do not look damaged.
MOVE AND
SAFELY
OPERATE
MACHINE
Bystanders can be run over.

- Pay the utmost attention not to run over
bystanders.
- Be sure and aware of the location of bystanders
before moving, swinging or operating the
machine.
- If fitted, keep the travel alarm and horn sounding
to warn people that the machine is about to move.
S0031
- When operating, swinging, or moving the

machine in a congested area use a signal man.
- Co-ordinate hand signals before starting the
machine.
S-6
EX255-EX285
SAFETY PRECAUTIONS
OPERATE ONLY FROM THE DRIVER'S
SEAT
Inappropriate engine starting procedures may
cause the machine unexpected movement,
possibly resulting in serious injury and even death.
- Start the engine only from the operators seat.
- NEVER start the engine while standing on the
track or on the ground.
- Do not start the engine by shorting across starter
motor terminals.
S0032
- Before starting the engine, ensure that all control

levers are in the neutral position.
KEEP RIDERS OFF THE MACHINE

Riders on the machine are subject to injuries such
as being struck by foreign objects and being thrown
off the machine.
- Only machine operator is
machine. Keep riders off.
allowed on the
- Riders also obstruct the operators visibility,

resulting in the machine being operated unsafely.
S0033
CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN
Incorrect travel controls operation may result in
serious injury and even death.
- Before driving the machine, be aware of the
undercarriage position relative to the operators
position. If travel motors are located at the front
of the cab, the machine will move reverse when
travel controls are moved towards cab front.
S0037
EX255-EX285
S-7
SAFETY PRECAUTIONS
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
To avoid back-over and swing accidents:
- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
- Keep the travel alarm in working condition (if
equipped).
- ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
S0042
- USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
- Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
- No machine motions shall be made unless
signals are clearly understood by both signalman
and operator.
- Learn the meanings of all flags, signs, and
markings used on the job and confirm with the
person in charge of signalling.
- Keep windows, mirrors, and lights clean and in
good condition.
- Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
- Read and understand all operating instructions in
the OPERATION AND MAINTENANCE
INSTRUCTION MANUAL.
S0043
S-8
EX255-EX285
SAFETY PRECAUTIONS
DRIVE MACHINE SAFELY
Before starting the machine carefully read the

OPERATION AND MAINTENANCE INSTRUCTION MANUAL. (Refer to the OPERATING INSTRUCTIONS chapter).
Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.
- Pushing down on the front of the travel pedals or
pushing the levers forward moves the machine
towards the idlers. (Refer to the OPERATION
AND
MAINTENANCE
INSTRUCTION
MANUAL).
S0038
Traveling on a grade may cause the machine to slip

or to overturn, possibly resulting in serious injury or
death.
- When traveling up or down a grade, keep the
bucket in the direction of travel, approximately 20
to 30 cm (A) above the ground.
- If machine starts to skid or becomes unstable,
lower the bucket immediately.
S0039
- Traveling across the face of a slope may cause

the machine to skid or to overturn. When
travelling (ascending/descending) on a slope, be
sure to point the tracks uphill/downhill.
S0004
- Turning on an incline may cause the machine to

tip over.
If turning on an incline is absolutely unavoidable,
do so at a place where the slope is gentle and the
surface is firm.
- When operating on a grade and the fuel reserve
indicator light lights, immediately refuel.
WRONG
S0005
EX255-EX285
S-9
SAFETY PRECAUTIONS
AVOID OVERTURNING
The danger of tipping is always present when
operating on a grade, possibly resulting in serious
injury or death.
To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the bucket low to the ground and close to
the machine.
- Reduce machine operating speed to avoid
tipping or slipping.
- Avoid changing direction when travelling on
grades.
- NEVER attempt to travel across a grade steeper
than 15 degrees.
- Reduce swing speed as necessary when
swinging loads.
S0002
Be careful when working on frozen ground.

- Temperature increases will cause the ground to
become soft and make ground travel unstable.
S0047
PARK MACHINE SAFELY

To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Turn auto-idle (A/I) switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Pull the safety lever (pilot-control shut-off lever) to
the LOCK position.
- Close windows, roof window, and cab door.
- Lock all access doors and compartments.
S0049
S-10
EX255-EX285
SAFETY PRECAUTIONS
AVOID INJURY FROM UNEXPECTED
MACHINE MOVEMENT
Death or serious injury may result if you attempt to
get on or off a moving machine.
To avoid roll-aways:
- Select level ground when possible to park
machine.
- Do not park the machine on a grade.
- Lower the bucket and/or other work tools to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
- Turn the auto-idle switch off.
- Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
- Stop the engine and remove the key from the key
switch.
- Pull the pilot shut-off lever to LOCK position.
- Block both tracks.
- Position the machine to prevent overturning.
- Park a reasonable distance from other machines.
S0040
S0041
PROVIDE SIGNALS FOR JOBS

INVOLVING A NUMBER OF MACHINES
For jobs involving several machines, provide
signals commonly known by all personnel involved.
Also, appoint a signal person to co-ordinate the job
site. Make sure that all personnel obey the signal
persons directions.
S0036
EX255-EX285
S-11
SAFETY PRECAUTIONS
INVESTIGATE JOB SITE BEFORE HAND
When working at the edge of an excavation or on a
road shoulder, the machine could overturn, possibly
- Investigate the configuration and ground
conditions of the job site beforehand to prevent the
machine from overturning and prevent the ground,
stockpiles, or banks from collapsing.
- Make a work plan. Use machines appropriate to
the work and job site.
- Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
- When working on an incline or road shoulder,
employ a signal person as required.
possibility of falling stones or landslides.
- When footing is weak, reinforce the ground before
starting the work.
- When working on frozen ground, be extremely
alert. As ambient temperature rises, footing
becomes loose and slipped.
S0034
PROTECT AGAINST FALLING STONES

AND LANDSLIDES
possibility of falling stones.
S0035
S-12
EX255-EX285
SAFETY PRECAUTIONS
DIG WITH CAUTION
Accidental severing of underground cables or gas
lines may cause an explosion and/or fire, possibly
- Before digging, check the location of cables, gas
lines, and water lines.
- Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic
cable should be accidentally severed, do not look
into the end. Doing so may result in serious eye
injury.
- Contact local authorities and/or the utility
companies directly (electric power, gas,
telephone, water, sewers, telecommunications,
etc.) to obtain information about underground
utility lines.
S0009
OPERATE WITH CAUTION

If the front attachment or any other part of the
machine hits against an overhead obstacle, such
as a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury may
results as well.
- Take care to avoid hitting overhead obstacles
with the boom or arm.
S0008
AVOID ELECTRIC LINES

Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.
- When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m plus twice the line insulator length (L).
- Check and comply with any local regulations that
may apply.
- Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
- Keep all bystanders or co-workers away from the
site.
S0205
EX255-EX285
S-13
SAFETY PRECAUTIONS
KEEP PERSONNEL CLEAR FROM
WORKING AREA
A person may be hit severely by the swinging front
attachment or counterweight and/or may be
crushed against an other object, resulting in serious
injury or death.
- Keep all persons clear from the area of operation
and machine movement.
- Before operating the machine, set up barriers to
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.
S0044
NEVER MOVE THE BUCKET OVER ANY

ONE
Never lift, move, or swing bucket above anyone or
a truck cab.
Serious injury or machine damage may result due
to bucket load spill or due to collision with the
bucket.
S0045
AVOID UNDERCUTTING
In order to retreat from the edge of an excavation if
the footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.
- If the footing starts to collapse and if sufficient
retreat is not possible, do not panic. Often, the
machine can be secured by lowering the front
attachment, in such cases.
S0011
S-14
EX255-EX285
SAFETY PRECAUTIONS
NEVER UNDERCUT A HIGH BANK
The edges could collapse or a land slide could
occur causing serious injury or death.
S0048
SAFETY LOADS MOVING

The excavator is no lifting and transportation
means, therefore it should not be used to position
loads accurately. Should it be exceptionally used to
lift and lay building components, special caution
must be taken as follows:
- The machine must be equipped without failure
with the appropriate variant supplied, upon
request, by FIAT KOBELCO. Also, totally comply
with the safety precautions for the operation of the
excavator as a lifting equipment.
- Secure the loads to be raised using cables or
chains fastened with appropriate hooking
mechanisms.
- Never hook cables or chains to the bucket teeth.
- Nobody should be allowed to remain under the
raised load or within the excavator operating
range for any reason whatever.
S0165
- Never exceed specified loading capacity.

Incorrect fastening of slings or chains may cause
boom/arm failure or failure of the lifting means
with consequent bodily injuries and even death.
- Always ensure that slings and chains used for
lifting are adequate to the load and in good
condition.
- All loading capacities are referred to the
machine on a level surface and should be
disregarded when working on a slope.
EX255-EX285
S-15
SAFETY PRECAUTIONS
SAFETY TRANSPORTING
The danger of tipping is present when loading/
unloading the machine onto/from a truck or trailer
bed.
- Be sure to observe local regulations when
transporting the machine on public roads.
- Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading/
unloading the machine:
1. Select firm level ground.
2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when loading/
unloading the machine.
4. Always turn the auto-idle (A/I) switch OFF when
loading or unloading the machine, to avoid
unexpected speed increase due to unintentional
operation of a control lever.
5. Always select the slow speed mode with the
travel speed selector. In the high speed mode,
travel speed may automatically increase.
6. Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify travelling direction, and begin to
drive again.
7. Do not operate any levers besides the travel
levers when driving up or down the ramp.
8. The top end of the ramp where it meets the
flatbed is a sudden jolt. Take care when traveling
over it.
9. Prevent possible injury from machine tipping
while the upperstructure is rotating.
10. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11. Securely fasten machine frame using chains or
cables. Refer to TRANSPORT chapter in the
OPERATION
AND
MAINTENANCE
INSTRUCTION MANUAL for details.
S0052
S-16
EX255-EX285
SAFETY PRECAUTIONS
SAFE MAINTENANCE
To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Kepp the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it is
in motion.
- Kepp hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Switch off the Auto-Idle (A/I).
4. Let the engine idle with no load for at least five
minutes until it has cooled down.
5. Move the key-start switch to the OFF position
to stop the engine.
6. Remove the ignition key from the start switch.
7. Apply the "Maintenance in progress" tag .
This tag can be applied o the left-hand control
lever, safety lever or cab door.
8. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
9. Let the engine cool down.
- Do not leave the machine unattended if servicing
requires the engine running .
- If the machine is to be raised, place boom and arm
at an angle 90 to 110. Lock machine components
which should be raised for maintenance or repair
using suitable supporting means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary.
Refer to the the OPERATION AND
- Keep all components in good condition and
properly install. Immediately repair any fault.
- Immediately repair any damage.Replace worn or
failed components. Remove grease, oil, debris
build-ups.
- Disconnect the negative cable () from the battery
before carry out any work on the electrical system
or arc-welding on the machine.
S0053
S0054
EX255-EX285
S-17
SAFETY PRECAUTIONS
WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause serious
injury.
- Before performing any work on the machine,
attach a maintenance in progress tag. This tag can
be applied o the left-hand control lever, safety
lever or cab door.
S0055
SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without
securing the machine first.
- Always lower the attachment or tool to the ground
before working on the machine.
- If you must work on a lifted machine or
attachment, securely support the machine or
attachment.
- Do not support the machine on cinder blocks,
bollow tires, or props that may crumble under
continuous load.
- Do not work under a machine that is supported
solely by a jack.
S0054
STAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause serious
injury.
To prevent accidents, care should be taken to
ensure that hands, feet, clothing, jewelry and hair do
not become entangled when working near rotating
parts.
S0056
S-18
EX255-EX285
SAFETY PRECAUTIONS
DISPOSE OF WASTE IN THE
APPROPRIATE MANNER
Waste improperly disposed of represents a danger
for the envinronment. Potentially dangerous waste
used on the FIAT KOBELCO excavators includes
lubricants, fuel, coolant, brake fluid, filters and
batteries.
- Used sealed containers when discharging fluids.
Do not use containers for food or beverages
which may induce drinking.
- Do not spill waste over the ground, into drains, or
water beds.
S0064
- Obtain information about the correct methods to

recycle or dispose of waste from local
Authorities, collection centres or your Dealer.
WORK IN A CLEAN AREA

Before starting an operation, clean the working
area.
Clear the area from all the objects that can be
dangerous for mechanics or people in the working
area.
S0166
PROPERLY LIGHT THE WORKING AREA

Properly and safely light the working area.
- Use safe portable lamps in order to work inside
and under the machine.
- Make sure that the lamp is shielded by a cage;
the incandescent filament of a lamp, accidentally
broken, can cause fuel or oil fire.
F1480
S0167
EX255-EX285
S-19
SAFETY PRECAUTIONS
REGULARLY WASH THE MACHINE
Remove all the traces of grease, oil and deposits,
in order to avoid people accidents or damages to
things.
- Do not spray water or steam in the cab.
F1462
S0153
F1463
S0058
STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic
breakers and blades can fall and cause serious
injury or death.
- Securely store attachments and implements to
prevent falling.
- Keep bystanders away from storage areas.
PREVENT ACID SCALDS

The sulphuric acid, contained in the battery, is
poisonous.
It is strong enough to scald the skin, corrode
clothes and cause blindness, if it is sprayed into
the eyes.
To avoid dangers:
- Fill the batteries in airy areas.
- Wear eye protections and rubber gloves.
- Avoid breathing the electrolyte vapours when
topping up.
- Avoid spilling or dripping the electrolyte.
- Use proper emergency starting techniques.
If you are touched with acid sprays:
- Rinse your skin well with water.
- Put on your skin sodium bicarbonate or clay to
help the acid neutralization.
- Rinse your eyes with water for 10-15 minutes.
If you have swallowed the acid:
- Drink a big quantity of water or milk, swallow
milk of magnesia, scrabbled eggs or vegetal oil.
F1474
S0168
S-20
EX255-EX285
SAFETY PRECAUTIONS
STARTING THE ENGINE WITH
BOOSTER BATTERIES
Battery gas may explode causing serious damages
and injuries.
- If the engine is to be started using booster
batteries, ensure to comply with all procedures
detailed in the chapter OPERATING
INSTRUCTIONS of the OPERATION AND
- The operator should be sitting in the drivers seat
to keep the machine under control when the
engine starts. Starting the engine with booster
batteries is a two man operation.
S0001
- Do not use batteries that have been stored in the

cold for a long time.
- Mistakes in following procedures detailed for
starting the engine with slave batteries may
cause the batteries to explode or machine to
move unexpectedly.
PREVENT BATTERY EXPLOSIONS

Battery gas can explode.
- Keep sparks, lighted matches, and flames away
from the top of battery.
- Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
- Do not charge a frozen battery; it may explode.
Warm battery to 16 C.
Battery electrolyte is poisonous. If the battery

should explode, battery electrolyte may be
splashed into eyes, possibly resulting in blindness.
- Be sure to wear eye protection when checking
electrolyte specific gravity.
S0001
EX255-EX285
S-21
SAFETY PRECAUTIONS
PREVENT BURNS
Hot spraying fluids:
After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
- To prevent possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap.
- The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.
S0019
Hot fluids and surfaces:

Engine oil, reduction gear oil and hydraulic oil also
become hot during operation.
The engine, hoses, lines and other parts become hot
as well.
- Wait for the oil and components to cool down
before starting any maintenance or inspection
work.
S0059
KEEP CLEAN THE MACHINE

Keep clean the engine compartment, radiator,
batteries, hydraulic pipes, fuel tank and operator's
position.
The engine compartment temperature can quickly
rise, after stopping the engine.
IN THESE CASES, BE CAREFUL TO POSSIBLE
FIRES.
Open the access doors in order to quicken the engine
cooling process and clean the compartment.
S0177
S-22
EX255-EX285
SAFETY PRECAUTIONS
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
- Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
SA0016
- Tighten all connections before applying

pressure.
- Search for leaks with a piece of cardboard; take
care to protect hands and body from highpressure fluids. Wear a face shield or goggles for
eye protection.
SA0017
- In an accident occurs, see a doctor familiar with

this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA0018
PREVENT PARTS FROM FLYING OFF

Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result
in serious injury, blindness, or death.
- NEVER attempt to remove GREASE FITTING
or VALVE ASSEMBLY.
face away from valve.
Travel reduction gears are under pressure.

face away from AIR RELEASE PLUG to avoid
injury. REDUCTION GEAR OIL is hot. Wait for
gear oil to cool down, then gradually loosen the air
release plug to release pressure.
F3635
S0178
EX255-EX285
S-23
SAFETY PRECAUTIONS
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body,
serious injury may result.
- Guard against injury from flying pieces of metal or
debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.
S0046
HANDLE FLUIDS SAFELY - AVOID

FIRES
Handle fuel with care: it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur,
- Do not refuel the machine while smoking or when
near open flame or sparks.
- Always stop the engine before refuelling the
machine.
- Fill the tank outdoors.
S0050
All fuels, most lubrificants, and some antifreeze

fluids are flammable.
- Store flammable fluids well away from fire
hazards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn
spontaneously.
S0051
S-24
EX255-EX285
SAFETY PRECAUTIONS
PREVENT FIRES
Check for Oil Leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other,
damage to the oil-cooler, and loose oil-cooler
flange bolts which may cause oil leaks.
- Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oilcooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts circuits which could cause fires:
- Clean and tighten all electrical connections.
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
Check Key-start Switch:
- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF position
to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:
- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S0051
EX255-EX285
S-25
SAFETY PRECAUTIONS
EVACUATING IN CASE OF FIRE
If a fire breaks out, evacuate the machine in the
following way:
- Stop the engine by turning the key-start switch to
the OFF position if there is time.
- Use a fire extinguisher if there is time.
- Exit the machine.
S0060
BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
- If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
S0061
USE APPROPRIATE TOOLS

Use tools appropriate for the job to be performed.
- Inappropriate tools, parts and procedures might
generate dangerous conditions.
- Use tools of correct size to tighten or loosening
securing elements, in order to avoid injuries
caused by a wrench getting out of control.
- Do not use U.S. Standard or British Standard
tools on metric fasteners and vice versa.
Use only FIAT KOBELCO genuine spare parts
(please refer to the PARTS CATALOG).
S0120
S-26
EX255-EX285
SAFETY PRECAUTIONS
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable materials.
Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other
materials when welding, soldering, etc.
S0062
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
- Do not weld or flame cut pipes or tubes that contain
flammable fluids.
- Clean them thoroughly with non-flammable solvent
before welding or flame cutting them.
REMOVE PAINT BEFORE WELDING OR

HEATING
Hazardous fumes can be generated when paints is
heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
- Avoid breathing potentially toxic fumes and dust.
- Do all such work outside or in a well-ventilated
area.
- Dispose of paint and solvents properly.
- Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the
dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
S0063
WORKSHOP MANUAL
EX255-EX285
ESCAVATOR
Section 1 - GENERAL INFORMATION

Group 1
Group 2
- Precautions for Disassembly and Assembly

- Tightening Torque
Section 2 - UPPERSTRUCTURE
Group 1
Group 2
Group 3
Group 4
Group 5
Group 6
Group 7
Group 8
Group 9
Group 10
Group 11
Cab
Counterweight
Main Frame
Pump Device
Control Valve
Swing Device
Pilot Valve
Shockless Valve
Solenoid Valve Unit
Pilot Relief Valve Unit
Section 3 - UNDERCARRIAGE
Group 1
Group 2
Group 3
Group 4
Group 5
Group 6
Group 7
Swing Bearing
Travel Device
Center Joint
Track Adjuster
Front Idler
Upper and Lower Roller
Tracks
Section 4 - FRONT ATTACHMENT

Group 1
Group 2
- Front Attachment
- Cylinders
Section 5 - ENGINE AND ACCESSORY

Group 01
Group 02
Group 03
Group 04
Group 05
Group 06
Group 07
Group 08
Group 09
Group 10
Group 11
Group 12
General Information
Maintenance
Engine Disassembly
Engine Inspection and Repair
Engine Reassembly
Lubricating System
Cooling System
Fuel System
Turbocharger
Starting and Charging
Troubleshooting
Repair Standards
SECTION 1
EX255-EX285
GENERAL INFORMATION
CONTENTS
Group 1 - Precautions for Disassembly and Assembly
Precautions for Disassembly and
Assembly ............................................. W1-1-1
Group 2 - Tightening Torque

Tightening Torque Specification .............. W1-2-1
Torque Chart .......................................... W1-2-2
Piping Joint ............................................ W1-2-5
EX255-EX285
W1-1-1
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

PRECAUTIONS FOR DISASSEMBLY AND
ASSEMBLY
Preparations for Disassembly
Precautions for Disassembly and Assembly
Clean the Machine
- To prevent dirt from entering, cap or plug the

removed pipes.
- Before disassembling, clean the exterior of the
components and place it on a work bench.
- Before disassembling, drain gear oil from the
reduction gear.
- Be sure to provide appropriate containers for
draining fluids.
- Use matching marks for easier reassembling.
- Be sure to use the specified special tools, when
instructed.
- If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
- Orderly arrange disassembled parts. Mark and
tag them as necessary.
- Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
- Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or
other damage.
- Measure and record the degree of wear and
clearances.
Thoroughly wash the machine before bringing it

into the shop. Bringing a dirty machine into the
shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well
as decreased efficiency in service work.
Inspect the Machine

Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help
avoid incorrect disassembling of components as
well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
- The machine model, machine serial number, and
hour meter reading.
- Reason for disassembly (symptoms, failed
parts, and causes).
- Clogging of filters and oil, water or air leaks, if
any.
- Capacities and condition of lubricants.
- Loose or damaged parts.
Prepare and Clean Tools and Disassembly Area

Prepare the necessary tools to be used and the
area for disassembling work.
Precautions for Disassembly
Precautions for Assembly

- Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace it.
- Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
- Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled. Apply a film of grease before installing.
- Be sure that liquid-gasket-applied surfaces are
clean and dry.
- If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to
remove the agent.
- Utilize matching marks when assembling.
- Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
- Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no tools are missing.
W1-1-2
EX255-EX285

Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:
Bleeding Air from Hydraulic Pump
IMPORTANT - If the engine is started with air trapped

in the hydraulic pump housing, damage to the pump
may result. Be sure to bleed air before starting the
engine.
- Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
- After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the
engine and run at slow idle speed.
- Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
- After bleeding all the air, securely tighten the
plug.
Bleeding Air from Travel Motor / Swing Motor

- With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.
Bleeding Air from Hydraulic Circuit

- After refilling hydraulic oil, start the engine. While
operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each
operation (never fully stroke the cylinders during
initial operation stage). As the pilot oil circuit has
an air bleed device, air trapped in the pilot oil
circuit will be bled while performing the above
operation for approx. 5 minutes.
- Reposition the front attachment to check hydraulic oil level.
- Stop the engine. Recheck hydraulic oil level.
Replenish oil as necessary.
SM1000
EX255-EX285
W1-1-3

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. Insert a piece of
cardboard to protect surfaces.
B
(2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear.
SM1001
(3) Check O-ring (B) for tears, breaks, deformation

or hardening.
2. If incorrectly assembled, oil leakage or damage will

occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting bores
with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with compressed air.
CORRECTLY
INCORRECTLY
(2) Clean the floating seal and seal mounting bores,

as dust on them tends to enter the floating seal
when installing it.
(3) Check that the O-ring is not twisted, and that it
is installed correctly on the seal ring.
(4) After installing the floating seal, check that seal
ring surface (C) is parallel with mating face (A)
by measuring the distances (a) and (b), as
illustrated. If these distances differ, correct the
O-ring seating.
SM1002
CORRECTLY
INCORRECTLY
A
a
C
B
b
a=b
b
ab
SM1003
W1-1-4
EX255-EX285

NOTES:
EX255-EX285
W1-2-1
TIGHTENING TORQUE
TIGHTENING TORQUE SPECIFICATIONS
No. Descriptions
Bolt Diam.
mm
Wrench
Size
mm
Torque
Nm
kgf m
lbf ft
Engine cushion rubber mounting bolt
18
27
392
40
290
Engine bracket mounting bolt
10
12
17
19
64
108
6.5
11
47
80
Hydraulic oil tank mounting bolt
20
30
390
40
290
Fuel tank mounting bolt
16
24
205
21
152
ORS fittings for hydraulic hoses and piping
* 1-3/16"-12
* 1-7/16"-12
* 1-11/16"-12
36
41
50
175
205
324
18
21
33
130
152
239
Pump device mounting bolt
10
17
49
36
Control valve mounting bolt
16
24
205
21
152
Control valve bracket mounting bolt
16
24
205
21
152
Swing device mounting bolt
22
32
665
68
490
10
Battery mounting bolt
10
17
9.8
11
Cab mounting nut
16
24
205
21
152
12
Swing bearing mounting bolt to upperst.

Swing bearing mounting bolt to undercar.
27
27
41
41
1230
1205
125
123
900
890
13
Travel device mounting bolt
20
30
620
63
456
14
Sprocket mounting bolt
20
30
490
50
362
15
Upper roller mounting bolt
16
24
265
27
195
16
Lower roller mounting bolt
20
30
500
51
369
17
Track shoe mounting bolt
22
32
940
96
694
18
Low pressure coupling and clamp
8
5
6
13
8
10
10.3to12.4
2.90
4.40
1.05to1.26
0.30
0.45
8 to 16
2
3
*: UNF thread
NOTE - (1) Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to stabilize friction
coefficient of them.
(2) Make sure bolt and nut threads are clean before installing.
(3) Apply Loctite to threads before installing and tightening swing bearing mounting bolts.
W1-2-2
EX255-EX285
TIGHTENING TORQUE
TORQUE CHART
WARNING
Use tools appropriate for the work to be done.
Makeshift tools and procedures can create safety
hazards. For loosening and tightening nuts and
bolts, use the correct tools. Avoid bodily injury
caused by slipping wrenches.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.
Four kinds of bolts, hexagon bolts T, H, M and socket
bolt, each made of different material, are used. Make
sure to employ the correct bolts and tighten them to
specification when assembling the machine or components.
Hexagon T Bolt
Hexagon H Bolt
SM1004
Hexagon M Bolt
Socket Bolt
SM1005
Specified Tightening Torque Chart

Bolt
Dia.
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
Wrench Hexagon
Size
Wrench
13
17
19
22
24
27
30
32
36
41
46
50
55
T Bolt, Socket bolt
H Bolt
M Bolt
Size
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
6
8
10
12
14
14
17
17
19
19
22
24
27
29.5
64
108
175
265
390
540
740
930
1 370
1 910
2 550
3 140
3
6.5
11
18
27
40
55
75
95
140
195
260
320
22
47
80
130
195
290
400
540
690
1 010
1 410
1 880
2 310
19.5
49
88
137
205
295
390
540
690
1 030
1 420
1 910
2 400
2
5
9
14
21
30
40
55
70
105
145
195
245
14.5
36
65
101
152
220
290
400
505
760
1 050
1 410
1 770
9.8
19.5
34
54
78
118
167
215
275
390
540
740
930
1
2
3.5
5.5
8
12
17
22
28
40
55
75
95
7.2
14.5
25.5
40
58
87
123
159
205
290
400
540
690
EX255-EX285
W1-2-3
TIGHTENING TORQUE
IMPORTANT
(1) Apply lubricant (i. e. white zinc B dissolved into
spindle oil) to nuts and bolts to stabilize their
friction coefficients.
(2) Torque tolerance is 10 %.
(3) Be sure to use bolts of correct length. Bolts that are
too long cannot be tightened, as the bolt tip comes
into contact with the bottom of the bolt hole. Bolts
that are too short cannot develop sufficient tightening force.
(4) The torques given in the chart are for general use
only.
Do not use these torques if a different torque is
given for a specific application.
(5) Make sure that the nut and bolt threads are clean
before installing. Remove dirt or corrosion, if any.
Bolt Tightening Order

When tightening two or more bolts, tighten them
alternately, as shown, to ensure even tightening.
Equally tighten upper

and lower alternately
Tighten diagonally
1
1,4
2,3
Tighten from center and diagonally
12
14
13
10
11
3
5
2
SM1006
W1-2-4
EX255-EX285
TIGHTENING TORQUE
Service Recommendations for Split Flange
IMPORTANT
(1) Be sure to clean and inspect sealing surfaces.
Scratches / roughness cause leaks and seal wear.
Unevenness causes seal extrusion. If defects
cannot be polished out, replace the component.
(2) Be sure to use only specified O-rings. Inspect Orings for any damage. Take care not to file O-ring
surfaces. When installing an O-ring into a groove,
use grease to hold it in place.
(3) Loosely assemble split flange halves. Make sure
that the split is centrally located and perpendicular
to the port. Hand-tighten the bolts to hold the parts
in place. Take care not to pinch the O-ring.
(4) Tighten bolts alternately and diagonally, as shown,
to ensure even tightening.
(5) Do not use air wrenches. Using an air wrench often
causes tightening of one bolt fully before tighten
the others, resulting in damage to O-rings or uneven tightening of bolts.
SM1007
WRONG
SM1008
Nut and Bolt Lockings
Lock Plate
SM1009
IMPORTANT- Do not reuse lock plates. Do not try to

bend the same point twice.
RIGHT
Cotter Pin
IMPORTANT- Do not reuse cotter pins. Match the

holes in the bolt and nut while tightening, not while
loosening.
Bend along edge sharply
RIGHT
WRONG
RIGHT
Do not bend it round
WRONG
Lock Wire
IMPORTANT - Apply wire to bolts in the bolt-tightening

direction, not in the bolt-loosening direction.
Bend along edge sharply

SM1010
RIGHT
RIGHT
RIGHT
WRONG
WRONG
Loosen
Tighten
SM1011
EX255-EX285
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
(1) Do not over-tighten union nut (3). Excessive force
will be applied to metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be sure to tighten
union nut (3) to specifications.
SM1012
37
(2) Scratches or other damage to sealing surfaces (4)

or (5) will cause oil leakage at the joint. Take care
not to damage them when connecting /disconnecting.
37
Male Union Joint
Female Union Joint

SM1013
Wrench Size
Type
37 Union Joint
Tightening Torque
Union Nut
Joint Body
Nm
kgf m
lbf ft
19
22
27
36
41
50
17
19
22
30, 32
36
46
29
39
78.5
157
205
255
3
4
8
16
21
26
22
29
69
116
152.5
188
NOTE - Tightening torque for the non-union type 37 male joint is the same as the 37 female union joint.
W1-2-6
EX255-EX285
TIGHTENING TORQUE
O-ring Seal Joint
O-ring (6) seats against the end face of adaptor (7) to
seal pressure oil.
7
IMPORTANT
(1) Be sure to replace O-ring (6) with a new one when
reconnecting.
(2) Before tightening union nut (9), confirm that Oring (6) is seated correctly in O-ring groove (8).
Tightening union nut (9) with O-ring (6) displaced
will damage O-ring (6), resulting in oil leakage.
10
Joint body
SM1014
(3) Take care not to damage O-ring groove (8) or

sealing face (10). Damage to O-ring (6) will cause
oil leakage.
(4) If union nut (9) is found to be loose, causing oil
leakage, do not tighten it to stop the leak. Instead,
replace O-ring (6) with a new one, then tighten union
nut (9) after confirming that O-ring (6) is securely
seated in place.
Wrench Size
Tightening Torque
Union
Nut
Joint
Body
Nm
kgf m
lbf ft
27
22
30, 32
36
46
93
175
205
320
9.5
18
21
33
69
130
152
240
36
41
50
EX255-EX285
W1-2-7
TIGHTENING TORQUE
Screwed-In Connection
PT
PF
30
IMPORTANT - Many types of screwed-in connections are used for hose connections.
Be sure to confirm that the thread pitch and thread type
(tapered or straight) are the correct type before using
any screw-in connection.
Male Tapered Thread
Male Straight Thread

SM1015
Male Tapered Thread

Wrench
Tightening Torque
Joint Body
Nm
kgf m
lbf ft
17, 19
19, 22
27, 22
36, 32
41
50
60
34
49
93
157
205
320
410
3.5
5
9.5
16
21
33
42
25
36
69
116
152.5
240
300
Internal Thread
Seal Tape Application

Seal tape is used to seal clearances between male and
female threads, so as to prevent any leakage between
threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap.
Clearance
External Thread
SM1016
Leave one to two pitch threads uncovered
Application Procedure
Confirm that the thread surface is clean, free of dirt
or damage.
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads.
SM1017
Low-Pressure-Hose Clamp Tightening Torque
T-Bolt Type
Worm Gear Type
Low-pressure-hose clamp tightening torque differs

depending on the type of clamp.
See below for correct tightening torque of each type of
low-pressure-hose clamp.
T-Bolt Type Band Clamp:
4.4 N m (0.45 kgf m, 3.25 lbf ft )
Worm Gear Type Band Clamp:
5.9 to 6.9 N m (0.6 to 0.7 kgf m, 4.3 to 5.1 lbf ft )
SM1018
SM1019
W1-2-8
EX255-EX285
TIGHTENING TORQUE
WRONG
Connecting Hose
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.
(2) Do not install hoses kinked. Application of high
oil pressure, vibration, or an impact to a kinked
hose may result in oil leakage, hose rupture or
separation of fitting. Utilize print marks on
hoses when installing hoses to prevent hose
from being installed kinked.
(3) If hoses rub against each other, wear to the
hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other.
Take care that hoses do not come into contact
with moving parts or sharp objects.
SM1020
WRONG
RIGHT
Rubbing Against Each Other
SM1021
WRONG
Clamp
RIGHT
Clamp
Rubbing
SM1022
WRONG
RIGHT
Rubbing
Clamp
SM1023
SECTION 2
EX255-EX285
UPPERSTRUCTURE
CONTENTS
Group 1 -
Cab
Remove and Install Cab ....................... W2-1-1
Group 2 -
Counterweight
Remove and Install Counterweight ....... W2-2-1
Group 3 -
Main Frame
Remove and Install Main frame ............ W2-3-1
Group 4 -
Pump Device
Remove and Install Pump Device ........ W2-4-1

Disassemble Pump Device .................. W2-4-2
Assemble Pump Device ..................... W2-4-10
Disassemble Regulator ...................... W2-4-22
Assemble Regulator ........................... W2-4-24
Disassemble and Assemble
Pilot Pump ......................................... W2-4-26
Maintenance Standard ....................... W2-4-28
Group 5 -
Control Valve
Remove and Install Control Valve ......... W2-5-1

Disassemble Control Valve 1 ................ W2-5-2
Assemble Control Valve 1-1 ................. W2-5-6
Assemble Control Valve 1-2 ................. W2-5-8
Disassemble Control Valve 2 .............. W2-5-10
Assemble Control Valve 2-1 ............... W2-5-14
Assemble Control Valve 5 .................. W2-5-40
Group 6 -
Swing Device
Remove and Install Swing Device ........ W2-6-1

Disassemble Swing Device (EX255) .... W2-6-2
Assemble Swing Device (EX255) ......... W2-6-6
Disassemble Swing Device (EX285) .. W2-6-12
Assemble Swing Device (EX285) ....... W2-6-16
Disassemble Swing Motor (EX255) .... W2-6-22
Assemble Swing Motor (EX255) ......... W2-6-26
Disassemble Swing Motor (EX285) .... W2-6-30
Assemble Swing Motor (EX285) ......... W2-6-34
Parking Brake Release Valve (EX285) W2-6-38
Group 7 -
Pilot Valve
Remove and Install Right Pilot Valve .... W2-7-1

Remove and Install Left Pilot Valve ...... W2-7-4
Remove and Install Travel
Pilot Valve ............................................ W2-7-7
Disassemble Right and Left
Pilot Valve ............................................ W2-7-8
Assemble Right and Left
Pilot Valve .......................................... W2-7-10
Disassemble Travel Pilot Valve ........... W2-7-14
Assemble Travel Pilot Valve ............... W2-7-16
Positioning Pilot Valve
(Triple Articulation Version) ................. W2-7-20
Special Tools ...................................... W2-7-31
Group 8 -
Pilot Shut-off Valve
Remove and Install Pilot

Shut-off Valve ...................................... W2-8-1
Disassemble Pilot Shut-off Valve ......... W2-8-2
Assemble Pilot Shut-off Valve .............. W2-8-4
Group 9 -
Shockless Valve
Remove and Install Shockless Valve ... W2-9-1

Shockless Valve .................................. W2-9-2
Group 10 -
Solenoid Valve Unit
Remove and Install Solenoid

Valve Unit .......................................... W2-10-1
Disassemble Proportional
Solenoid Valve ................................... W2-10-2
Assemble Proportional
Solenoid Valve ................................... W2-10-4
Group 11 -
Pilot Relief Valve Unit
Remove and Install Pilot Relief

Valve Unit .......................................... W2-11-1
Disassemble Pilot Relief Valve ........... W2-11-2
Assemble Pilot Relief Valve ............... W2-11-4
EX255-EX285
W2-1-1
CAB
REMOVE AND INSTALL CAB
Remove Cab
1. Remove nuts (2) and seat (1).
: 13 mm
1
2
SM1125
2. Loosen bolts (6) (3 used) and bolts (4) (4 used)

behind the cab and remove rear cover (5).
: 13 mm
4
3. Loosen bolts (8) to remove rear under cover (7).

: 13 mm
6
SM1126
4. Remove filter (20). Loosen screws (9) to remove

duct (10) from the cab.
20
9
10
SM1127
W2-1-2
EX255-EX285
CAB
5. Disconnect cable connectors (11, relais), (12, antenna, ceiling lamp and windshield wiper), (13,
loudspeaker) behind the cab and ground (14) inside
the cab.
12
13
11
SM5526
6. Remove washer vinyl hose (15) behind the cab.
SM5509
7. Remove cap (21) from duct cover (16). Loosen

screws (17) to remove duct cover (16).
21
17
16
SM1130
8. While pushing the mating surface of duct (18)

toward the rear side of the cab, remove duct (18).
Mating surface of duct
18
SM1131
EX255-EX285
W2-1-3
CAB
9. Attaccare la cabina al paranco utilizzando cinghie
di sollevamento.
WARNING
The approximate weight of cab:
250 kg (551 lb)
SM1132
10. Remove bolts (19) and nuts (22).

: 17 mm
19
: 24 mm
: 8 mm
22
SM1133
11. Carefully remove cab.
SM1134
W2-1-4
EX255-EX285
CAB
Installation
WARNING
The approximate weight of cab:
250 kg (551 lb)
1. Attach cab to hoist using straps.

Install cab onto frame.
SM1134
2. Tighten bolts (19) and nuts (22).

: 17 mm
19
: 49 N m (5 kgfm, 36 lbf ft)

22
: 24 mm
: 205 N m (21 kgf m, 152 lbf ft)
: 8 mm
SM1133
: 64 N m (6.5 kgf m, 47 lbf ft)
3. Install duct (10) to the cab with screws (9).

Install filter (20) into duct (10).
: 4.9 N m (0.5 kgf m, 3.6 lbf ft)
20
9
10
4. Install harness connectors (11, relais), (12, antenna, ceiling lamp and windshield wiper), (13,
loudspeaker) behind the cab and ground (14)
inside the cab.
SM1127
12
13
: 19.5 N m (2 kgf m, 14.5 lbf ft)
11
SM5526
EX255-EX285
W2-1-5
CAB
5. Connect washer vinyl hose (15) at the rear of the
cab inside.
SM5509
6. Install rear under cover (7) with bolts (8).
: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)
4
7. Install rear cover (5) with bolts (6) (3 used) and

bolts (4) (4 used).
: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)
6
SM1126
8. Push duct (18) toward the front of the cab to insert

it into the front duct.
Mating surface of duct
18
SM1131
W2-1-6
EX255-EX285
CAB
9. Install duct cover (16) with screws (17).
Install caps (21) onto duct cover (16).
21
17
16
SM1130
10. Secure seat (1) with nuts (2).

: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)
1
2
SM1125
EX255-EX285
W2-2-1
COUNTERWEIGHT
REMOVE AND INSTALL COUNTERWEIGHT
1
Removal
WARNING
Approximate weight of counterweight:
5 700 kg (12 566 lb)
1. Remove caps (1) from counterweight.

Install eye-bolts to the counterweight.
SM1135
Eye-bolts: M36, Pitch 4.0
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.
SM1136
3. Remove bolts (3).

Lift counterweight using a crane or hoist.
: 46 mm
SM1137
4. Lower the counterweight on proper stand.
SM1138
W2-2-2
EX255-EX285
COUNTERWEIGHT
Installation
WARNING
Approx. weight of counterweight:
5 700 kg (12 566 lb)
1. Attach lifting tools to counterweight.

Lift counterweight (4) and install it onto the frame.
Install bolts (3) and washers to counterweight and
tighten temporarily.
4
3
: 46 mm
SM1137
2. Remove wire rope.

Tighten the bolts with a power wrench (6) and
torque wrench (7).
: 46 mm
: 1 570 N m (160 kgf m, 1 157 lbf ft)
3. Remove the eye-bolts.

Install caps (1) to counterweight.
SM1139
SM1135
EX255-EX285
W2-3-1
MAIN FRAME
REMOVE AND INSTALL MAIN FRAME
WARNING
Escaping fluid under pressure can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns.
Be sure to wait for oil and components to cool before starting work.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release
valve on top of the hydraulic oil tank to release any remaining pressure.
Preparation
1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top
of the hydraulic oil tank to release any remaining
pressure.
Refer to "Hydraulic Circuit Pressure Release Procedure" on page W4-2-12.
3. Remove hydraulic oil tank cap. Connect a vacuum

pump to maintain negative pressure in the hydraulic oil tank.
NOTE - Be sure to run the vacuum pump continuously

while working.
Removal
WARNING
Approximate weight of cab: 250 kg (551 lb)
1. Remove cab assembly. (See Cab section)
: 24 mm, 17 mm, 13 mm
: 8 mm
SM1134
WARNING
5 700 kg (12 566 lb)
2. Remove the counterweight.

(See Counterweight section)
: 46 mm
SM1136
W2-3-2
EX255-EX285
MAIN FRAME
WARNING
Approx. weight of front attachment assembly:
EX255 monobloc: 4550 kg (10 031 lb)
EX255 triple articulation: 4890 kg (10 780 lb)
3. Remove front attachment assembly from the

upperstructure. (See Front Attachment section)
: 19 mm, 30 mm, 36 mm, 41 mm
SM1140
4. Drain hydraulic oil from the hydraulic oil tank, and

disconnect hydraulic lines from the control valve to
the center joint on top of the center joint.
Disconnect drain hose, and remove the fitting and
stopper from the center joint.
: 19 mm, 22 mm, 27 mm, 36 mm
SM1141
EX255-EX285
W2-3-3
MAIN FRAME
WARNING
Approximate weight of main frame:
EX255: 4000 kg (8818 lb)
EX285: 4500 kg (9921 lb)
5. Attach wire ropes to the front and rear of main

frame. See wire ropes taut using a crane. Use chain
blocks for easy adjustment of wire rope lengths and
to level the frame.
Rear
SM1142
IMPORTANT - Make sure rear slings do not touch

engine.
Front
SM1143
SM1144
6. Put matching marks on swing bearing and main

frame.
Remove bolts (14) from the swing bearing.
: 32 mm
14
SM1380
W2-3-4
EX255-EX285
MAIN FRAME
7. Lift main frame slightly from undercarriage.
Level main frame by adjusting the chain blocks.
Remove main frame.
SM1146
EX255-EX285
W2-3-5
MAIN FRAME
Installation
13
WARNING
Approximate weight of main frame:
EX255: 4000 kg (8818 lb)
EX285: 4500 kg (9921 lb)
1. Fasten hoist to front and rear of main frame.

Level main frame by adjusting chain blocks (13)
and lower main frame onto undercarriage.
Align the matching mark on the swing bearing with
that on the main frame.
SM1146
2. Install bolts (14) on the swing bearing and tighten

temporary.
Install main frame and tighten bolts to specification.
: 32 mm
Upperstructure side
: 640 N m (65 kgf m, 470 lbf ft)
14
SM1380
3. Install fitting (10) and connect hose (8) to the

center joint.
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
Connect lines (4 to 7).

: 22 mm, 27 mm, 36 mm
: 39 N m (4 kgf m, 29 lbf ft)
: 93 N m (9.5 kgf m, 69 lbf ft)
Install stopper (9).

: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)
10
SM1141
W2-3-6
EX255-EX285
MAIN FRAME
WARNING
4. Install front attachment assembly (3).

(See Front Attachment section)
: 19 mm
: 29.5 N m (3 kgf m, 21.5 lbf ft)
: 30 mm
: 540 N m (55 kgf m, 400 lbf ft)
: 36 mm
: 137 N m (14 kgf m, 101 lbf ft)
3
: 41 mm
SM1140
: 205 N m (21 kgf m, 152 lbf ft)
WARNING
5 700 kg (12 566 lb)
1
5. Install counterweight (1).
(See Counterweight in this section)
: 46 mm
: 1 570 N m (160 kgf m, 1 157 lbf ft)
SM1136
WARNING
Approximate weight of cab: 250 kg (551 lb)
6. Install cab (2).

(See Cab in this section)
2
: 24 mm
: 205 N m (21 kgf m, 159 lbf ft)
: 17 mm
: 49 N m (5 kgf m, 36 lbf ft)
: 13 mm
: 20 N m (2 kgf m, 14 lbf ft)
: 8 mm
: 64 N m (6.5 kgf m, 47 lbf ft)
SM1134
EX255-EX285
W2-3-7
MAIN FRAME
7. Fill the hydraulic oil tank with hydraulic oil to the
specified level.
Run the engine at slow idle. Check hose connections for any oil leakage.
SM1147
W2-3-8
EX255-EX285
MAIN FRAME
NOTES:
EX255-EX285
W2-4-1
PUMP DEVICE
REMOVE AND INSTALL PUMP DEVICE
WARNING
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.
Preparation
pressure.

while working.
Removal
Air bleed plug
1. Disconnect connectors.
WARNING
Pump device weight: 170 kg (375 lb)
10
3
9
2. Disconnect hoses (1 to 4, 6 to 10) and pipe (5) from
the pump device.
: 19 mm, 22 mm, 27 mm, 36 mm
: 8 mm, 10 mm
4
8
7
3. Attach eyebolts (M12, Pitch 1.75, Length 22) to the
pump device, then connect to a hoist.
4. Remove pump device mounting bolts to remove
pump device.
Installation
1. Install the pump device with pump device mounting
bolts.
2. Connect hoses (1 to 4, 6 to 10) and pipes (5).
3. Connect connectors.
IMPORTANT - Be sure to check hydraulic oil level and
oil leakage, after assembling.
Bleed the air from the pump. (Refer to W1-1-2)
: 41 mm
SM1044
: 17 mm
Wrench
Size (mm)
Tightening Torque
Nm
Remark
kgf m lbf ft
: 27
93
9.5
69
Hose
: 36
69
51
Hose
: 10
108
11
80
Bolt
: 17
49
36
Bolt
:8
49
36
Bolt
: 19
29
22
Hose
: 22
49
36
Pipe
: 78 N m (8 kgf m, 58 lbf ft)
W2-4-2
EX255-EX285
PUMP DEVICE
DISASSEMBLE PUMP DEVICE
69
97
79
81
97
70
98
98
68
65
66
17
24
21
22
87
20
74 8
87 9
67
73
38
72
66 68
74
19
83
11
24
84
12
62
82
2
20
8
9
13
38
67
38
49
18
12
38
49
61
13
55
SM1045
52
36
47
23
48
15
34
45
37
46
1
32
16
31
30
40
14
39
41
28
43
3
54
53
55
26 25
SM1046
5 4
19
EX255-EX285
W2-4-3
PUMP DEVICE
88
51
96
50
74
74
85
75
86
64
60
93
38
38
71
89
44
92
35
75
35
64
75
35 33
57
58
42
29 33
27
77
76
91
56 59
33
78
96
35
77
76
35 90
29
88
33 75
78
SM1047
1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Gear Casing
Pump Casing
Pilot Gear
Gear Shaft
Bearing (2 Used)
Retaining Ring
Retaining Ring
Bearing (2 Used)
Bearing Nut (2 Used)
Drive Disc
Oil Seal (2 Used)
Retaining Ring (2 Used)
Gear
Gear
Drive Disc
Spring Pin (2 Used)
Plunger (14 Used)
Spacer Ring (2 Used)
Bolt (6 Used)
Spring Washer (6 Used)
Packing
Bearing (2 Used)
Oil Seal
Retaining Ring
Valve Plate
Pilot Pump
Pin (4 Used)
Socket Bolt (2 Used)
Washer (2 Used)
Pin (4 Used)
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
64
Adapter (2 Used)
Plug
Level Gauge
O-Ring (6 Used)
Pipe Gauge
Packing
Servo Piston (2 Used)
Plug
Set Screw (2 Used)
N sensor
(Engine Speed Sensor)
O-Ring
Washer
Socket Bolt
Plug (2 Used)
O-Ring (2 Used)
Stopper (2 Used)
Plug (2 Used)
Adapter
Plug
Fitting plug (2 Used)
Servo Pipe
Clamp (2 Used)
Bolt
Spring Washer
O-Ring (2 Used)
Thrust Ring
Pump Pressure Sensor
(2 Used)
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
81
82
83
84
85
86
87
88
89
90
91
92
93
96
97
98
Pin (2 Used)
Center Shaft (2 Used)
Plug (2 Used)
Spring (2 Used)
Regulator (2 Used)
Cylinder Block (2 Used)
Valve Plate
Spring Pin (4 Used)
O-Ring (2 Used)
O-Ring (20 Used)
Lever (4 Used)
Pin (2 Used)
Link (2 Used)
Pin (2 Used)
Pipe
Adapter (2 Used)
Clamp
Socket Bolt
Spring Washer
Backup Ring
O-Ring
O-Ring (4 Used)
Spring Pin (2 Used)
Stopper (2 Used)
O-Ring (2 Used)
Pin (2 Used)
Selector Head
Spring Washer(16 Used)
W2-4-4
EX255-EX285
PUMP DEVICE
69
79
81
97
SM1045
83
84
82
2
88
51
96
50
74
74
60
93
64
44
92
64
36
47
57
58
42
48
91
56 59
96
34
45
90
88
46
1
43
53
55
SM1046
SM1048
EX255-EX285
W2-4-5
PUMP DEVICE
Disassemble Pump Device
1. Remove plug (43) to drain oil.
Drain oil: Approx. 1.0 L (1.06 US qt)
8. Remove socket bolts (88), spring washers (96),

stoppers (90), (51) and O-rings (91), (50), (74) from
selector head (93).
: 6 mm
: 8 mm
2. Remove plug (36) and adapters (34).
IMPORTANT - Be sure to heat set screw (44) to

remove it. LOCTITE 829 was applied to set screw (44)
when installed.
: 17 mm, 36 mm
9. Remove set screws (44), pins (92) and servo
pistons (42) from selector head (93).
3. Loosen socket bolt (83) and then remove spring
washer (84), clamp (82) and N sensor (45) connectors from pump casing (2).
: 5 mm
: 6 mm
10. Remove socket bolt (48), spring washer (47), N

sensor (45) and O-ring (46) from gear casing (1).
: 5 mm
WARNING
Pump device weight: 170 kg (375 lb)
4. Place the pump device with the transmission side

positioned to the bottom side and secure it.
5. Remove bolt (58), adapter (53) and fitting plug (55).

Remove spring washer (59), clamp (57) and servo
pipe (56) from selector head (93).
: 13, 17, 19 mm
WARNING
Selector head weight: 30 kg (66 lb)
6. Remove socket bolts (60) from selector head (93).

Remove selector head (93) assembly from pump
casing (2).
: 10 mm
7. Remove pump pressure sensors (64) from selector

head (93).
: 27 mm
11.Remove pipe (79) and adapters (81) from regulators (69).

: 22 mm
W2-4-6
EX255-EX285
PUMP DEVICE
85
75
86
71
35
89
75
35
75
35 33
29 33
27
77
76
33
78
35
77
35
29
SM1047
76
33
75
78
69
97
81
97
70
98
98
68
65
66
74
21
22
73
87
66 68
74
19
SM1045
19
EX255-EX285
W2-4-7
PUMP DEVICE
12. Loosen socket bolts (97) and remove spring washers (98), regulators (69) and O-rings (73), (74), (87)
from pump casing (2).
: 8 mm
13. Remove backup ring (85), O-ring (86) and spring

pins (89).
IMPORTANT - Valve plates (27) and (71) are exclusively used in the right and left pumps respectively.
Take care not to mistake the up and down positions.
14. Remove retaining rings (35) and pins (29) to

remove valve plates (27), (71).
: 7 mm
15. Remove cylinder blocks (70), center shafts (66),

springs (68) and plungers (19) from pump casing
(2).
16. Remove links assemblies (77) from pump casing

(2).
17. Remove retaining rings (35), pins (78), (33), (76)

and levers (75) from links (77).
WARNING
Pump casing weight: 43 kg (95 lb)
18. Attach the pump casing to crane or hoist using

wire ropes.
Loosen bolts (21) and remove pump casing (2)
from gear casing (1).
: 24 mm
W2-4-8
EX255-EX285
PUMP DEVICE
17
24
20
8
SM1045
11
24
62
12
20
2
8
9
13
18
12
61
13
52
23
15
32
31
30
16
1
14
28
5
26 25
SM1046
5 4
EX255-EX285
W2-4-9
PUMP DEVICE
19. Remove spring pins (18) from pump casing (2).
Remove packing (23) from gear casing (1).
15
Aligning Mark
14
IMPORTANT - If aligning marks are not made, it is

very hard to align pump timing when reassembling.
17
20. Put three aligning marks on each mashed parts:
between gear (14) and drive disc (11) spline, gear
(15) and drive disc (17) spline, gears (14) and (15),
as illustrated.
11
16
16
SM1049
21. Remove retaining rings (16) and gears (14) and

(15) from to drive discs (11) and (17).
22. Remove retaining rings (13) and oil seals (12) from
drive discs (11) and (17).
75301492
23. Loosen plugs (52) to remove O-rings (61). Using a
press, pull drive discs (11) and (17) assembly out
of pump casing (2). Then, remove thrust ring (62).
24. Using special tool (75301492), remove bearing

nuts (9) from drive discs (11) and (17).
SM1050
25. Using a press, remove bearings (8), (24) and

spacer rings (20) from drive discs (11) and (17).
26. Loosen bolts (30) to remove pilot pump (28) from

gear casing (1).
: 6 mm
75301488
27. Remove retaining rings (6) and (7) from gear
casing (1). Pull off upper side bearing (5) and gear
shaft (4) using special tool (75301488).
28. Remove pilot gear (3) from gear casing (1). Then,
pull off the other side bearing (5).
29. Remove retaining ring (26) and oil seal (25) from
gear casing (1).
SM1051
W2-4-10
EX255-EX285
PUMP DEVICE
ASSEMBLE PUMP DEVICE
34
36
59
58
10
57
56
55
SM3017
53
37
39 40
41
43
64
28
60
30
31
32
1
3
4
5
6
7
16
14
15
18
23
45-46
47-48
98
97
82
83
84
SM1053
EX255-EX285
W2-4-11
PUMP DEVICE
74 51
50 88 79
86
35
81 85 87 74 69 73 76 78 77 65 66 2 8 9 12
13
16
17
68
11
75
72
44
92
25
26
62
29 35
42
93
38
49
71
27
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Gear Casing
Pump Casing
Pilot Gear
Gear Shaft
Bearing (2 Used)
Retaining Ring
Retaining Ring
Bearing (2 Used)
Bearing Nut (2 Used)
Main pump
Drive Disc
Oil Seal (2 Used)
Gear
Gear
Drive Disc
Spring Pin (2 Used)
Plunger (14 Used)
Spacer Ring (2 Used)
Bolt (6 Used)
Packing
Bearing (2 Used)
Oil Seal
Retaining Ring
Valve Plate
Pilot Pump
Pin (4 Used)
Washer (2 Used)
91 96 90 89 33 70 19 52 24 20
61
35
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
64
Pin (4 Used)
Adapter (2 Used)
Plug
Level Gauge
O-Ring (6 Used)
Pipe Gauge
Packing
Servo Piston (2 Used)
Plug
Set Screw (2 Used)
N sensor
(Engine Speed Sensor)
O-Ring
Washer
Socket Bolt
Plug (2 Used)
O-Ring (2 Used)
Stopper (2 Used)
Plug (2 Used)
Adapter
Plug
Fitting plug (2 Used)
Servo Pipe
Clamp (2 Used)
Bolt
Spring Washer
O-Ring (2 Used)
Thrust Ring
Pump Pressure Sensor (2 Used)
SM1054
22-21
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
81
82
83
84
85
86
87
88
89
90
91
92
93
96
97
98
Pin (2 Used)
Center Shaft (2 Used)
Plug (2 Used)
Spring (2 Used)
Regulator (2 Used)
Cylinder Block (2 Used)
Valve Plate
Spring Pin (2 Used)
O-Ring (2 Used)
O-Ring (20 Used)
Lever (4 Used)
Pin (2 Used)
Link (2 Used)
Pin (2 Used)
Pipe
Adapter (2 Used)
Clamp
Socket Bolt
Spring Washer
Backup Ring
O-Ring
O-Ring (4 Used)
Spring Pin (2 Used)
Stopper (2 Used)
O-Ring (2 Used)
Pin (2 Used)
Selector Head
W2-4-12
EX255-EX285
PUMP DEVICE
34
1
3
SM3017
4
5
43
SM1053
8
17
11
SM1055
24
20
EX255-EX285
W2-4-13
PUMP DEVICE
Assemble Pump Device
1. Drive bearing (5) into gear casing (1). Install pilot

gear (3). Drive in gear shaft (4) so that the spline
aligns with that of pilot gear (3).
1
3
2. Drive the other bearing (5) onto gear shaft (4).

5
3. Install retaining ring (7) to gear casing (1) and
retaining ring (6) to gear shaft (4).
4. Wind seal tape around adapters (34) (2 used) and

tighten them to gear casing (1).
: 36 mm
SM1056
20
20
: 69 N m (7 kgf m, 51 Ibf ft)

24
24
5. Tighten plug (43).

: 8 mm
11
17
: 49 N m (5 kgf m, 36 Ibf ft)

SM1057
6. Heat inner race of bearings (24) and (8) to 50 to

80 C (122 to 176 F). Apply a film of hydraulic oil
to inner race of bearings (24), then install bearings
(24) onto drive discs (11) and (17) using a press.
75301492
7. Apply a film of hydraulic oil to inner race of

bearings (8), then install spacer rings (20) and
bearings (8) onto drive discs (11) and (17) using a
press.
8. Apply a film of hydraulic oil to bearing nuts (9) (2

used) thread.
Tighten bearing nuts (9) until they come in contact
with bearings (8), using special tool (75301492).
SM1050
9. Rotate bearings (8) 2 to 3 turns for break-in, using

special tool (75301491).
10. Follow the above three steps to adjust starting
torque to specification.
Starting torque specification:
2.160.49 N m (0.220.05 kgf m, 1.590.36 Ibf ft)
75301491
9
8
20
IMPORTANT - If starting torque is increased over the
specification, loosen bearing nut (9) then tap drive
discs (11) and (17) shaft end to release load. Retry
steps 8. to 10. to adjust the starting torque.
24
11-17
SM1058
W2-4-14
EX255-EX285
PUMP DEVICE
2
62
11
17
SM1059
24
16
14
15
SM1053
12
13
SM1055
52-61
EX255-EX285
W2-4-15
PUMP DEVICE
11. Install thrust ring (62) into pump casing (2). (Drive
disc (11) side only.)
12. Heat pump casing (2) to 50 to 80 C (122 to 176 F).
Apply a film of hydraulic oil to the outer circumference of roller bearings (8) and (24). Install drive
disc (11) and (17) assemblies into pump casing (2).
75301490
12
13. Apply a film of grease to O-rings (61) (2 used) then

install them onto plugs (52) (2 used).
Tighten plugs (52) to pump casing (2).
: 19 mm
: 34 N m (3.5 kgf m, 25 Ibf ft)
14. Install special tools (75301489 and 75301490)
over the spline parts of drive discs (11) and (17) to
protect oil seals (12) from being damaged. If the
special tools are not available, wind adhesive
tapes over the spline parts.
IMPORTANT - Apply a film of grease to oil seal (12) (2
used) lip.
Shaft side
Long
Shaft
Side
15. Drive oil seal (12) (2 used) as illustrated. Remove

the special tools.
16. Install retaining rings (13) (2 used).
SM1060
75301489
Short
Shaft
Side
75301493
When replacing drive discs (11), (17) and / or

transmission gears (14), (15)
IMPORTANT - Install special tool with the D mark
facing toward long drive disc (11) side.
M8x1,25
SM1061
17. Install special tool (75301493) to drive discs (11),

(17).
18. Rotate drive discs (11), (17) clockwise, as viewed
from the shaft end side to remove circumferential
play between the special tool and drive discs (11),
(17).
15
19. Install gear (15) and retaining ring (16) onto drive
disc (17).
20. Install gear (14) so that both splines on drive disc
(11) and gear (15) teeth, can correctly engage with
those of gear (14). Install retaining ring (16) onto
drive disc (11).
IMPORTANT - Although drive disc (11) is held
unrotable with special tool (75301493), it may be
necessary to jolt drive disc (11) in order to install gear (14).
When not replacing drive discs (11), (17) and/or
transmission gears (14),(15)
21. Align the marks for drive disc (11) and gear (14). Also,
align the marks for drive disc (17) and gear (15).
Aligning Mark
14
17
11
16
16
SM1049
W2-4-16
EX255-EX285
PUMP DEVICE
28
30
31
32
53
39 40
55
41
28
SM3017
14
23
18
22-21
35
76 78 77
17
11
75
33-35
SM1054
SM1053
EX255-EX285
W2-4-17
PUMP DEVICE
22. Install spring pins (18) (2 used) and packing (23) to
gear casing (1).
WARNING
Pump casing weight: 43 kg (95 Ib)
23. Sling pump casing (2) with a crane and install it to

gear casing (1) so that pilot gear (3) engages gear
(14).
24. Tighten bolts (21) (6 used) with spring washers

(22) (6 used).
: 24 mm
: 147 N m (15 kgf m, 109 Ibf ft)
25. Apply THREEBOND 1215 to gear casing (1) surface.

Install pilot pump (28) to gear casing (1), then
tighten socket bolts (30) (2 used) with spring
washers (31) (2 used) and washers (32) (2 used).
: 8 mm
: 49 N m (5 kgf m, 36 Ibf ft)
26. Install adapter (53) and fitting plug (55) onto pilot
pump (28).
: 27 mm
: 93 N m (9.5 kgf m, 69 Ibf ft)
: 6 mm
: 34 N m (2 kgf m, 15 Ibf ft)
27. Install packing (41) and pipe gauge (39) to gear

casing (1).
Then tighten with socket bolts (40) (2 used).
: 6 mm
: 19.5 N m (2 kgf m, 15 Ibf ft)
28. With retaining rings (35) (2 used) installed to the

one side of pins (76) (2 used), drive pins (76) (2
used) into links (77) (2 used). Then, install
retaining rings (35) (2 used) to the other side of pins
(76) (2 used).
29. Install levers (75) (4 used), pins (33) (4 used), and

retaining rings (35) (4 used) to the U type end of
links (77) (2 used).
30. Install pins (78) (2 used) to links (77) (2 used).
W2-4-18
EX255-EX285
PUMP DEVICE
74
86
85 87 74 69 73
78 77 65 66
68
17
75
11
44
92
35- 29
42
93
SM1054
89
70 19
45-46
47-48
98
97
SM1053
EX255-EX285
W2-4-19
PUMP DEVICE
31. Apply a film of hydraulic oil to the spherical
surface of drive discs (11) and (17) and insert
plungers (19) (7 used).
32. After applying grease to the hole of center shaft

(66) (2 used), install pins (65). Install center shafts
(66) into the center spherical surface section of
drive discs (11) and (17). Then, install springs (68)
(2 used).
33. Assemble plungers (19) (14 used) and center

shafts (66) (2 used) into cylinder blocks (70)
(2 used).
34. Pinch the tip of center shafts (66) with pliers to

rotate the center shaft and install pins (65)
(2 used) into the groove on cylinder blocks (70)
(2 used).
38. Install O-rings (73) (2 used), (74) (10 used), and

(87) (4 used) onto pump casing (2).
Install regulators (69) (2 used) onto pump casing
(2) using socket bolts (97) (8 used) and spring
washers (98) (8 used).
(Refer to "Assemble Regulator" on page W2-4-24.)
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)
39. Install backup ring (85), spring pins (89) (2 used)

and O-ring (86) into pump casing (2).
Install O-rings (74) (4 used) to selector head (93).
40. Apply a film of grease to O-ring (46). Install N

sensor (45) to gear casing (1) then tighten with
socket bolt (48) and washer (47).
: 5 mm
: 9.8 N m (1 kgf m, 7.2 lbf ft)
IMPORTANT - Take care not to damage the O-ring

(73) groove when driving in pins (78).
41. Assemble servo pistons (42) (2 used) and pins

(92) (2 used) to selector head (93).
35. After installing links (77) (2 used) assembly into

pump casing (2), drive pins (78) (2 used) into the
groove on the mounting surface of regulators (69)
so that the pin end is flush with the mounting
surface.
IMPORTANT - Apply LOCTITE LI829 to set screws

(44).
36. Apply a film of LOCTITE LI829 to the threads of

pins (29) (4 used). Then, tighten the pins (2 used)
into valve plates (27) and (71).
: 7 mm
: 9.8 N m (1 kgf m, 7.2 lbf ft)
37. Install pins (29) into the hole of levers (75).

Install retaining rings (35) (4 used).
IMPORTANT - Valve plates (27) and (71) are exclusively used in the right and left pumps respectively.
Replacing the right with the left or up-side-down is not
applicable. Install the valve plates so that the suction
port is positioned to the upper side of the center when
viewed from the front.
42. Tighten set screws (44) (2 used) to the smaller

diameter side of servo pistons (42) (2 used) to
secure pins (92) (2 used).
: 6 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
W2-4-20
EX255-EX285
PUMP DEVICE
96
88 51
50
74
11
93
25
26
SM1054
91 88 90 89
96
34
56
59
58
57
36
82
83
84
93
55
64
60
SM3017
EX255-EX285
W2-4-21
PUMP DEVICE
43. Apply a film of grease to stoppers (51) (2 used),
(90) (2 used) and O-rings (50) (2 used), (91)
(2 used). Assemble O-rings (50) (2 used), (91)
(2 used) to stoppers (51) (2 used), (90) (2 used).
Install stoppers (51) (2 used), (90) (2 used) to
selector head (93), then tighten with spring
washers (96) (16 used) and socket bolts (88)
(16 used).
: 6 mm
: 19.5 N m (2 kgf m, 15 lbf ft)
50. Connect servo pipe (56) then clamp it using bolt

(58) and clamp (57).
: 13 mm
: 2.9 N m (0.3 kgf m, 25 lbf ft)
51. Fix the N sensor connector on pump casing (2)

using clamp (82), spring washer (84), and socket
bolt (83).
: 5 mm
: 10 N m (1 kgf m, 7.2 lbf ft)
WARNING
Selector head weight: 30 kg (66 lb)
44. Sling selector head (93) assembly with a crane.

Install O-ring (74) (6 used) to pump casing (2).
Install the selector head onto pump casing (2) so
that spring pins (89) (2 used) align with the pin
holes on the selector head. Then tighten socket
bolts (60) (12 used).
52. Install special tool (75301490) to drive disc (11).

Apply a film of grease to oil seal (25) and install the
oil seal to drive disc (11). Remove special tool
(75301490) and drive in oil seal (25). Install retaining ring (26). If special tool (75301490) is not
available, wind tape around the spline of drive disc
(11) to protect the oil seal from being damaged
when installing.
: 10 mm
: 108 N m (11 kgf m, 80 lbf ft)
45. Tighten pump pressure sensors (64) (2 used) to

selector head (93).
: 27 mm
: 98 N m (10 kgf m, 72 lbf ft)
53. Supply oil into gear casing (1) through adapter (34)
about 1.0 liters (1.06 US qt). Tighten plug (36) to
adapter (34).
: 17 mm
: 69 N m (7 kgf m, 51 lbf ft)
54. Install level gauge to pipe gauge (39).
46. Temporarily tighten fitting plug (55) onto pump

casing (2).
47. Temporarily tighten clamps (57) (2 used) to selector head (93) with washer (59) and bolt (58).
75301490
25
48. Insert servo pipe (56) between clamps (57)

(2 used) and tighten the nut for fitting plug (55).
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
49. Tighten servo pipe (56).
: 17 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
SM1062
W2-4-22
EX255-EX285
PUMP DEVICE
DISASSEMBLE REGULATOR
49
24
27
28
20
21
14
34
15
29
17
17
12
16
16
14
SM1063
35
97-98
40
47 48
41
14
15
13
37-38
12
36
SM1064
1
2
3
5
6
7
8
9
12
13
14
Regulator Casing
Sleeve A
Spool A
Load Cylinder
Load Piston
O-Ring
Backup Ring
O-Ring
Stopper (2 Used)
Stopper
O-Ring (3 Used)
15
16
17
20
21
24
27
28
29
34
35
O-Ring (2 Used)
Nut (2 Used)
Nut (2 Used)
Piston
Cylinder
Inner Stopper
Sleeve B
Spool B
Set Screw
Nut
Cover
36
37
38
40
41
47
48
49
97
98
Cover
Plug
O-Ring
Spring
Spring
Spring
EX255-EX285
W2-4-23
PUMP DEVICE
Disassemble Regulator
IMPORTANT - When disassembling the regulator, do
not disassemble adjusting parts (12), (16), (17), (29),
(34) unless necessary. If disassembled the performance curve of the regulator is changed. To adjust the
regulator, refer to the Operational Perform-ance Test.
Section in the Technical Manual (Troubleshooting).
1. Hold regulator casing (1) of regulator with a vice and

remove plug (40).
: 41 mm
2. Loosen socket bolts (37) to remove covers (36),

(35) assembly.
: 6 mm
3. Remove springs (47), (48) from regulator casing

(1).
4. Remove load cylinder (5) from regulator casing (1)

by pushing spool A (3).
5. Remove load piston (6), O-ring (7), (9) and backup

ring (8) from load cylinder (5).
6. Remove sleeve A (2) with spool A (3) from regulator

casing (1).
7. Remove spool A (3) from sleeve A (2).
8. Remove sleeve B (27), spool B (28) and spring (49)

from regulator casing (1).
9. Remove piston (20), O-ring (14) and cylinder (21)

from regulator casing (1).
W2-4-24
EX255-EX285
PUMP DEVICE
ASSEMBLE REGULATOR
49
24
27
28
20
21
14
34
15
29
17
17
12
16
16
14
SM1063
47 48
14
15
13
12
76
SM1066
79
35
97-98
40
41
37-38
36
SM1065
87
1
2
3
5
6
7
8
9
12
13
14
15
16
Regulator Casing
Sleeve A
Spool A
Load Cylinder
Load Piston
O-Ring
Backup Ring
O-Ring
Stopper (2 Used)
Stopper
O-Ring (3 Used)
O-Ring (2 Used)
Nut (2 Used)
17
20
21
24
27
28
29
34
35
36
37
38
40
Nut (2 Used)
Piston
Cylinder
Inner Stopper
Sleeve B
Spool B
Set Screw
Nut
Cover
Cover
Plug
74
73
41
47
48
49
73
74
76
79
81
87
97
98
O-Ring
Spring
Spring
Spring
O-Ring
O-Ring (5 Used)
Pin
Pipe
Adapter
O-Ring (2 Used)
EX255-EX285
W2-4-25
PUMP DEVICE
Assemble Regulator
IMPORTANT - Take care not to mistake the combination and direction of spool B (28) and sleeve B (27).
1. Apply a film of hydraulic oil to spool B (28) and
sleeve B (27).
Install spool B (28) into sleeve B (27) and install into
regulator casing (1).
2. Apply a film of hydraulic oil to spool A (3) and

sleeve A (2), install into regulator casing (1).
10. Install regulator casing assembly to pump casing,

then tighten with socket bolts (97) (4 used) and
spring washers (98) (4 used).
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)
IMPORTANT - Install the pin for the link in the groove

for sleeve B (27) and sleeve A (2) in regulator casing
(1). Using tape, hold the grooves for sleeve B (27) and
sleeve A (2) so that both grooves are aligned. Then,
after installing, be sure to remove the tape. Check
through the hole of plug (40) that pin (76) is surely
installed into sleeve B (27) and sleeve A (2).
3. Apply a film of grease to O-ring (7), (9) then install

O-rings (7), (9) and backup ring (8) to load cylinder
(5).
Before operating the pump, bleed air trapped in the

pump casing and fill the pump casing with hydraulic oil.
4. Install load piston (6) into load cylinder (5) and

install into regulator casing (1).
11. Tighten adapter (81) and pipe (79) onto regulator

casing (1).
: 19 mm
5. Apply a film of grease to O-rings (14) (2 used) then

install on stoppers (12) (2 used).
IMPORTANT - Stopper (13) length is different from
that of inner stopper (24).
Inner stopper (24) is the shortest.
6. Install cover (35) with spring (49) onto regulator

casing (1).
Install and tighten socket bolts (37) (4 used) and
: 34 N m (3.5 kgf m, 25 lbf ft)

: 22 mm
: 49 N m (5 kgf m, 36 lbf ft)
12. Install O-ring (41) onto plug (40), tighten it onto

regulator casing (1).
: 41 mm
: 78 N m (8 kgf m, 58 lbf ft)
: 6 mm
: 19.8 N m (2 kgf m, 15 lbf ft)
7. Install O-ring (14), piston (20) in cylinder (21), and

install into regulator casing (1).
8. Install cover (36) with springs (48), (47) onto regulator casing (1)
Install and tighten socket bolts (37) (4 used) and
: 6 mm
: 19.8 N m (2 kgf m, 15 lbf ft)
9. Apply a film of grease to O-rings (73), (74)

(5 used), (87) (2 used) and install them onto the
pump casing (2).
IMPORTANT - Be sure to fill the casing with hydraulic

oil before operating the pump.
W2-4-26
EX255-EX285
PUMP DEVICE
DISASSEMBLE AND ASSEMBLE PILOT PUMP
27
13
26
10
10
12
1
9
26
14
27
6
9
2
3
16
15
SM1066
7
12
EX255-EX285
W2-4-27
PUMP DEVICE
Item
Part Name
Q.ty Wrench Size

mm
Tightening Torque
lbf ft
kgf m
Nm
Remarks
Housing
Flange
Oil Seal
Retaining Ring
Seal
Cover
Backup Ring
10
Key
12
O-ring
13
Gear
14
Gear
15
Washer
16
Bolt
26
Bushing
Apply a film of hydraulic oil to

bushing when installing
27
Bushing
Apply a film of hydraulic oil to

bushing when installing
Apply grease to oil seal lip when

installing
Apply grease to seal when

installing
Apply grease to backup ring when

installing
Apply grease to O-ring when

installing
:17
39 to 44 4 to 4.5 29 to 33
W2-4-28
EX255-EX285
PUMP DEVICE
MAINTENANCE STANDARD
Pump device
Unit: mm (in)
Gear Backlash
Standard
Allowable Limit
Rimedy
0.68 (0.03)
1.5 (0.06)
Replace
Main Pump
1. Tooth thickness (Driving disc splines).
Unit: mm (in)
Standard
Allowable Limit
5.4 (0.21)
3.8 (0.15)
2. Sleeve diameter (Driving disc).

Unit: mm (in)
Standard
Allowable Limit
45 (1.77)
44.8 (1.76)
55 (2.17)
54.8 (2.16)
55 (2.17)
54.8 (2.16)
SM1068
3. Clearance between plunger and driving disc (b).

Unit: mm (in)
Standard
Allowable Limit
0.058 (0.002)
0.4 (0.016)
SM1069
4. Clearance between plunger (a) and cylinder

block (D).
(D - a)
Unit: mm (in)
Standard
Allowable Limit
0.043 (0.002)
0.08 (0.003)
D
a
SM1070
EX255-EX285
W2-4-29
PUMP DEVICE
5. Clearance between plunger and connecting rod.
Unit: mm (in)
Standard
Allowable Limit
0.15 (0.006)
0.4 (0.016)
Plunger
Connecting rod
SM1071
6. Clearance between small chamber (D) and servo

piston (a).
D-a
Unit: mm (in)
Standard
Allowable Limit
0.083 (0.003)
0.2 (0.008)
Small
Chamber
Side
D
a
7. Clearance between large chamber (D) and servo

piston (a).
D-a
Unit: mm (in)
Standard
Allowable Limit
a
0.079 (0.003)
0.2 (0.008)
8. Clearance between valve plate (D) and servo piston

(a).
D-a
Unit: mm (in)
Standard
Allowable Limit
0.051 (0.002)
0.3 (0.011)
Large
Chamber
Side
SM1072
SM1073
W2-4-30
EX255-EX285
PUMP DEVICE
NOTES
EX255-EX285
W2-5-1
CONTROL VALVE
REMOVE AND INSTALL CONTROL VALVE
WARNING
Be sure to wait for oil to cool before starting work.
Preparation
pressure.
Refer to Hydraulic Circuit Pressure Release Procedure on page W4-2-12.

Removal
1. Install control valve to frame and tighten the bolts.
NOTE - Attach caps to hoses and pipes.

Attach labels or tags to hoses and pipes, to aid in
assembly.
2. Connect all hoses, pipes and connectors to the

control valve.
1. Disconnect all hoses, pipes and connectors from

the control valve.
: 17 mm
: 9.8 N m (1 kgf m, 7 lbf ft)
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
: 22 mm
: 49 N m (5 kgf m, 36 lbf ft)
: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)
: 8 mm
: 64 N m (6.5 kgf m, 147 lbf ft)
: 10 mm
: 108 N m (11 kgf m, 80 lbf ft)

while working.
IMPORTANT - After completing installation:

Check hydraulic oil level. Add oil if necessary. Run the
engine. Check the engine components for any oil
leakage.
A B
D
E
SM1191
E D
WARNING
Control valve assembly weight: 240 kg (530 lb)
2. Remove control valve mounting bolts.
: 24 mm
: 205 N m (21 kgf m, 150 lbf ft)
Installation
SM1192
NOTE - Refer to Removal section above for wrench

sizes and tightening torques.
A = Swing
B = Arm I
C = Boom II
D = Auxiliary
E = Travel left
W2-5-2
EX255-EX285
CONTROL VALVE
DISASSEMBLE CONTROL VALVE 1
E = Travel Flow Control Valve

F = Pump Control Valve
E
3
4
5
17
17
18
12
19
20
F
21
55
22
39
40
40
51
41
39
39
35
38
38
23
37
24
25
26
27
28
35
29
42
30
43
31
44
34
39
36
32
33
SM1193
1
2
3
4
5
6
7
8
12
17
18
19
20
21
Plug (Restriction)
O-Ring
Plug
Spool
Seat
Spring
O-Ring
Plug
Pilot Plate
Socket Bolt
Lock Nut
Screw
Washer
O-Ring
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Plug
O-Ring
Spring
Seat
Spool
Sleeve
O-Ring
Spool
Sleeve
O-Ring
Seat
Retaining Ring
Spring
O-Ring
36
37
38
39
40
41
42
43
44
51
55
Housing (5-Spool Side)

O-Ring
O-Ring
O-Ring
Spring
Check Valve
Spring
Poppet
Sleeve
Check Valve
Pilot Plate
EX255-EX285
W2-5-3
CONTROL VALVE
Disassemble Control Valve 1
Be sure to thoroughly read Precautions for Disassembly and Assembly on page W1-1-1 before
starting the disassembly work.

1. Loosen and remove plug (8) from pilot plate
(12).
: 36 mm
2. Remove spring (6), seat (5), and spool (4) from

pilot plate (12).

(12).

(12).
: 5 mm
5. Loosen socket bolts (17) to remove pilot plate

(12) from housing (36).
: 10 mm

: 10 mm
W2-5-4
EX255-EX285
CONTROL VALVE
17
18
19
X
55
40
51
22
40
24
41
25
26
27
Y
29
42
30
43
44
34
36
X = Pump Control Valve

Y = Load Check Valve
Z = Load Check Valve
32
33
SM1193
EX255-EX285
W2-5-5
CONTROL VALVE
Load Check Valve

7. Remove springs (40) and (42), check valves
(41) and (51), poppet (43), and sleeve (44) from
housing (36).
Pump Control Valve

8. Remove plug (22) from housing (36). Take
care not to drop spring (24), seat (25), and
spool (26) at this time.
: 38 mm
NOTE - Do not remove lock nut (18) and screw (19).
9. Attach the nut (M8 Pitch 1.25) to spool (29).

Remove spool (29) together with sleeve (30)
from housing (36).
10. Remove retaining ring (33), seat (32), and

spring (34).
11. Pull out spool (29) and sleeve (27) from sleeve
(30).
W2-5-6
EX255-EX285
CONTROL VALVE
ASSEMBLE CONTROL VALVE 1-1
B
A
36
36
51
51
39
39
40
40
55
55
38
40
36
17
17
12
55
39
SM1194
51
SM1195
SM1196
18 21 25 26
28 27 29
32 34 32 33
A=
B=
C=
D=
E=
F=
D
SM1197
19 20 22 23 24
31
Side View of 5 - Spool Control Valve

Swing
Arm I
Pump Control Valve
Boom II
Travel (left)
30
F
36
44
36
43
51
39
39
42
40
12
12
40
38
39
41
SM1199
SM1198
12
17
18
19
20
21
22
23
Pilot Plate
Socket Bolt
Lock Nut
Screw
Washer
O-Ring
Plug
O-Ring
24
25
26
27
28
29
30
31
Spring
Seat
Spool
Sleeve
O-Ring
Spool
Sleeve
O-Ring
32
33
34
36
38
39
40
41
Seat
Retaining Ring
Spring
O-Ring
O-Ring
Spring
Check Valve
42
43
44
51
55
Spring
Poppet
Sleeve
Check Valve
Pilot Plate
EX255-EX285
W2-5-7
CONTROL VALVE
Assemble Control Valve 1-1
Pump Control Valve

1. Insert spool (29) onto sleeve (30).
2. Install seat (32), spring (34), and seat (32) on
spool (29), in that order. Secure with retaining
ring (33).
3. Install O-rings (28) (2 used) on sleeve (27).

Insert sleeve (27) into sleeve (30).
Install sleeve (30) into housing (36).
5. Install spool (26) onto spool (29).
6. Install spring (24), seat (25), and O-ring (23)
onto plug (22). Install plug (22) onto housing
(36).
: 38 mm
: 84 N m (8.6 kgf m, 62 lbf ft)
Load Check Valve (5-spool side)

7. Install poppet (43) and spring (42) into sleeve
(44). Install sleeve (44) into housing (36).
8. Install pairs of check valve (41) and spring
(40), and check valves (51) and springs (40)
(5 used each) into housing (36).
9. Install O-rings (39) and (38) onto housing (36).
10. Install pilot plate (55) on housing (36).
: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)
W2-5-8
EX255-EX285
CONTROL VALVE
36
17
17
12
55
55
51
36
SM1194
SM1196
A = Side view of 5 Spool Control Valve

B = Arm I
C = Cross Section X
D = Auxiliary
E = Travel (left)
F = Travel Flow Control Valve
SM1200
12
36
39
36
F
40
51
12
37
12
38
SM1199
SM1201
1
2
3
4
5
Plug (Restriction)
O-Ring
Plug
Spool
Seat
6
7
8
12
17
Spring
O-Ring
Plug
Pilot Plate
Socket Bolt
36 - Housing
(5-Spool Side)
37 - O-Ring
38 - O-Ring
39 - O-Ring
40 - Spring
51 - Check Valve
55 - Pilot Plate
EX255-EX285
W2-5-9
CONTROL VALVE
Load Check Valve (5-spool side)

1. Install check valve (51) and spring (40) into
housing (36).
2. Install O-rings (37), (38), and (39) on housing
(36).
3. Install pilot plate (12) on housing (36).
: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)

4. Install spool (4), seat (5), spring (6) into pilot
plate (12). Install O-ring (7) on plug (8). Install
plug (8) onto pilot plate (12).
: 36 mm
: 98 N m (10 kgf m, 72 lbf ft)
5. Install plug (1) onto pilot plate (12).
6. Install O-ring (2) onto plug (3). Install plug (3)
onto pilot plate (12).
: 5 mm
: 15 N m (1.5 kgf m, 11 lbf ft)
W2-5-10
EX255-EX285
CONTROL VALVE
1
61
59
60
3
58
57
5
56
55
21
54
23
53
24
22 6
H
G
52
51
20
50
30
49
29
31
47
48
46
45
26
25
32
27
33
34 28
10
11
12
30
38
13
L
37
14
39
36
35
15
16
19
17
18
19
F=
G=
H=
L =
SM1202
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Spool
Spring
O-Ring
Plug
O-Ring
Check Valve
Spring
Poppet
Poppet
Spring
Plug
Spring
Spacer
15
16
17
18
19
20
21
22
23
24
25
26
27
28
O-Ring
O-Ring
Plug
Filter
Socket Bolt
Check Valve
Check Valve
O-Ring
O-Ring
O-Ring
Plug
Screw
O-Ring
Backup Ring
29
30
31
32
33
34
35
36
37
38
39
45
46
47
Load Check Valve

Load Check Valve
Bucket Flow Control (Restriction)
Bucket Flow Control Valve
(Switch Valves A and B)
Plug
O-Ring
Retaining Ring
Seat
Spring
Spool
Pilot Plate
Spool
Seat
Spring
Pilot Plate
Screw
Lock Nut
Washer
48
49
50
51
52
53
54
55
56
57
58
59
60
61
O-Ring
Plug
O-Ring
Spring
Seat
Spool
Sleeve
O-Ring
Spool
Sleeve
O-Ring
Seat
Spring
Retaining Ring
EX255-EX285
W2-5-11
CONTROL VALVE
: 10 mm
Bucket Flow Control Valve (Switch Valve A)

2. Remove plug (29) from pilot plate (35).
: 10 mm
3. Remove spool (34) from pilot plate (35).
spring (33) from spool (34).
Bucket Flow Control Valve

(Switch Valve B, Poppet Valve)
5. Remove plug (29) from pilot plate (35).
6. Remove spring (38), seat (37), and spool (36)
from pilot plate (35).
7. Loosen socket bolts (19) to separate pilot plate
NOTE - Take care not to drop spacer (14) and spring

(13) at this time.
:10 mm
8. Remove plug (12) from housing (1). Remove
spring (11) and poppet (10) from poppet (9).
: 8 mm
Load Check Valve

9. Remove springs (8) and check valves (7), (20),
and (21) from housing (1).
W2-5-12
EX255-EX285
CONTROL VALVE
F
61
59
60
G
3
57
5
56
54
53
52
51
49
46
45
17
SM1202
F = Pump Control Valve

G = Flow Combiner Valve
EX255-EX285
W2-5-13
CONTROL VALVE
Pump Control Valve
10. Remove plug (49) from housing (1). Take care
not to drop spring (51), seat (52), and spool (53)
at this time.
: 38 mm
NOTE - Do not remove lock nut (46) and screw (45).
11. Attach the nut of bolt (M8 Pitch 1.25) to spool

(56). Remove spool (56) together with sleeve

spring (60).
13. Pull out spool (56) and sleeve (54) from sleeve
(57).
Flow Combiner Valve

14. Remove plug (5), spring (3) and spool (2) from
housing (1).
: 36 mm
15. Remove plug (17) from housing (1).
: 19 mm
W2-5-14
EX255-EX285
CONTROL VALVE
A
1
21
1
39
6
8
35
39
8
SM1203
57 54
55 53 50 49
6
21
47 46 45
SM1204
A = Side View of 4 - Spool Valve

B = Arm II
C = Pump Control Valve
D = Boom I
E = Bucket
C
SM1209
61 59 60 56
58
52 51 48
21
6
8
35
39
1
6
7
8
20
21
35

O-Ring
Check Valve
Spring
Check Valve
Check Valve
Pilot Plate
39
45
46
47
48
49
50
Pilot Plate
Screw
Lock Nut
Washer
O-Ring
Plug
O-Ring
20
SM1206
SM1205
51
52
53
54
55
56
57
Spring
Seat
Spool
Sleeve
O-Ring
Spool
Sleeve
58
59
60
61
O-Ring
Seat
Spring
Retaining Ring
EX255-EX285
W2-5-15
CONTROL VALVE
Pump control valve

1. Insert spool (56) onto sleeve (57).
spool (56), in that order. Secure with retaining
ring (61).

Insert sleeve (54) into sleeve (57).
Install sleeve (57) into housing (1).
5. Install spool (53) onto spool (56).
6. Install spring (51), seat (52), and O-ring (50)
onto plug (49). Install plug (49) onto housing
(1).
: 38 mm
: 84 N m (8.6 kgf m, 62 lbf ft)
Check Valve (4-spool side)

7. Install check valve (7), check valve(20), check
valves (21) (3 used) and spring (8) (5 used) into
housing (1).
8. Install O-rings (6) (5 used) on housing (1).
W2-5-16
EX255-EX285
CONTROL VALVE
39
17
19
19
39
35
5
SM1203
10 11
12
SM1204
A=
B=
C=
D=
E=
Side View of 4-Spool Control Valve

Arm II
Bucket
Travel (Right)
Bucket Flow Control Valve A
(Switch Valve)
F = Bucket Flow Control Valve B
(Switch Valve Orifice)
G = Flow Combiner Valve
C
SM1210
1 15 16 18
13-14
36
35
6
26
25
34
37
38
30
22 29
30

Spool
Spring
O-Ring
Plug
O-Ring
Poppet
Poppet
Spring
SM1207
35
SM1206
1
2
3
4
5
6
9
10
11
27-28
33
32
31
29
17
SM1208
12
13
14
15
16
17
18
19
22
Plug
Spring
Spacer
O-Ring
O-Ring
Plug
Filter
Socket Bolt
O-Ring
25
26
27
28
29
30
31
32
33
Plug
Screw
O-Ring
Backup Ring
Plug
O-Ring
Retaining Ring
Seat
Spring
34
35
36
37
38
39
Spool
Pilot Plate
Spool
Seat
Spring
Pilot Plate
EX255-EX285
W2-5-17
CONTROL VALVE
Bucket Flow Control Valve (Switch Valve B,

Poppet Valve)
Flow Combiner Valve

10. Install spool (2) and spring (3) into housing (1).
11. Tighten plug (5) onto housing (1).
1. Attach poppet (10) and spring (11) to poppet (9).

Tighten plug (12) onto poppet (9).
: 8 mm
: 39 N m (4 kgf m, 29 lbf ft)
2. Install poppet (9) into housing (1).
4. Install spacer (14) and spring (13) into pilot plate
(35). Install pilot plate (35) onto housing (1).
5. Tighten pilot plate (35) onto housing (1) using
socket bolts (19).
: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)
6. Install spool (36), seat (37), and spring (38) into
pilot plate (35). Tighten plug (29) onto pilot plate
(35).
: 10 mm
: 71 N m (7.2 kgf m, 52 lbf ft)
Bucket Flow Control Valve (Switch Valve A)

7. Attach seat (32) onto spool (34) and secure it
using retaining ring (31).
8. Install spring (33) onto spool (34) and insert

them into pilot plate (35).
9. Install O-ring (30) onto plug (29). Tighten plug
(29) onto pilot plate (35).
: 10 mm
: 71 N m (7.2 kgf m, 52 lbf ft)
: 36 mm
: 157 N m (16 kgf m, 116 lbf ft)
12. Install O-rings (15) and (16) onto plug (17).
Tighten plug (17) onto housing (1).
: 19 mm
: 76 N m (7.7 kgf m, 56 lbf ft)
W2-5-18
EX255-EX285
CONTROL VALVE
L = Anti-Drift Valve
M = Travel/Boom Lower
Selector Valve
N = Arm Regenerative Valve
1
4
6
44
7
45
46
47
48
13
49
50
4
12
43
42
41
1
0
40
11
M
26
N
27
39
J
1
2
3
4
5
6
7
8
9
10
11
12
13
38
37
28
29
35
30
32
16
22
33
20
18
21
12
19
34
14
15
16
17
18
19
20
21
22
23
24
25
26
27
15
23
17
31
10
14
24
36
Plug
Socket Bolt
Pilot Plate
Overload Relief Valve
O-Ring
Main Relief Valve
Pilot Housing
Bolt (5 Used)
Seat (10 Used)
Spring (5 Used)
Spool (Travel Left)
O-Ring
O-Ring
25
Spool (Swing)
Spool (Arm I)
Spool (Boom II)
Spool (Auxiliary)
Spacer
Backup Ring
O-Ring
Spring
Check Valve
Sleeve
Spool
Spring
O-Ring
Check Valve
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Spring
O-Ring
Backup Ring
O-Ring
O-Ring
Spacer
Spring
Spacer
Backup Ring
O-Ring
Spool
O-ring
Socket Bolt
Plug
SM1211
42
43
44
45
46
47
48
49
50
O-Ring
Body
Spacer
O-Ring
Spring
Seat
Spool
O-Ring
Plug
EX255-EX285
W2-5-19
CONTROL VALVE

9. Remove spring (34) and spool (38) from housing (5).
10. Heat spacer (35) mounting part on spool (38)
using a hair dryer to melt adhesive.
5-Spool Side Main Spool

11. Put spool (38) in a vise. Remove spacer (35)
from spool (38).
1. Loosen socket bolts (1), then remove pilot plate

(2) and pilot housing (7) from housing (5).
: 10 mm
2. Pull out five spools (11) , (14 to 17) from housing
(5).
NOTE - Place protectors, such as wooden plates,

between the vise and the spool so as not to damage
the spool.
3. Put the chamfered end of spool (11) in a vise.

Remove bolt (8).
: 14 mm
: 22 mm
4. Remove seat (9), spring (10) and seat (9) from
bolt (8).
5. Disassemble spools (14), (15), (16) and (17),
referring to the steps 3 and 4 above.

6. Loosen socket bolts (40) to remove body (43)
from housing (5).
NOTE - Spacer (44) and spring (46) may fly off at this
time.
: 10 mm
7. Pull out spacer (18) from housing (5) using a bolt
(M5, Pitch 0.8).
8. Pull out spring (21) and check valve (22) from
housing (5) using a magnet.

12. Remove sleeve (23), spool (24), and spring
W2-5-20
EX255-EX285
CONTROL VALVE
27
28
33
SM1211
EX255-EX285
W2-5-21
CONTROL VALVE
Check Valve
13. Pull out spacer (33) from housing (5) using a
bolt (M6, Pitch 1.0).

15. Remove overload relief valve (3) from housing
(5).
: 32 mm
Main Relief Valve

16. Loosen plug (J) to remove main relief valve (6)
from housing (5).
: 32 mm
W2-5-22
EX255-EX285
CONTROL VALVE
B
A
34
39
41-42
35
36
37
M
M
38
SM1212
SM1214
SM1213
3 43 40
A=
B=
C=
E=
F=
G=
H=
I =
Cross section
M-M
H
26
Top View of Control Valve

Bottom View of Control Valve
Arm I
Anti-Drift Valve
Boom II
Main Relief Valve
24
23
25
G
SM1215
I
6
E
43 48 50
49
47
46
45- 44
12
20-19
18
21
22
J
3
12
32
31
33
30
29
28
27
5
2
3
SM1198
SM1196
J
1
2
3
4
5
6
12
18
19
20
Plug
Socket Bolt
Pilot Plate
O-Ring
Main Relief Valve
O-Ring
Spacer
Backup Ring
O-Ring
SM1216
21
22
23
24
25
26
27
28
29
30
31
Spring
Check Valve
Sleeve
Spool
Spring
O-Ring
Check Valve
Spring
O-Ring
Backup Ring
O-Ring
32
33
34
35
36
37
38
39
40
41
42
O-Ring
Spacer
Spring
Spacer
Backup Ring
O-Ring
Spool
O-Ring
Socket Bolt
Plug
O-Ring
43
44
45
46
47
48
49
50
Body
Spacer
O-Ring
Spring
Seat
Spool
O-Ring
Plug
EX255-EX285
W2-5-23
CONTROL VALVE

1. Install two overload relief valves (3) to housing (5).
: 32 mm
: 83 N m (8.5 kgf m, 62 lbf ft)
2. Install five O-rings (4) onto housing (5).
3. Install pilot plate (2) onto housing (5) using
socket bolts (1) (6 used).
: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)
Check Valve
housing (5).
5. Install O-rings (29), (31), and (32) and backup
ring (30) onto spacer (33). Install spacer (33)
into housing (5).

6. Install O-ring (37) and backup ring (36) onto
spacer (35).
7. Apply LOCTITE 271 to the threads of spacer
(35). Install spacer (35) onto spool (38).
8. Put spool (38) in a vise. Tighten spacer (35)
onto spool (38).

the spool.
: 14 mm
: 18.6 N m (1.9 kgf m, 14 lbf ft)
9. Install spool (38) and spring (34) into housing
(5).
10. Install O-ring (39) onto housing (5).
W2-5-24
EX255-EX285
CONTROL VALVE
M
M
SM1212
SM1214
SM1213
43 40
Cross section
M-M
H
26
A=
B=
C=
E=
F =
G=
H=
I =

Arm I
Arm Anti-Drift
Boom II
Main Relief Valve
24
23
25
G
SM1215
I
6
E
43 48 50
49
47
46
45- 44
12
20-19
18
21
22
J
5
12
5
5
SM1196
SM1198
SM1216
EX255-EX285
W2-5-25
CONTROL VALVE

housing (5).
12. Install O-rings (12) and (20) and backup ring
(19) on spacer (18). Install spacer (18) into
housing (5).
body (43).
14. Install O-ring (45) onto spacer (44). Install
spacer (44) into body (43).
15. Install O-rings (12) (3 used) onto housing (5).
16. Install body (43) onto housing (5).
: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)
17. Install O-ring (49) onto plug (50). Install plug
(50) onto body (43).
: 6 mm
: 29 N m (3 kgf m, 22 lbf ft)

18. Install spring (25), spool (24), and sleeve (23)
into housing (5).
19. Install O-ring (26) onto housing (5).
Main Relief Valve

20. Install main relief valve (6) onto housing (5).
21. Tighten plug (J) of main relief valve (6).
: 32 mm
: 83 N m (8.5 kgf m, 62 lbf ft)
W2-5-26
EX255-EX285
CONTROL VALVE
A=
B=
C=
D=
E=
F=

Travel (left)
Auxiliary
Boom II
Arm I
Swing
SM1212
F
9
10
8
9
4
7
13
5
11
14
15
16
17
SM1217
Cross section A-A
1
4
5
7
8
Socket Bolt
O-Ring
Pilot Housing
Bolt (5 Used)
9
10
11
13
14
Seat (10 Used)

Spring (5 Used)
Spool (Travel Left)
O-Ring
Spool (Swing)
15 - Spool (Arm I)
16 - Spool (Boom II)
17 - Spool (Auxiliary)
EX255-EX285
W2-5-27
CONTROL VALVE

2. Install seat (9), spring (10), and seat (9) on spool
(11) in that order.
Install bolt (8).
: 22 mm
: 15 N m (1.5 kgf m, 11 lbf ft)
3. Assemble spools (14) to (17) referring to steps
1 and 2 above.
4. Install spools (11), (14), (15), (16), and (17) into
housing (5).
5. Install O-rings (4) (5 used) and O-rings (13)
(3 used) onto housing (5).
6. Install pilot housing (7) onto housing (5).
7. Tighten socket bolts (1) (6 used).
:10 mm
: 78 N m (8 kgf m, 58 lbf ft)
W2-5-28
EX255-EX285
CONTROL VALVE
3
A = Boom Anti-Drift Valve
16
15
1
14
18
13
10
5
17
12 5
11
19
22
17
21
22 20 19
23
24
25
41
40
39
38
37
36
42
52
1
2
3
4
5
6
7
8
9
10
11
12
13
51
Pilot Plate
Socket Bolt
Body
Socket Bolt
O-Ring
Plug
Lock Nut
Poppet
O-Ring
Plug
Plug
Spool
Seat
43
50
44
49
26
34
35
45
48
46
34
20
33
29
32
31
28
30
47
14
15
16
17
18
19
20
21
22
23
24
25
26
27
SM1218
Spring
O-Ring
Spacer
O-Ring
O-Ring
O-Ring
Pilot Housing
Spool (Travel Right)
Spool (Bucket)
Spool (Boom I)
Backup Ring
27
28
29
30
31
32
33
34
35
36
37
38
39
Plug
O-Ring
Spring
Washer
Sleeve
Poppet
Bolt (4 Used)
Seat (8 Used)
Spring (4 Used)
Spool (Arm II)
Poppet
Spring
O-Ring
40
41
42
43
44
45
46
47
48
49
50
51
52
Backup Ring
Plug
Check Valve
Spring
O-Ring
Backup Ring
Spacer
Check Valve
Spring
O-Ring
Backup Ring
O-Ring
Spacer
EX255-EX285
W2-5-29
CONTROL VALVE

10. Loosen socket bolts (4) to remove body (3)
from housing (18).
NOTE - Spacer (16) and spring (14) may fly off at this
time.

: 10 mm
1. Loosen socket bolts (2), then remove pilot plate
(1) and pilot housing (21) from housing (18).
: 10 mm
2. Pull out four spools (36), (23 to 25) from housing
(18).

bolt (M5 Pitch 0.8).

Remove bolt (33).
: 22 mm
4. Remove seat (34), spring (35) and seat (34)
from bolt (33).
5. Disassemble spools (23), (24), (25), referring to
the steps 3 and 4 above.

6. Heat plug (27), (41) mounting part on spool (25)
using a hair dryer to melt adhesive.
75301502
7. Put spool (25) in a vise. Remove plugs (27),

(41) from spool (25) using special tool
(75301502).
the spool.
8. Remove spring (29), washer (30), sleeve (31),
and poppet (32) from one end of spool (25).
9. Remove spring (38) and poppet (37) from the
other end of spool (25).
SM1219
W2-5-30
EX255-EX285
CONTROL VALVE
A = Emergency Boom Lower Mechanism
A
3
7
8
18
10
22
52
48
47
SM1218
EX255-EX285
W2-5-31
CONTROL VALVE
Check Valve
bolt (M6 Pitch 1.0).

15. Remove overload relief valves (22) from housing (18).
: 32 mm
Emergency Boom Lower Mechanism

16. Loosen lock nut (7) to remove poppet (8) from
body (3).
: 13 mm
: 4 mm
17. Remove plug (10) from body (3).
: 19 mm
W2-5-32
EX255-EX285
CONTROL VALVE
A=
B=
C=
D=
E=
11

Boom I
22
12
13
10
14
22
16
4
15
5
SM1220
18
3
20
20
44-45
46
SM1212
43
C
42
18
22
18
SM1205
SM1214
22
3
4
5
6
7
8
9
10
Body
Socket Bolt
O-Ring
Plug
Lock Nut
Poppet
O-Ring
Plug
11
12
13
14
15
16
18
Plug
Spool
Seat
Spring
O-Ring
Spacer
Housing
(4-Spool Side)
20
22
42
43
44
45
46
O-Ring
Check Valve
Spring
O-Ring
Backup Ring
Spacer
EX255-EX285
W2-5-33
CONTROL VALVE
Overload relief valve

1. Install four overload relief valves (22) to housing
(18).
: 32 mm
: 83 N m (8.5 kgf m, 62 lbf ft)

9. Install O-ring (9) onto poppet (8). Install poppet
(8) into plug (10).
onto body (3).
11. Tighten poppet (8) until it comes in contact with
body (3) inside. Then, install lock nut (7).

housing (18).
3. Install O-rings (20) and (44) and backup ring (45)
on spacer (46). Install spacer (46) into housing
(18).
body (3).
5. Install O-ring (15) onto spacer (16). Install
spacer (16) into body (3).
6. Install O-rings (20) (3 used) onto housing (18)
and tighten socket bolts (4).
7. Install body (3) onto housing (18).
: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)
onto body (3).
: 6 mm
: 29 N m (3 kgf m, 22 lb ft)
NOTE - Use an alien wrench so that poppet (8) does

not turn when tightening lock nut (7).
: 13 mm
: 29 N m (3 kgf m, 22 lbf ft)
: 4 mm
W2-5-34
EX255-EX285
CONTROL VALVE
A=
B=
C=
D=
E=
G=
H=

Travel (right)
Bucket
Boom I
Arm II
33
34
21
35
19
34
18
17
23
36
18
25
47
21
48
49-50
51
24
52
1
Cross Section A-A
17
SM1221
34
SM1212
35
33
34
27
29
26
30
28
32
31
25
37
38
39-40
1
41
18
1
2
17
18
19
21
23
24
25
26
27
Pilot Plate
Socket Bolt
O-Ring
O-Ring
Pilot Housing
Spool (Travel Right)
Spool (Bucket)
Spool (Boom I)
Backup Ring
Plug
SM1214
SM1222
28
29
30
31
32
33
34
35
36
37
38
O-Ring
Spring
Washer
Sleeve
Poppet
Bolt (4 Used)
Seat (8 Used)
Spring (4 Used)
Spool (Arm II)
Poppet
Spring
39
40
41
47
48
49
50
51
52
O-Ring
Backup Ring
Plug
Check Valve
Spring
O-Ring
Backup Ring
O-Ring
Spacer
EX255-EX285
W2-5-35
CONTROL VALVE
Check Valve
housing (18).
2. Install O-rings (49) and (51) and backup ring
(50) on spacer (52). Install spacer (52) into
housing (18).
3. Install O-rings (17) (4 used) onto housing
(18).
4. Install pilot plate (1) onto housing (18) using
socket bolts (2) (7 used).
: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)

5. Attach poppet (32) and spring (29) to sleeve
(31).
plug (27). Apply LOCTITE 271 to the threads
of plug (27).
75301502
7. Put spool (25) in a vise. Tighten plug (27)

onto spool (25) using special tool
(75301502).
SM1219

the spool.
: 14 mm
: 15 N m (1.5 kgf m, 11 lbf ft)
8. Attach poppet (37) and spring (38) to spool
(25).
plug (41). Apply LOCTITE 271 to the threads
of plug (41).
75301502
10. Put spool (25) in a vise. Tighten plug (41)

onto spool (25) using a special tool
(75301502).
the spool.
: 14 mm
: 15 N m (1.5 kgf m, 11 lbf ft)
SM1219
W2-5-36
EX255-EX285
CONTROL VALVE
A=
B=
C=
D=
E=
G=

Travel (right)
Bucket
Boom I
Arm II
33
34
21
35
19
34
18
18
17
23
36
25
21
A
24
Cross Section A-A

SM1221
SM1212
34
35
33
34
25
18
SM1214
SM1222
EX255-EX285
W2-5-37
CONTROL VALVE
4 - Spool Side Main Spool

spool (36) in that order.
Install bolt (33).
: 22 mm
: 15 N m (1.5 kgf m, 111 lbf ft)
13. Assemble spools (23) to (25) referring to steps
11 and 12 above.
14. Install spools (36), (23), (24), and (25) into
housing (18).
15. Install O-rings (17) (4 used) and O-rings (19) (3
used) onto housing (18).
16. Install pilot housing (21) onto housing (18).
17. Tighten socket bolts (2) (7 used).
: 10 mm
: 78 N m (8 kgf m, 58 lbf ft)
W2-5-38
EX255-EX285
CONTROL VALVE
A=
Hydraulic Timer
1
8
7
8
7
6
4
15
13
14
12
10
11
2
3
SM1223
1
2
3
4

O-Ring
Plug
Check Valve
5
6
7
8
Spring
O-Ring
Cover
Socket Bolt
9
10
11
12

Spring
Filter
Restriction
13 - Poppet
14 - O-Ring
15 - Plug
EX255-EX285
W2-5-39
CONTROL VALVE
Hydraulic Timer
1. Remove plug (15) from housing (9).
: 22 mm
2. Remove poppet (13) and spring (10) from housing (9). Note that filter (11) cannot be removed
as it is fixed to poppet (13).
Check Valve
3. Loosen socket bolts (8) to remove covers (7)
from housings (1) and (9).
: 8 mm
4. Remove springs (5) and check valves (4) from
housings (1) and (9).
5. Remove plugs (3) from housings (1) and (9).
: 19 mm
W2-5-40
EX255-EX285
CONTROL VALVE
ASSEMBLE CONTROL VALVE 5
A = Hydraulic Timer
1
7
8
6
7
6
5
4
SM1217
SM1221
A
15
2
14
12
11
13
10
SM1227
SM1224
8
8
7
9
1
SM1226
SM1225
1
2
3
4

O-Ring
Plug
Check Valve
5
6
7
8
Spring
O-Ring
Cover
Socket Bolt
9 - Housing
(4-Spool Side)
10 - Spring
11 - Filter
12
13
14
15
Restriction
Poppet
O-Ring
Plug
EX255-EX285
W2-5-41
CONTROL VALVE
Assemble Control Valve 5
Check Valve
1. Install check valves (4) (3 used) and springs (5)
(3 used) into housings (1) and (9).
2. Install O-rings (6) (3 used) onto housings (1) and
(9). Install cover (7) onto housing (1) and tighten
socket bolt (8).
: 8 mm
: 61 N m (6.2 kgf m, 45 lbf ft)
Hydraulic Timer
3. Attach poppet (13) and spring (10) to plug (15).
onto housing (9).
: 22 mm
: 76 N m (7.7 kgf m, 56 lbf ft)
5. Install O-ring (2) on each plug (3) (2 used).
Install plugs (3) on housings (1) and (9).
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
W2-5-42
EX255-EX285
CONTROL VALVE
NOTES
EX255-EX285
W2-6-1
SWING DEVICE
REMOVE AND INSTALL SWING DEVICE
WARNING
Preparation
pressure.

while working.
Removal
1. Disconnect hoses (1, 3, 5 to 8).
: 41 mm
: 205 N m (21 kgf m, 152 lbf ft)
: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft)
: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)
: 8 mm
: 64 N m (6.5 kgf m, 147 lbf ft)
2
3
NOTE - Attach caps to hoses and pipes.
2. Remove adapter (2) and install an eyebolt to the

swing device assembly to sling it with a wire rope.
Eyebolts: (M27 Pitch 2.0)
: 36 mm
: 108 N m (11 kgf m, 80 lbf ft)
7
6
5
4
WARNING
Swing device assembly weight: 330 kg (730 lb)
3. Remove swing device mounting bolts (4).
4. Sling the swing device assembly with a crane or
hoist.
: 32 mm
: 640 N m (65 kgf m, 470 lbf ft)
SM1024
Installation
1. Install the swing device assembly to frame and
tighten bolts (4).
IMPORTANT - Before installing the swing device
assembly, apply liquid packing to both mounting
surfaces on the swing reduction gears and frame.
2. Install adapter (2). Connect hoses (1, 3, 5 to 8).

IMPORTANT - Be sure to fill the swing motor with
hydraulic oil after installing it. Check hydraulic oil
level. Add oil if necessary. Run the engine. Check the
components for any oil leakage.
W2-6-2
EX255-EX285
EX255
SWING DEVICE
DISASSEMBLE SWING DEVICE (EX255)
31
2
3
4
5
30
29
22
28
23
27
21
20
19
9
7
26
18
10
17
11
16
12
15
13
24
25
14
13
SM3501
1
2
3
4
5
6
7
8
9
10
11
Swing Motor
Thrust Plate (2 Used)
Pin (3 Used)
Spring Pin (3 Used)
Needle Bearing (3 Used)
First Stage Planetary Gear (3 Used)
Pin (3 Used)
12
13
14
15
16
17
18
19
20
21
22
Spring Pin (3 Used)

Second Stage Planetary Gear (3 Used)
Bearing
Retaining Ring
O-Ring
Ring Gear
First Stage Carrier
Drain Pipe
23
24
25
26
27
28
29
30
31
Drain Plug
Bolt (10 Used)
Oil Seal
Cover
Shaft
O-Ring
Sleeve
Bearing
Housing
EX255-EX285
EX255
W2-6-3
SWING DEVICE
Disassemble Swing Device
1. Remove plug (23) to drain oil and disconnect drain

pipe (22).
Drain oil: 13.2 L (13.95 US qt)
: 27 mm
WARNING
Swing motor weight: 60 kg (132 Ib)
2. Put matching marks on swing motor, ring gear
(19), and housing (31). Remove socket bolts (2).
Remove motor (1) using a crane.
: 10 mm
NOTE - Insert a screwdriver between the motor and
ring gear (19) to pry the motor up for easy separation.
3. Remove first stage sun gear (3). Remove first
stage carrier (21) assembly from ring gear (19).
WARNING
Ring gear weight: 29 kg (64 lb)
4. Remove socket bolts (10). Remove ring gear (19)
using a crane.
: 14 mm
NOTE - Insert a screwdriver to the notches on housing (31) to pry ring gear (19) up for easy separation.
5. Remove O-ring (18) from housing (31).
WARNING
Second stage carrier assembly weight:
30 kg (66 lb)
6. Remove second stage sun gear (20) and second

stage carrier (17) assembly.
7. Remove retaining ring (16) from shaft (27).
WARNING
Remaining component weight
(Housing, shaft,etc.): Approx. 160 kg (350 lb)
8. Turn over housing (31). Loosen bolts (24). Remove cover (26).
: 19 mm
9. Remove oil seal (25) from cover (26).
10. Push shaft (27) out of housing (31) using a press.
W2-6-4
EX255-EX285
EX255
SWING DEVICE
31
2
3
4
5
30
29
22
28
23
27
21
20
19
9
7
26
25
18
10
17
11
16
12
15
13
24
14
13
SM3501
EX255-EX285
EX255
W2-6-5
SWING DEVICE
11. Pull bearing (30) out of shaft (27) using a press.
12. Remove sleeve (29) from shaft (27). Remove
O-ring (28) from sleeve (29).
13. Remove bearing (15) from housing (31).
14. Drive spring pins (6) (3 used) out of first stage
carrier (21) using a round bar and a hammer.
15. Remove pins (5) (3 used), first stage planetary
gears (9) (3 used), thrust plates (7) (6 used), and
needle bearings (8) (3 used) from first stage
carrier (21).
16. Remove thrust plate (4) from first stage carrier
(21).
17. Disassemble second stage carrier (17) assembly
referring to steps 14 to 16 above. (Note that no
needle bearings are used on the second stage
planetary gears).
EX255
EX255-EX285
W2-6-6
SWING DEVICE
ASSEMBLE SWING DEVICE (EX255)
21
8
9
7
12
19
14
20
10
18
13
17
11
16
4
15
22
30
31
24
26
25
23
29
1
2
3
4
5
6
7
8
9
10
11
Swing Motor
Pin (3 Used)
Spring Pin (3 Used)
Pin (3 Used)
SM3518
27
28
12
13
14
15
16
17
18
19
20
21
22
Spring Pin (3 Used)

Bearing
Retaining Ring
O-Ring
Ring Gear
First Stage Carrier
Drain Pipe
23
24
25
26
27
28
29
30
31
Drain Plug
Bolt (10 Used)
Oil Seal
Cover
Shaft
O-Ring
Sleeve
Bearing
Housing
EX255-EX285
EX255
W2-6-7
SWING DEVICE
Assemble Swing Device
1. Install needle bearing (8) in each of first stage
planetary gears (9) (3 used).
WARNING
Housing weight: 92 kg (203 lb)
IMPORTANT - Set thrust plate (4) with the grooved

side upwards.
9. Attach housing (31) to a crane using eye bolts. Lift

and mount housing (31) onto shaft (27).
2. Install thrust plate (4) in first stage carrier (21).
IMPORTANT - Set thrust plates (7) with the grooved

sides facing toward the planetary gear end. Also, set
the thrust plates so that the bent parts fit along the
periphery of the carrier flange.
3. Install first stage planetary gears (9) (3 used) and

thrust plates (7) (6 used) into first stage carrier
(21).
4. Aligning the hole on pin (5) with spring pin hole on

first stage carrier (21), drive pins (5) (3 used) into
first stage carrier (21).
5. Tap spring pins (6) (3 used) into first stage carrier

(21) and pin (5).
NOTE - Be sure that the slit part of spring pin (6) faces
upwards as shown.when driving it into the first stage
carrier and the pin.
5
6
Slit
6. Assemble second stage carrier (17), referring to

steps 2 to 5 above.
NOTE - Thrust plates (13) do not have any bent parts.
7. Install O-ring (28) on sleeve (29). Install sleeve

(29) onto shaft (27).
8. Install bearing (30) onto shaft (27) using a press.
10. Install bearing (15) into housing (31) using a

press.
11. Install retaining ring (16) onto shaft (27).
EX255
EX255-EX285
W2-6-8
SWING DEVICE
21
10
19
20
18
17
31
24
26
25
27
SM3518
EX255-EX285
EX255
W2-6-9
SWING DEVICE
12. Apply THREEBOND 1215 to oil seal (25) mounting part of cover (26). Install oil seal (25) onto
cover (26).
18. Install first stage carrier (21) into ring gear (19).
IMPORTANT - Be sure to position the sun gear with

the stepped end facing downward.
13. Apply THREEBOND 1215 on cover (26) mounting part of housing (31).
19. Install first stage sun gear (3) into first stage
carrier (21).
WARNING
Total weight assembled so far
(housing, shaft, etc.): Approx. 145 kg (320 lb)
IMPORTANT - Be sure that the lip part of oil seal (25)

does not come into contact with the tooth end of shaft
(27) when installing the cover.
14. Turn over housing (31). Install cover (26) using

bolts (24).
: 19 mm
: 88 N m (9 kgf m, 65 lbf ft)
WARNING
Second stage carrier weight: 30 kg (66 lb)
15. Turn over housing (31). Install second stage

carrier (17) assembly into housing (31). Install Oring (18) on housing (31).
16. Install second stage sun gear (20) into second

stage carrier (17).
WARNING
17. Attach ring gear (19) to a crane using eye bolts

(M12 Pitch 1.75).
Lift and install ring gear (19) into housing (31).
Tighten socket bolts (10).
NOTE - Be sure to align the matching mark on ring
gear (19) with that on housing (31).
: 14 mm
: 205 N m (21 kgf m, 152 lbf ft)
W2-6-10
EX255-EX285
EX255
SWING DEVICE
19
22
31
23
SM3518
EX255-EX285
EX255
W2-6-11
SWING DEVICE
20. Install drain plug (23) on drain pipe (22). Install
drain pipe (22) onto housing (31).
: 10 mm
: 49 N m (5 kgf m, 36 Ibf ft)
: 27 mm
: 93 N m (9.5 kgf m, 69 Ibf ft)
21. Fill the swing reduction gear with proper oil.

Proper Oil: 13.2 L (13.95 US qt)
22. Apply THREEBOND 1102 to the swing motor

mounting surface of ring gear (19).
WARNING
Swing motor weight: Approx. 60 kg (132 lb)
23. Lift and mount motor (1) onto ring gear (19).
NOTE - Be sure to align the matching mark on motor

(1) with that on ring gear (19).
: 10 mm
: 88 N m (9 kgf m, 65 Ibf ft)
W2-6-12
EX255-EX285
EX285
SWING DEVICE
DISASSEMBLE SWING DEVICE (EX285)
1
2
16
15
3
4
5 6
21
31
7
8
9
7
20
12 11
22
30
33
23
17
26
24
29
25
13
28
14
13
32
10
19
27
18
SM5102
1
2
3
4
5
6
7
8
9
10
11
Swing Motor
Pin (3 Used)
Spring Pin (3 Used)
Pin (3 Used)
12
13
14
15
16
17
18
19
20
21
22
Spring Pin (3 Used)

Bearing
Retaining Ring
O-Ring
Ring Gear
First Stage Carrier
Drain Pipe
23
24
25
26
27
28
29
30
31
32
33
Drain Plug
Bolt (10 Used)
Oil Seal
Cover
Shaft
O-Ring
Sleeve
Bearing
Housing
O-Ring
O-Ring
EX255-EX285
EX285
W2-6-13
SWING DEVICE
Disassemble Swing Device
1. Remove plug (23) to drain oil and disconnect drain

pipe (22).
Drain oil: 17 L (17.96 US qt)
: 27 mm
WARNING
Swing motor weight: 70 kg (154 Ib)
2. Put matching marks on the swing motor, ring gear
(19), and housing (31). Remove socket bolts (2).
Remove motor (1) using a crane.
: 10 mm
NOTE - Insert a screwdriver between the motor and
ring gear (19) to pry the motor up for easy separation.
3. Remove first stage sun gear (3). Remove first
stage carrier (21) assembly from ring gear (19).
Remove O-ring (32) from ring gear (19).
WARNING
4. Remove socket bolts (10). Remove ring gear (19)
using a crane.
: 17 mm
NOTE - Insert a screwdriver to the notches on housing (31) to pry ring gear (19) up for easy separation.
5. Remove O-ring (18) from housing (31).
WARNING
Second stage carrier assembly weight:
35 kg (77 lb)

stage carrier (17) assembly.
7. Remove retaining ring (16) from shaft (27).
WARNING
Remaining component weight
(housing, shaft,etc.): approx. 210 kg (463 lb)
8. Turn over housing (31). Loosen bolts (24). Remove cover (26).
: 19 mm
9. Remove oil seal (25) and O-Ring (33) from cover
(26).
10. Push shaft (27) out of housing (31) using a press.
W2-6-14
EX255-EX285
EX285
SWING DEVICE
1
2
16
15
3
4
5 6
21
31
20
12 11
30
33
22
23
7
8
9
7
17
26
24
29
25
13
28
14
13
32
10
27
19
18
SM5102
EX255-EX285
EX285
W2-6-15
SWING DEVICE
11. Pull bearing (30) out of shaft (27) using a press.
12. Remove sleeve (29) from shaft (27). Remove
O-ring (28) from sleeve (29).
13. Remove bearing (15) from housing (31).
14. Drive spring pins (6) (3 used) out of first stage
carrier (21) using a round bar and a hammer.
15. Remove pins (5) (3 used), first stage planetary
gears (9) (3 used), thrust plates (7) (6 used), and
needle bearings (8) (3 used) from first stage
carrier (21).
16. Remove thrust plate (4) from first stage carrier
(21).
referring to steps 14 to 16 above. (Note that no
needle bearings are used on the second stage
planetary gears).
W2-6-16
EX255-EX285
EX285
SWING DEVICE
ASSEMBLE SWING DEVICE (EX285)
6
5
1
2
4
19
32
8
9
7
12
14
21
20
10
17
13
18
11
16
4
15
22
30
31
33
26
25
24
29
23
28
27
SM5103
1
2
3
4
5
6
7
8
9
10
11
Swing Motor
Pin (3 Used)
Spring Pin (3 Used)
Pin (3 Used)
12
13
14
15
16
17
18
19
20
21
22
Spring Pin (3 Used)

Bearing
Retaining Ring
O-Ring
Ring Gear
First Stage Carrier
Drain Pipe
23
24
25
26
27
28
29
30
31
Drain Plug
Bolt (10 Used)
Oil Seal
Cover
Shaft
O-Ring
Sleeve
Bearing
Housing
EX255-EX285
EX285
W2-6-17
SWING DEVICE
Assemble Swing Device
1. Install needle bearing (8) in each of first stage
planetary gears (9) (3 used).
WARNING
IMPORTANT - Set thrust plate (4) with the grooved

side upwards.
9. Attach housing (31) to a crane using eye bolts.

Lift and mount housing (31) onto shaft (27).
2. Install thrust plate (4) in first stage carrier (21).
IMPORTANT - Set thrust plates (7) with the grooved

sides facing toward the planetary gear end. Also, set
the thrust plates so that the bent parts fit along the
periphery of the carrier flange.
3. Install first stage planetary gears (9) (3 used) and

thrust plates (7) (6 used) into first stage carrier
(21).
4. Aligning the hole on pin (5) with spring pin hole on

first stage carrier (21), drive pins (5) (3 used) into
first stage carrier (21).
5. Tap spring pins (6) (3 used) into first stage carrier

(21) and pin (5).
upwards as shown.when driving it into the first stage
carrier and the pin.
5
6
Slit
6. Assemble second stage carrier (17), referring to

steps 2 to 5 above.
NOTE - Thrust plates (13) do not have any bent parts.
7. Install O-ring (28) on sleeve (29). Install sleeve

(29) onto shaft (27).
8. Install bearing (30) onto shaft (27) using a press.
10. Install bearing (15) into housing (31) using a

press.
11. Install retaining ring (16) onto shaft (27).
W2-6-18
EX255-EX285
EX285
SWING DEVICE
32
21
19
20
10
17
18
31
33
24
26
25
27
SM5103
EX255-EX285
EX285
W2-6-19
SWING DEVICE
12. Apply THREEBOND 1215 to oil seal (25) mounting part of cover (26). Install oil seal (25) and Oring (33) onto cover (26).
18. Install first stage carrier (21) and O-ring (32) into
ring gear (19).
19. Install first stage sun gear (3) into first stage
carrier (21).
13. Apply THREEBOND 1215 on cover (26) mounting part of housing (31).
WARNING
Total weight assembled so far
(Housing, shaft, etc.): Approx. 190 kg (420 lb)

does not come into contact with the tooth end of shaft
(27) when installing the cover.
14. Turn over housing (31). Install cover (26) using

bolts (24).
: 19 mm
: 88 N m (9 kgf m, 65 lbf ft)
WARNING
Second stage carrier weight: 35 kg (77 lb)
15. Turn over housing (31). Install second stage

carrier (17) assembly into housing (31). Install Oring (18) on housing (31).

stage carrier (17).
WARNING
17. Attach ring gear (19) to a crane using eye bolts

(M12 Pitch 1.75).
Lift and install ring gear (19) into housing (31).
NOTE - Be sure to align the matching mark on ring
gear (19) with that on housing (31).
: 14 mm
: 205 N m (21 kgf m, 152 lbf ft)
IMPORTANT - Be sure to position the sun gear with

the stepped end facing downward.
EX285
EX255-EX285
W2-6-20
SWING DEVICE
1
2
19
22
31
23
SM5103
EX255-EX285
EX285
W2-6-21
SWING DEVICE
20. Install drain plug (23) on drain pipe (22). Install
drain pipe (22) onto housing (31).
: 10 mm
: 49 N m (5 kgf m, 36 Ibf ft)
: 27 mm
: 93 N m (9.5 kgf m, 69 Ibf ft)
21. Fill the swing reduction gear with proper oil.

Proper Oil: 17.0 L (18 US qt)
22. Apply THREEBOND 1102 to the swing motor

mounting surface of ring gear (19).
WARNING
Swing motor weight: Approx. 70 kg (154 lb)
23. Lift and mount motor (1) onto ring gear (19).
NOTE - Be sure to align the matching mark on motor

(1) with that on ring gear (19).
: 10 mm
: 88 N m (9 kgf m, 65 Ibf ft)
W2-6-22
EX255-EX285
EX255
SWING DEVICE
DISASSEMBLE SWING MOTOR (EX255)
7
8
9
10
11
12
13
14
15
33
16
32
31
17
34
17
18
30
17
27
19
20
24
25
26
28
35
29
36
37
21
38
22
39
23
40
41
42
SM1027
43
1 - Roller Bearing
2 - O-Ring
3 - Valve Casing
(Brake Valve)
4 - Socket Bolt (4 Used)
5 - Poppet (2 Used)
6 - Spring (2 Used)
7 - O-Ring (2 Used)
8 - Plug (2 Used)
9 - Valve Plate
10 - Spring (18 Used)
11
12
13
14
15
16
17
18
19
20
21
Brake Piston
O-Ring
Friction Plate (3 Used)
Relief Valve (2 Used)
Pin (2 Used)
Push Rod (12 Used)
Spacer (3 Used)
Holder
Cover
O-Ring
22
23
24
25
26
27
28
29
30
31
32
Spring
Spool
Plug (3 Used)
Spool
Spring
Rotor
O-Ring
Plug
Spring
Retaining Ring
Plate (4 Used)
33
34
35
36
37
38
39
40
41
42
43
O-Ring
Plunger (9 Used)
Retainer Plate
Thrust Plate
Spacer
Roller Bearing
Oil Seal
Seal Cover
Retaining Ring
Casing
EX255-EX285
EX255
W2-6-23
SWING DEVICE
Disassemble Swing Motor
WARNING
Weight of swing motor assembly:
approx. 60 kg (130 Ib)
5. Remove valve casing (3) from casing (43).
NOTE - Valve plate (9) may be stuck on the bottom of

valve casing (3). Take care not to drop valve plate (9)
when removing valve casing (3).
6. If valve plate (9) has not been removed in the
previous step, remove it. Then, remove springs
(10) (18 used ).
1. Remove relief valves (14) (2 used) from valve

casing (3).
NOTE - Never attempt to disassemble relief valves
(14).
: 36 mm
2. Remove plugs (8) (2 used).
IMPORTANT - If a screwdriver or similar tool is used

to separate (pry) valve plate (9) from the rotor side,
take care not to damage the sealing surfaces. (Note
that the top surface of the valve plate differs from the
bottom surface.)
7. Apply two hooks to the notch A and pull the hooks

to remove brake piston (11).
: 14 mm
8. Remove O-rings (12), (33) from casing (43).
3. Remove springs (6) (2 used) and poppets (5) (2
used).
4. Put align marks on valve casing (3) and casing

(43). Loosen and remove socket bolts (4) (4 used).
: 17 mm
11
43
NOTE - Note that valve casing (3) will be raised by

springs (10) as socket bolts (4) are loosened.
SM1028
W2-6-24
EX255-EX285
EX255
SWING DEVICE
13
16
32
31
17
34
17
18
30
17
27
35
29
19
20
25
36
26
37
21
38
22
39
23
40
41
42
SM1027
43
EX255-EX285
EX255
W2-6-25
SWING DEVICE
9. Lay casing (43) on its side. Pull out rotor (27) from
shaft (37).
10. Remove plates (32) (4 used) and friction plates

(13) (3 used) from casing (43).
WARNING
Be sure to press and hold spacer (17) using a press
when removing retaining ring (31).
Attempting to remove retaining ring (31) without
pressing the spacer down may cause the spacer
and/or retaining ring (31) to spring up, possibly
resulting in personal injury.
11. Remove thrust plate (36).
12. Lay casing (43) on its side. Drive shaft (37) out of
casing (43) using a plastic hammer.
18. Press and hold spacer (17) using a press, and

remove retaining ring (31).
19. Remove spacer (17), spring (30), and spacer (17).

13. Remove retaining ring (42) and seal cover (41)
from casing (43).
20. Remove plug (29), spring (26), and spool (25) from
casing (43).
: 6 mm
14. Remove oil seal (40) from casing (43).

21. Remove socket bolts (19), cover (20) and O-ring
(21).
15. Remove the outer race of roller bearing (39) from
casing (43) using a metal bar and a plastic hammer.
: 4 mm
22. Remove spring (22) and spool (23) from casing

(43).
16. Remove the inner race of roller bearing (39), from
shaft (37) using a press. Remove spacer (38) from
shaft (37).
17. Remove plungers (34) (9 used), retainer plate (35),

holder (18), spacer (17), push rods (16)
(12 used) from rotor (27).
NOTE - Although a filter and an orifice are install in

spool (23), do not attempt to remove them unless
restriction or deformation is found.
W2-6-26
EX255-EX285
EX255
SWING DEVICE
ASSEMBLE SWING MOTOR (EX255)
14
Y
29
28
30
17
31
15
10
2
Cross Section Y-Y
26
11
24
12
19
33
20
13
21
22
23
25
32
35
27
36
16
17
34
18
38
40
1 - Roller Bearing
2 - O-Ring
3 - Valve Casing
(Brake Valve)
5 - Poppet (2 Used)
6 - Spring (2 Used)
7 - O-Ring (2 Used)
8 - Plug (2 Used)
9 - Valve Plate
11
12
13
14
15
16
17
18
19
20
21
41
Brake Piston
O-Ring
Pin (2 Used)
Push Rod (12 Used)
Spacer (3 Used)
Holder
Cover
O-Ring
37
42
22
23
24
25
26
27
28
29
30
31
32
39
43
Spring
Spool
Plug (3 Used)
Spool
Spring
Rotor
O-Ring
Plug
Spring
Retaining Ring
Plate (4 Used)
SM1029
33
34
35
36
37
38
39
40
41
42
43
- O-Ring
- Plunger (9 Used)
- Retainer Plate
- Thrust Plate
- Shaft (Output Shaft)
- Spacer
- Roller Bearing
- Oil Seal
- Seal Cover
- Retaining Ring
- Casing
EX255-EX285
EX255
W2-6-27
SWING DEVICE
Assemble Swing Motor
1. Install spacer (38) onto shaft (37).
Install the inner race of roller bearing (39) onto shaft
(37) using a press.
10. Attach plungers (34) (9 used) on retainer plate (35).

Insert plungers (34) into rotor (27).
2. Install retaining ring (42) onto casing (43).

Install the inner race of roller bearing (1) onto shaft
(37) using a press.
IMPORTANT - Be sure to apply a film of hydraulic oil

on the rotor bore surface before inserting plungers (43).

faces upwards when installing it.
3. Turnover casing (43). Install seal cover (41) into

casing (43). Install oil seal (40) into casing (43)
using a protection plate and a press.
11. Lay casing (43) on its side.

Install rotor (27) assembly onto shaft (37).
IMPORTANT - On each of plate (32) periphery is a

series of tab-like protrusions with four of the protrusions missing at an interval. Likewise, four teeth are
missing on each friction plate. When installing plates
(32) and friction plates (13), be sure to align these
missing parts.
4. Install the outer race of roller bearing (39) onto

casing (43) a metal bar and a hammer.
12. Stand casing (43) upright. Install plates (32)
(4 used) and friction plates (13) (3 used) one by one
alternately.
5. Lay casing (43) on its side. Install shaft (37) into
casing (43).
13. Install O-rings (12) and (33) on casing (43).
6. Stand casing (43) upright. Install thrust plate (36)
into casing (43).
7. Install spacer (17), spring (30), and spacer (17) into

rotor (27), in that order.
8. Press down spacer (17) to give enough clearance

for retaining ring (31) installation. Install retaining
ring (31).
9. Insert push rods (16) (12 used) into rotor (27).

Install spacer (17) and holder (18) onto rotor (27), in
that order.
14. Install brake piston (11) into casing (43). If brake

piston (11) does not enter the casing smoothly due
to the installation of the O-rings above, tap the
periphery of the brake piston evenly with a plastic
hammer.
15. Install spring (10) (18 used ) on brake piston (11).
EX255
EX255-EX285
W2-6-28
SWING DEVICE
14
Y
29
28
2
Cross Section Y-Y
26
19
20
21
25
22
23
43
SM1029
EX255-EX285
EX255
W2-6-29
SWING DEVICE
IMPORTANT - Be sure that the model stamped end of
roller bearing faces upwards when installing.
21. Install spool (25) and spring (26) into casing (43).
Tighten attached plug (29), O-ring (28).
: 6 mm
: 36 N m (3.7 kgf m, 27 lbf ft)
16. Install roller bearing (1) into valve casing (3) using
a plastic hammer.
22. Install spool (23) and spring (22) into casing (43).
17. Install O-ring (2) and valve plate (9) on valve
casing (3).
NOTE - Be sure to apply grease to the contact surface
of valve plate (9) so as to prevent it from dropping when
installing valve casing (3) onto the casing.
IMPORTANT - Take care not to drop valve plate (9).

Also, be sure to align the matching marks on valve
casing (3) and casing (43).
18. Install valve casing (3) onto casing (43). Tighten

valve casing (3) onto casing (43) using socket
bolts (4)(4 used).
: 17 mm
: 430 N m (44 kgf m, 320 lbf ft)
19. Insert poppets (5) (2 used) and springs (6)

(2 used) into valve casing (3). Tighten attached
plugs (8), O-ring (7).
: 14 mm
: 330 N m (34 kgf m, 245 lbf ft)
20. Install relief valves (14) (2 used) into valve casing

(3).
: 36 mm
: 175 Nm (18 kgf m, 130 lbf ft)
23. Install O-ring (21) and cover (20) onto casing (43).
: 4 mm
: 7 N m (0.7 kgf m, 5 lbf ft)

hydraulic oil after installing it.
W2-6-30
EX255-EX285
EX285
SWING DEVICE
DISASSEMBLE SWING MOTOR (EX285)
1
9
10
11
12
13
5
6 7 8
14
44 15
33
16
34
18
17
30
45
19
31
32
38
46
27
35
43
36
37
39
40
41
42
47
SM5507
45
47
48
1 - Roller Bearing
2 - O-Ring
3 - Valve Casing
(Brake Valve)
5 - Poppet (2 Used)
6 - Spring (2 Used)
7 - O-Ring (2 Used)
8 - Plug (2 Used)
9 - Valve Plate
10
11
12
13
14
15
16
17
18
19
Spring (24 Used)

Brake Piston
O-Ring
Pin (2 Used)
Push Rod (12 Used)
Spacer
Holder
30
31
32
33
34
35
36
37
38
39
Spring
Retaining Ring
Plate (3 Used)
O-Ring
Plunger (9 Used)
Retainer Plate
Thrust Plate
Spacer
Roller Bearing
40
41
42
43
44
45
46
Oil Seal
Seal Cover
Retaining Ring
Casing
Retaining Ring
Spacer (3 Used)
Parking Brake
Release Valve
47 - Retaining Ring (2 Used)
48 - O-Ring
EX255-EX285
EX285
W2-6-31
SWING DEVICE
Disassemble Swing Motor
WARNING
Weight of swing motor assembly:
Approx. 70 kg (155 Ib)
1. Remove relief valves (14) (2 used) from valve

casing (3).
NOTE - Never attempt to disassemble relief valves
(14).
: 36 mm
2. Remove plugs (8) (2 used).

: 14 mm
3. Remove springs (6) (2 used) and poppets (5) (2

used).
6. Remove valve casing (3) from casing (43).
NOTE - Valve plate (9) may be stuck on the bottom of

valve casing (3). Take care not to drop valve plate (9)
when removing valve casing (3).
7. If valve plate (9) has not been removed in the

previous step, remove it. Then, remove springs
(10) (24 used ).
IMPORTANT - If a screwdriver or similar tool is used

to separate (pry) valve plate (9) from the rotor side,
take care not to damage the sealing surfaces. (Note
that the top surface of the valve plate differs from the
bottom surface.)
8. Apply two hooks to the notch A and pull the hooks

to remove brake piston (11).
9. Remove O-rings (12), (33) from casing (43).
4. Loosen socket bolts (19) to remove parking brake

release valve (46) from casing (43).
: 10 mm
11
43
5. Put align marks on valve casing (3) and casing

(43). Loosen and remove socket bolts (4) (4 used).
: 17 mm
NOTE - Note that valve casing (3) will be raised by

springs (10) as socket bolts (4) are loosened.
SM1028
EX285
EX255-EX285
W2-6-32
SWING DEVICE
9
10
11
12
13
5
6 7 8
14
44 15
33
16
34
18
17
30
45
19
31
32
38
46
27
35
43
36
37
39
40
41
42
47
45
47
48
SM5507
EX255-EX285
EX285
W2-6-33
SWING DEVICE
10. Lay casing (43) on its side. Pull out rotor (27) from
shaft (37).
11. Remove plates (32) (3 used) and friction plates

(13) (2 used) from casing (43).
12. Remove thrust plate (36).
13. Remove retaining ring (42) and seal cover (41)

from casing (43).
WARNING
Be sure to press and hold spacer (45) using a press
when removing retaining ring (31).
Attempting to remove retaining ring (31) without
pressing the spacer down may cause the spacer
and/or retaining ring (31) to spring up, possibly
resulting in personal injury.
19. Press and hold spacer (45) using a press, and

remove retaining ring (31).
20. Remove spacer (45), spring (30), and spacer (38).
14. Remove oil seal (40) from seal cover (41).
15. Lay casing (43) on its side. Drive shaft (37) out of
16. Remove retaining rings (44) and (47) (2 used).

Remove the outer race of roller bearing (39) from
casing (43) using a metal bar and a plastic hammer.
17. Remove the inner races of roller bearings (39) and

(1), from shaft (37) using a press. Remove spacer
(45) from shaft (37).
18. Remove plungers (34) (9 used), retainer plate (35),

holder (18), spacer (17), push rods (16) (12 used)
from rotor (27).
21. Remove the outer race of roller bearing (1), from

valve casing (3), using a bearing puller.
W2-6-34
EX255-EX285
EX285
SWING DEVICE
ASSEMBLE SWING MOTOR (EX285)
44
3
1
31
15
45
11
12
10
33
30
13
38
32
19
27
46
18
34
35
16
17
36
47
43
45
39
48
41
37
40
42
5
14
7
SM5508
1 - Roller Bearing
2 - O-Ring
3 - Valve Casing
(Brake Valve)
5 - Poppet (2 Used)
6 - Spring (2 Used)
7 - O-Ring (2 Used)
8 - Plug (2 Used)
9 - Valve Plate
11
12
13
14
15
16
17
18
19
27
30
Brake Piston
O-Ring
Pin (2 Used)
Push Rod (12 Used)
Spacer
Holder
Rotor
Spring
31
32
33
34
35
36
37
38
39
40
41
- Retaining Ring
- Plate (4 Used)
- O-Ring
- Plunger (9 Used)
- Retainer Plate
- Thrust Plate
- Shaft (Output Shaft)
- Spacer
- Roller Bearing
- Oil Seal
- Seal Cover
42
43
44
45
46
Retaining Ring
Casing
Retaining Ring
Spacer (3 Used)
Parking Brake
Release Valve
47 - Retaining Ring (2 Used)
48 - O-Ring
EX255-EX285
EX285
W2-6-35
SWING DEVICE
Assemble Swing Motor
1. Install retaining ring (47) and spacer (45) onto
shaft (37).
Install the inner race of roller bearing (39) onto
shaft (37) using a press.
Install spacer (45) and retaining ring (47) onto
shaft (37).
2. Install the inner race of roller bearing (1) onto shaft
(37) using a press. Install retaining ring (44) onto
shaft (37).

faces upwards when installing it.
3. Install oil seal (40) onto seal cover (41) using a

protection plate and a press.
4. Install the outer race of roller bearing (39) onto

casing (43) a metal bar and a hammer.
5. Lay casing (43) on its side. Install shaft (37) into

casing (43).
6. Stand casing (43) upright. Install O-ring (48) into

casing (43).
7. Install seal cover (41) into casing (43). Secure

with retaining ring (42).
8. Install spacer (38), spring (30), and spacer (45)

into rotor (27), in that order.
9. Press down spacer (45) to give enough clearance

for retaining ring (31) installation. Install retaining
ring (31).
10. Insert push rods (16) (12 used) into rotor (27).
Install spacer (17) and holder (18) onto rotor (27),
in that order.
11. Attach plungers (34) (9 used) on retainer plate (35).

Insert plungers (34) into rotor (27).

on the rotor bore surface before inserting plungers (34).
12. Lay casing (43) on its side.

Install thrust plate (36) onto rotor (27). Install them
onto shaft (37).
IMPORTANT - On each of plate (32) periphery is a

series of tab-like protrusions with four of the protrusions missing at an interval. Likewise, four teeth are
missing on each friction plate. When installing plates
(32) and friction plates (13), be sure to align these
missing parts.
13. Stand casing (43) upright. Install plates (32)

(3 used) and friction plates (13) (2 used) one by one
alternately.
14. Install O-rings (12) and (33) on casing (43).
15. Install brake piston (11) into casing (43). If brake

piston (11) does not enter the casing smoothly due
to the installation of the O-rings above, tap the
periphery of the brake piston evenly with a plastic
hammer.
16. Install spring (10) (24 used ) on brake piston (11).
EX285
EX255-EX285
W2-6-36
SWING DEVICE
44
3
1
31
15
45
11
12
10
33
30
13
38
32
19
27
46
18
34
35
16
17
36
47
43
45
39
48
41
37
40
42
5
14
7
SM5508
EX255-EX285
EX285
W2-6-37
SWING DEVICE
IMPORTANT - Be sure that the model stamped end of
roller bearing faces upwards when installing.
22. Install parking brake release valve (46) onto casing (43) using socket bolts (19) (3 used).
: 10 mm
17. Install the outer race of roller bearing (1) into valve
18. Install O-ring (2) and valve plate (9) on valve

casing (3).
NOTE - Be sure to apply grease to the contact surface
of valve plate (9) so as to prevent it from dropping when
installing valve casing (3) onto the casing.
IMPORTANT - Take care not to drop valve plate (9).

Also, be sure to align the matching marks on valve
casing (3) and casing (43).
19. Install valve casing (3) onto casing (43). Tighten

valve casing (3) onto casing (43) using socket
bolts (4)(4 used).
: 17 mm
: 430 N m (44 kgf m, 320 lbf ft)
20. Insert poppets (5) (2 used) and springs (6)

(2 used) into valve casing (3). Tighten attached
plug (8) O-ring (7).
: 14 mm
: 330 N m (34 kgf m, 245 lbf ft)
21. Install relief valves (14) (2 used) into valve casing

(3).
: 36 mm
: 175 Nm (18 kgf m, 130 lbf ft)
: 9.8 N m (1 kgf m, 2 lbf ft)

EX285
EX255-EX285
W2-6-38
SWING DEVICE
DISASSEMBLE AND ASSEMBLE
PARKING BRAKE RELEASE VALVE (EX285)
40
34
39
41
38
33
37
42
36
32
35
31
43
SM5106
31
32
33
34
35
Housing
Spool
Spring
Plunger
Bushing
36
37
38
39
40
Filter
Spacer
Orifice
Spring
O-Ring
41 - O-Ring (2 Used)
42 - Steel Ball
43 - Bolt (3 Used)
EX255-EX285
W2-6-39
SWING DEVICE
Swing motor
d
1. Plunger and rotor bore clearance (d, D)

Unit: mm (in)
Standard Clearance
Allowable Limit
EX255
0.027 (0.00106)
0.052 (0.00205)
EX285
0.032 (0.00126)
0.062 (0.00244)
SM1030
SM1031
2. Plunger and shoe clearance (a)

Unit: mm (in)
Standard Clearance
Allowable Limit
0.3 (0.012)
SM1032
SM1033
W2-6-40
EX255-EX285
SWING DEVICE
3. Thickness of shoe (t)
Unit: mm (in)
Standard Clearance
Allowable Limit
EX255
5.5 (0.216)
5.3 (0.209)
EX285
6.0 (0.236)
5.8 (0.228)
t
SM1034
4. Thickness of friction plate

Unit: mm (in)
Standard Clearance
Allowable Limit
EX255
1.8 (0.071)
1.6 (0.063)
EX285
4 (0.157)
3.6 (0.142)
5. Total clearance of retainer plate (1) and holder (2):

(H - h)
SM1035
2
1
Unit: mm (in)
Standard Clearance
Allowable Limit
EX255
5.5 (0.216)
5.0 (0.197)
EX285
7.0 (0.276)
6.5 (0.256)
h H
If the dimension is reduced to below allowable limit,

replace retainer plate (1) and holder (2).
SM1036
EX255-EX285
W2-7-1
PILOT VALVE
REMOVE AND INSTALL RIGHT PILOT VALVE
WARNING
Preparation
Removal

pressure.
1. Loosen screws (6) (2 used), (1) (2 used) and (5) (2

used) to remove cover (7) and frame (2).
Loosen screws (4) (4 used) to dislocate boot (3).
4
5
6
7
SM1105
2. Confirm that the console is in the forefront position.

If not, position the console in the forefront position.
Loosen bolts (8) (2 used) to disconnect the joints.
Raise stand (9).
: 17 mm
SM1106
3. Remove screws (10) and (12). Dislocate cover (11)

to the right.
10
11
12
SM1107
W2-7-2
EX255-EX285
PILOT VALVE
4. Loosen screw joint (13) to remove the lever.
: 24 mm
13
IMPORTANT - Attach an identification tag on each

hose to aid in reassembly.
14
5. Disconnect hoses (15) to (20).

: 22 mm
15
NOTE - Attach a cap on each of disconnected hose
ends.
16
17
6. Loosen bolts (14) to remove the pilot valve.

: 13 mm
15 - Hose H : (To the bucket roll-out section in the control
valve)
16 - Hose P3 : (From the pilot control shut-off valve)
17 - Hose A : (To the boom raise section in the control
valve)
18 - Hose G : (To the bucket roll-in section in the control
valve)
19 - Hose T6 : (To the hydraulic oil tank)
20 - Hose B : (To the boom lower section in the control
valve)
20
19
18
SM1108
Installation
1. Mount the pilot valve using bolts (14).
13
14
: 13 mm
: 9.8 N m (1.0 kgf m, 7.2 lbf ft)
2. Connect hoses (15) to (20).

: 22 mm
15
: 39 N m (4.0 kgf m, 29 lbf ft)
16
17
3. Attach the lever. Tighten screw joint (13) to secure

the lever.
: 24 mm
: 88 N m (9.0 kgf m, 65 lbf ft)
15 - Hose H : (To the bucket roll-out section in the control

valve)
16 - Hose P3 : (From the pilot control shut-off valve)
17 - Hose A : (To the boom raise section in the control valve)
18 - Hose G : (To the bucket roll-in section in the control valve)
19 - Hose T6 : (To the hydraulic oil tank)
20 - Hose B : (To the boom lower section in the control valve)
20
19
18
SM1108
EX255-EX285
W2-7-3
PILOT VALVE
4. Install cover (11) using screws (10) and (12).
10
11
12
SM1107
5. Secure stand (9) using bolts (8) (2 used).

: 17 mm
: 49 N m (5.0 kgf m, 36 lbf ft)
1
6. Install frame (2) using screws (1) (2 used) and
screws (5) (2 used).
Install cover (7) using screws (6) (2 used).
Set the boot in position, and secure it using screws
(4) (4 used).
SM1106
3
4
5
6
engine. Check the components for any oil leakage.
7
SM1105
W2-7-4
EX255-EX285
PILOT VALVE
REMOVE AND INSTALL LEFT PILOT VALVE
WARNING
Preparation

pressure.
Removal
3
1. Loosen screw (2) (2 used), to remove cover (1).
Loosen screws (4) (4 used) to dislocate boot (3).
2
1
SM5515
2. Remove pad (13).To remove pad, disengage the

two latches while pressing and pushing pad (13) in
the direction indicated by arrow. Then, slide the pad
to the opposite of the direction indicated by arrow
to remove it.
3. Loosen screws (15) (2 used) and screws (16)
(2 used) to remove cover (14).
13
14
15
16
16
SM1109
4. Confirm that the console is in the forefront position.

If not, position the console in the forefront position.
Loosen bolts (8) (2 used) to disconnect the joints.
Raise stand (9).
: 17 mm
SM1106
EX255-EX285
W2-7-5
PILOT VALVE
5. Loosen screws (10) and (12) to dislocate cover (11)
to the right.
10
11
12
SM1107
6. Loosen screw joint (17) to remove the lever.
17
18
: 24 mm
19
20
: 22 mm
21
NOTE - Attach a cap on each of the disconnected hose
ends.
: 13 mm
19
20
21
22
23
24
- Hose D :
- Hose P2 :
- Hose E :
- Hose C :
- Hose T5 :
- Hose F :
(To the right swing section in the control valve)

(From the pilot control shut-off valve)
(To the arm roll-in section in the control valve)
(To the left swing section in the control valve)
(To the hydraulic oil tank)
(To the arm roll-out section in the control valve)
SM1110
24
Installation
23
17
22
18

: 13 mm
: 9.8 N m (1.0 kgf m, 7 lbf ft)
19
20

: 22 mm
: 39 N m (4.0 kgf m, 29 lbf ft)
21
3. Attach the lever. Tighten screw joint (17) to secure

the lever.
: 24 mm
: 88 N m (9.0 kgf m, 65 lbf ft)
19 - Hose D
20 - Hose P2
21 - Hose E
22 - Hose C
23 - Hose T5
24 - Hose F
:
:
:
:
:
:
(To the right swing section in the control valve)

(From the pilot control shut-off valve)
(To the arm roll-in section in the control valve)
(To the left swing section in the control valve)
(To the hydraulic oil tank)
(To the arm roll-out section in the control valve)
SM1110
24
23
22
W2-7-6
EX255-EX285
PILOT VALVE
4. Install cover (11) using screws (10) and (12).
10
11
12
SM1107
5. Secure stand (9) using bolts (8) (2 used).

: 17 mm
: 49 N m (5.0 kgf m, 36 lbf ft)
6. Install cover (14) using screws (15) (2 used) and

screws (16) (2 used).
13
7. Install pad (13) on cover (14).
SM1106
14
15
16
16
SM1109
8. Set boot (3) in position, and secure it using screws

(4) (4 used).
3
4
9. Install cover (1) using screws (2) (2 used).

2
1
SM5515
EX255-EX285
W2-7-7
PILOT VALVE
REMOVE AND INSTALL TRAVEL PILOT VALVE
WARNING
Preparation
Removal
1. Loosen bolt (2) to remove pedal (1).

pressure.

: 17 mm
: 22 mm
ends.

: 17 mm
Installation
: 17 mm
: 49 Nm (5.0 kgf m, 36 lbf ft)

: 22 mm
: 39 N m (4.0 kgf m, 29 lbf ft)
3. Mount pedal (1) using bolts (2).

: 17 mm
: 49 N m (5.0 kgf m, 36 lbf ft)
3
8
9
7
6
5
SM1111
3 - Hose 12: (To the right reverse travel section in the control
valve)
4 - Hose 10: (To the left reverse travel section in the control
valve)
5 - Hose P1: (From the pilot control shut-off valve)
6 - Hose 9 : (To the left forward section in the control valve)
7 - Hose 11: (To the right forw. section in the control valve)
8 - Hose T4 : To the hydraulic oil tank
W2-7-8
EX255-EX285
PILOT VALVE
DISASSEMBLE RIGHT AND LEFT PILOT VALVE
1
25
23
24
2
22
21
21
20
20
19
19
4
18
18
17
6
7
12
16
15
11
10
14
13
SM1112
1
2
3
4
5
6
7
8
9
Screw Joint
Cam
Universal Joint
Plate
Oil Seal (4 Used)
O-Ring (4 Used)
Bushing A (2 Used)
Pusher A (2 Used)
Spring Guide A (2 Used)
10
11
12
13
14
15
16
17
18
Spring Guide B (2 Used)

Pusher B (2 Used)
Bushing B (2 Used)
Socket Bolt
Plate
O-Ring
Seal Washer
Casing
Piston (4 Used)
19
20
21
22
23
24
25
Spool (4 Used)
Spacer (4 Used)
Shim (20 Used)
Return Spring A (2 Used)
Balance Spring A (2 Used)
Return Spring B (2 Used)
Balance Spring B (2 Used)
EX255-EX285
W2-7-9
PILOT VALVE
Disassemble Right and Left Pilot Valve
As casing (17) and spools (19) are precision parts
specially made to fit each other, they must be
replaced as a set. Do not attempt to replace these
parts individually.
Note that return spring A (22) and balance spring
A (23), which are used in ports 1 and 3, differ from
return spring B (24) and balance spring B (25),
which are used in ports 2 and 4.
For this reason, be sure to indicate the port number
from which it is removed. Port numbers are
stamped on casing (17).
10. Remove spools (19) (4 used) from casing (17).

11. Compress balance spring A (23) or B (25) to
remove spacers (20) from each spool (19).
Remove balance spring A (23) or B (25) and shims
(21) from each spool (19).
12. Remove spring guide A (9) or B (10), and return
spring A (22) or B (24) from each seat.
1. Remove screw joint (1) and cam (2).

: 19 mm, 32 mm
2. Temporarily tighten plate (4) using two bolts (M8,
Pitch 1.25). Loosen universal joint (3) to remove it
from casing (17).
3. Turn over casing (17) and place it in a vise.
Remove socket bolt (13).
: 10 mm
4. Pull out plate (14) using a pulling bolt (M16, Pitch
2). Remove O-ring (15) from the plate. Remove
seal washer (16) from casing (17).
5. Remove piston (18) from spool (19) in each port.
(Four pistons in total)
6. Turn over casing (17). Attach special tool
(75301512) to the universal joint connecting hole.
Tighten plate (4) using the special tool.
75301512
4
17
7. Remove the bolts (2 used) temporarily installed in

the step 2. Gradually loosen the special tool until
pushers A (8), B (11) and plate (4) are fully raised,
unloading spring compresssion.
8. Remove plate (4) and pushers A (8), B (11) from
casing (17).
9. Remove pusher A (8), O-ring (6), and oil seal (5)
from each bushing A (7). Remove pusher B (11),
O-ring (6), and oil seal (5) from each bushing B
(12).
SM1113
W2-7-10
EX255-EX285
PILOT VALVE
ASSEMBLE RIGHT AND LEFT PILOT VALVE
11
2
3
8
12
5
4
20
10
9
25
23
24
22
21
19
17
18
13
14
16
15
SM5516
1
2
3
4
5
6
7
8
9
Screw Joint
Cam
Universal Joint
Plate
Oil Seal (4 Used)
O-Ring (4 Used)
Bushing A (2 Used)
Pusher A (2 Used)
Spring Guide A (2 Used)
10
11
12
13
14
15
16
17
18
Spring Guide B (2 Used)

Pusher B (2 Used)
Bushing B (2 Used)
Socket Bolt
Plate
O-Ring
Seal Washer
Casing
Piston (4 Used)
19
20
21
22
23
24
25
Spool (4 Used)
Spacer (4 Used)
Shim (20 Used)
Return Spring A (2 Used)
Balance Spring A (2 Used)
Return Spring B (2 Used)
Balance Spring B (2 Used)
EX255-EX285
W2-7-11
PILOT VALVE
Assemble Right and Left Pilot Valve
1. Insert special tool (75301504) into each port on
casing (17). Be sure to insert the smaller end of the
special tool first.
IMPORTANT - The number of shims (21) has been

determined during the perfomance test at the factory.
Take care not lose them. Install spacer (20) with its
concave side facing the spring.
2. Install shims (21) (20 used) and balance spring A

(23) (2 used) or B (25) (2 used) onto each spool (19)
(4 used). While compressing balance spring A (23)
(2 used) or B (25) (2 used), insert spacer (20) (4
used) onto the neck part of each spool (19) (4
used).
SM1115
75301504
IMPORTANT - Install spring guide A (9) or B (10) with

its concave side facing the spring.
3. Install spring guide A (9) (2 used) or B (10)

(2 used) and return spring A (22) (2 used) or B (24)
(2 used) onto each spool (19) (4 used).
IMPORTANT - Be sure to confirm the applicable port

number for each spool (19) before inserting.
4. Insert spools (19) into casing (17).

5. Install oil seal (5) (4 used) and O-ring (6) (4 used)
onto each bushing A (7) (2 used) or B (12)
(2 used). Insert pusher A (8) (2 used) or B (11)
(2 used) into each bushing A (7) or B (12), respectively.
Oil Seal Driving Tool: 75301503
75301512
6. Put each of the pusher assemblies onto the respective spool assembly.
7. Install plate (4) on bushings A (7) and B (12). Install
special tool (75301512) into the universal joint
connecting hole on casing (17).
8. Gradually tighten the special tool until the bottom
of bushings A (7) and B (12) is flush with the top
surface of casing (17). Remove special tool
(75301504) from each casing port.
SM1116
9. Temporarily secure plate (4) using two bolts (M8,

Pitch 1.25). Remove special tool (75301512).
W2-7-12
EX255-EX285
PILOT VALVE
11
2
3
8
19
17
18
13
14
16
15
SM1114
EX255-EX285
W2-7-13
PILOT VALVE
10. Insert piston (18) into each spool (19), with the
smaller end first.
11. Install seal washer (16) on casing (17).
Install O-ring (15) onto plate (14).
12. Secure plate (4) onto casing (17) using socket bolt
(13).
: 10 mm
: 49 N m (5 kgf m, 36 lbf ft)
13. Turn over casing (17). Apply LOCTITE 262 to
universal joint (3). Install universal joint (3) into
casing (17).
: 17 mm
: 24.5 N m (2.5 kg m, 18.1 lbf ft)
14. Sufficiently apply grease to the joint part of universal joint without giving any air gaps. Apply grease
to the top of pushers A (8) (2 used) and B (11) (2
used).
15. Install cam (2) onto universal joint (3).
16. Tighten screw joint (1) while keeping the clearance
between pushers A (8) and B (11) and cam (2) to
0 to 0.2 mm (0 to 0.008 in).
Remove the two temporarily installed bolts.
Filler Gauge
: 17 mm, 32 mm
: 69 to 88 N m
(7 to 9 kgf m, 50 to 65 lbf ft)
W2-7-14
EX255-EX285
PILOT VALVE
DISASSEMBLE TRAVEL PILOT VALVE
3
4
5
10
11
24
10
23
22
21
20
19
17
16
9
18
15
14
25
13
12
SM1117
1
2
3
4
5
6
7
8
9
Cover
Sems Bolt (2 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
Cam (2 Used)
Pin (2 Used)
Holder
10
11
12
13
14
15
16
17
18
Bushing (2 Used)
Bushing (2 Used)
Plug
O-Ring
Casing
Spool (4 Used)
Spacer (4 Used)
Shim
Return Spring (4 Used)
19
20
21
22
23
24
25
Balance Spring (4 Used)

Spring Guide (4 Used)
Pusher (4 Used)
Bushing (4 Used)
O-Ring (4 Used)
Oil seal (4 Used)
Plate
EX255-EX285
W2-7-15
PILOT VALVE
Disassemble Travel Pilot Valve
As casing (14) and spools (15) are precision parts
specially made to fit each other, they must be
replaced as a set. Do not attempt to replace these
parts individually.
1. Remove sems bolts (2) (2 used) to remove cover
(1) from holder (9).
: 10 mm
2. Turn over casing (14), and put it in a vise. Remove
plug (12) from casing (14). Remove O-ring (13)
from plug (12).
75301513
3. Turn over casing (16), and put it in a vise. Remove

one of two socket bolts (6). Install special tool
(75301513) into the bolt hole.
: 8 mm
4. Remove the other socket bolt (6). Install special
tool (75301513) into the bolt hole.
: 8 mm
5. Loosen (operate) both special tools (75301513)
evenly at the same time. Remove holder (9) from
casing (14).
6. Put holder (9) in a vise. Remove spring pins (3) (2
Used) and (4) (2 Used) using special tool
(75301487).
7. Remove pin (8) (2 Used) and cam (5) (2 Used)
from holder (9). Do not remove bushings (10) and
(11) unless they are damaged.
8. Remove the pusher assemblies (4 Used). Remove pusher (21), O-ring (23), oil seal (24), from
each bushing (22).
9. Remove spools (15) (4 used) from casing (14).
10. Compress balance spring (19) to remove spring

guide (20) from each spool (15). Remove balance
spring (19), shims (17) and spacers (16) from
each spool (15). Remove return spring (18) from
each port.
SM1118
W2-7-16
EX255-EX285
PILOT VALVE
ASSEMBLE TRAVEL PILOT VALVE
10
11
6-7
3-4
21
2
24
22
23
25
20
14
19
18
17
16
15
SM1119
12-13
1
2
3
4
5
6
7
8
9
Cover (2 Used)
Sems Bolt (2 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
Cam (2 Used)
Pin (2 Used)
Holder
10
11
12
13
14
15
16
17
18
Bushing (2 Used)
Bushing (2 Used)
Plug
O-ring
Casing
Spool (4 Used)
Spacer (4 Used)
Shim
Return Spring (4 Used)
19
20
21
22
23
24
25
Balance Spring (4 Used)

Spring Guide (4 Used)
Pusher (4 Used)
Bushing (4 Used)
O-ring (4 Used)
Oil seal (4 Used)
Plate
EX255-EX285
W2-7-17
PILOT VALVE
Assemble Travel Pilot Valve
IMPORTANT - The number of shims (17) has been

determined during the perfomance test at the factory.
Take care not lose them. Install spring guide (20) with
its concave side facing the spring.
1. Attach shims (17) spacer (16) (4 used) and balance

spring (19) (4 used) onto each spool (15) (4 used).
While compressing balance spring (19), insert
spring guide (20) (4 used) onto the neck part of each
spool (15).
2. Turn over casing (14), and clamp with a vise.
3. Install O-ring (13) onto plug (12), and install plugs
(12) onto casing (14).
: 8 mm
: 34 N m (3,5 kgf m, 25 lbf ft)
4. Turn over casing (14) and clamp with a vise. Insert
return springs (18) (4 used) into casing (14).
IMPORTANT - Be sure to confirm the applicable port

number for each spool (15) before inserting.
5. Insert spool (15) (4 used) assemblies into casing

(14).
6. Install oil seal (24) and O-ring (23) onto each
bushing (22). Insert pusher (21) into of each bushing (22) (4 used).
7. Put each of the pusher (21) assemblies onto the
respective spool (15) (4 used) assembly.
75301513
8. Install holder (9) on the pusher (21) (4 used)
assembly. Install special tools (75301513) (2 used)
into the bolt holes on casing (14).
9. Gradually tighten the special tools until the bottom
of bushings (22) is flush with the top surface of
casing (14).
SM1120
W2-7-18
EX255-EX285
PILOT VALVE
6-7
3-4
21
SM1119
EX255-EX285
W2-7-19
PILOT VALVE
10. Remove one of special tools (75301513). Temporarily tighten spring washer (7) and socket bolt
(6).
75301513
11. Remove the other special tool (75301513). Temporarily tighten the other spring washer (7) and
socket bolt (6). Tighten both socket bolts (6) (2
used) to specification.
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)
IMPORTANT - When inserting pin (8), the spring pin

hole nearer to the pin end must be facing outerwards.
12. Apply grease to the top of pushers (21) (4 used).

Place cam (5) (2 used) on holder (9), aligning the
pin holes. Insert pin (8) (2 used) into the pin hole.
IMPORTANT - Be sure to drive spring pins (3) and (4)

until they extrude approx. 3 mm (0.12 in) down from the
bottom of cam (5). Then, mushroom the spring pin
ends at the top of the cam to prevent them from coming
out.
13. Insert spring pins (3) and (4) using special tool
(75301487).
14. Install cover (1) onto holder (9) using sems bolts
(2) (2 used).
: 10 mm
: 2 N m (0.2 kgf m, 1.5 lbf ft)
SM1121
W2-7-20
EX255-EX285
PILOT VALVE
POSITIONING PILOT VALVE
(triple articulation version)
WARNING
Preparation

pressure.
Removal
1. Loosen bolts (2) to remove pedal (1).
: 17 mm

Check hydraulic oil level. Add oil if necessary. Run
the engine. Check the components for any oil
leakage.

: 22 mm
ends.
3. Loosen bolts to remove the pilot valve (3).

: 17 mm
Installation
1. Mount the pilot valve (3) using bolts.
: 17 mm
: 44 N m (5.0 kgf m, 36 lbf ft)
SM3520

: 22 mm
: 39 N m (4.0 kgf m, 29 lbf ft)
3. Mount pedal (1) using bolts (2).

: 17 mm
: 49 N m (5.0 kgf m, 36 lbf ft)
4
5
6
7
(Hose
(Hose
(Hose
(Hose
T7) H) I) R4) -
To hydraulic oil tank

To connection upper extra control valve
To connection lower extra control valve
From hydraulic oil tank
EX255-EX285
W2-7-21
PILOT VALVE
11B
11C
11
35
11A
11E
31
11D
13
30
29
27
1
39
28
25
38
15
24
40
37
36
16
17
1 2 5 6 11 11A11B-
Return spring
Balance spring
Spacer
Shim
Tappet
Bushing
Dust seal
11C11D11E 13 15 16 17 -
O-Ring
Piston
Oil seal
Spring guide
Plunger
O-Ring
Plug
SM3521
24
25
27
28
29
30
31
Plate
Socket Bolt
Cam
Pin
Spring pin
Spring pin
Cover
35
36
37
38
39
40
Screw
Plug
O-Ring
Spool
Bushing
Body
W2-7-22
EX255-EX285
PILOT VALVE
Disassemble positioning pilot valve
1. Remove the two screw (35) and cover (31).

35
31
SM3523
2. Remove plug (17) and (36) and extract O-rings (16)

and (37).
37
36
16
17
SM3524
3. Remove plunger (15).
15
SM5518
EX255-EX285
W2-7-23
PILOT VALVE
4. Pull-out the two spring pins (29) and (30), pin (28)
and remove cam (27), bushings (39) and plate (24).
30
29
27
39
28
24
5. Remove one of the socket bolt (25) from the valve
body, and install tool 75298319 in the valve body.
SM3526
6. Remove the other socket bolt (25) and install

another tool 75298319 in the valve body.
25
7. Loosen progressively the two tools 75298319 until
the force of the springs is neutralized.
24
SM3527
8. Remove the two tools 75298319 from the valve

body.
75298319
SM3528
W2-7-24
EX255-EX285
PILOT VALVE
9. Extract the two tappet assemblies (11).
Separate piston (11D) from bushing (11A).
11A
11D
SM3529
10. Remove O-ring (11C) from bushing (11A).
11C
11A
SM3530
11. Remove dust seal (11B).
11B
11A
SM3531
12. Remove oil seal (11E).

11A
11E
SM3532
EX255-EX285
W2-7-25
PILOT VALVE
13. Remove the two spool assemblies.
Remove spacer (5) from spool (38) pushing on
balance spring (2).
2
38
SM3533
14. Pull-out balance spring (2) and shims (6) from

spool (38).
2
6
38
SM3534
15. Remove spring guide (13) and return spring (1)

from seat.
13
1
40
SM3537
W2-7-26
EX255-EX285
PILOT VALVE
Assemble positioning pilot valve
1. Clean all components and lubricate with clean

hydraulic oil all inner parts.
SM3535
2. Insert shims (6) and balance spring (2) into spool

(38).
2
6
NOTE - The quantity of shims is established during the

performance test.
38
SM3534
3. Will pressing spring (2) insert spacer (5).

5
NOTE - Make sure that the spacer is positioned with

the spring seat toward the spring.
SM5517
4. Mount tool 75298321 in the two lower holes of the

valve body.
75298321
SM3536
EX255-EX285
W2-7-27
PILOT VALVE
5. Insert return spring (1) and spring guide (13) into
body (40).
13
NOTE - Make sure that the spring seat is positioned

toward the spring.
1
40
SM3537
6. Insert the spool assemblies into spring guide (13).

NOTE - Insert the single assemblies making reference to
the cylinder number.
13
SM3538
7. Position dust seal (11B) in bushing (11A) with

some grease, using tool 75298322.
75298322
11B
11A
SM3539
8. Position oil seal (11E) in bushing (11A).

11A
11E
SM3532
W2-7-28
EX255-EX285
PILOT VALVE
9. Mount O-ring (11C) in bushing (11A).
11C
11A
SM3530
10. Insert piston (11D) into bushing (11A) from the oil
seal side (11E).
11A
NOTE - Smear some grease inside the bushing.
11D
SM3529
11. Position the two tappet assemblies into their

seats, install plate (24) and mount the two tools
75298319 in the valve body.
75298319
24
Tighten the two tools until the lower surface of the

bush is in line with the upper surface of the valve
body.
SM3528
EX255-EX285
W2-7-29
PILOT VALVE
75298319
12. Remove tool 75298319 from the left side and

temporary tighten socket bolt (25).
25
SM3541
13. Remove other tool 75298319 and temporary

tighten other socket bolt (25).
Tightening both socket bolts (25).
25
Tightening torque: 39 N m (4 kgf m, 29 lbf ft).
SM3542
14. Remove the two tools 75298321 from the bottom

of the valve body.
75298321
SM3540
W2-7-30
EX255-EX285
PILOT VALVE
15. Lock the valve body into a vise and insert plunger
(15).
15
SM5518
16. Position O-rings (37) and (16) on plugs (36) and

(17).
37
36
16
17. Install plugs (36) and (17).
17
SM3524
Tightening torque: 49 N m (5 kgf m, 36 lbf ft)
35
18. Install cover (31) using screw (35).
31
SM3523
EX255-EX285
W2-7-31
PILOT VALVE
SPECIAL TOOLS
Special Tools for Right and Left Pilot Valve
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
SM1124
SM1123
ITEM
Tools No.
Tool Name
Remarks
75301513
Valve holder assembly
For disassembling and assembling valve
75301487
Spring pin driving guide
For tapping in/out spring pin
Special tools for Positioning Pilot Valve (Triple articulation version):

ITEM
Tools No.
Tool Name
Remarks
75298319
Valve holder assembly
For disassembling and assembling valve
75298321
Spring pin driving guide (q.ty 4)
For tapping in/out spring pin
75298322
Inserting tool
For inserting dust seal
W2-7-32
EX255-EX285
PILOT VALVE
NOTES:
EX255-EX285
W2-8-1

REMOVE AND INSTALL PILOT SHUT-OFF VALVE
WARNING
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.
Preparation
pressure.

while working.
Removal
1. Remove the outer panel located under the driver's
compartment, by removing the six securing
screws.
: 17 mm
3
5
2. Remove ball joint (10).

: 13 mm
NOTE - Attach labels or tags to hoses and pipes, to aid
in assembly.
11
3. Disconnect pilot hoses (1 to 9).

: 17, 19, 22 mm
4. Remove bolts (11) to remove the pilot shut-off
valve.
: 8 mm
Installation
SM1311
1. Install the pilot shut-off valve using bolts (11).
10
2. Connect pilot hoses (1 to 9).

3. Install ball joint (10).
4. Install the outer panel.
Wrench size
(mm)
Tightening Torque
N m kgf m lbf ft
Remark
: 13
10
Nut
: 22
39
29
Hoses
:8
20
15
Bolt
: 17
49
36
Bolt
: 19
29
22
Hoses
1
2
3
4
5
6
7
8
9
10
11
Hose P2 :
Hose P1 :
Hose P3 :
Hose T6 :
Hose DP :
Hose PF :
Hose T5 :
Hose T4 :
Hose A4 :
Ball Joint
Bolt
(To Swing and Arm Pilot Valve)

(To Travel Left and Right Pilot Valve)
(To Boom and Bucket Pilot Valve)
(From Bucket and Boom Pilot Valve)
(To Solenoid Valve Unit)
(From Pilot Relief Valve)
(From Swing and Arm Pilot Valve)
(From Travel Left and Right Pilot Valve)
(To Shockless Valve)
W2-8-2
EX255-EX285

DISASSEMBLE PILOT SHUT-OFF VALVE
1
2
3
4
5
6
7
8
14
13
12
11
10
SM1312
1
2
3
4
Retaining Ring
Washer
Backup Ring
O-Ring
5
6
7
8
O-Ring
Backup Ring
Washer
Retaining Ring
9
10
11
12
Spring Pin
Lever
Spool
Socket Bolt
13 - Steel Ball
14 - Body
EX255-EX285
W2-8-3

Disassemble Pilot Shut-Off Valve
Before disassembling, be sure to read and understand all the "Precautions for Disassembly and
Assembly" on page W1-1-1.
1. Remove retaining ring (1) and washer (2) and
pull out spool (11).
NOTE - Mark spool (11) and lever (10) for alignment

when installing.
2. Pull out spring pin (9) from spool (11), and

remove lever (10).
3. Remove washer (7) and retaining ring (8) from
spool (11).
4. Remove backup ring (3), (6) and O-ring (4), (5)
from body (14).
5. Loosen socket bolt (12) from body (14).
: 6 mm
W2-8-4
EX255-EX285

ASSEMBLE PILOT SHUT-OFF VALVE
SM1313
1
2
3
4
Retaining Ring
Washer
Backup Ring
O-Ring
5
6
7
8
O-Ring
Backup Ring
Washer
Retaining Ring
9
10
11
12
Spring Pin
Lever
Spool
Socket Bolt
13 - Steel Ball
14 - Body
EX255-EX285
W2-8-5

Assemble Pilot Shut-Off Valve
IMPORTANT - Apply a film of grease to O-rings (4) and

(5), and backup rings (3) and (6).
1. Install O-rings (4) and (5), backup rings (3) and (6)
to body (14).
2. Install washer (7) and retaining ring (8) to spool (11).
3. Drive spring pin (9) alignmenting spool (11) and
lever (10). (Alignment marks made when disassembling.)

to spool (11).
4. Install spool (11) to body (14).

5. Install washer (2) and retaining ring (1) to spool (11).
6. Install and tighten socket bolt (12).
: 6 mm
: 44 N m (4.5 kgf m, 33 lbf ft)
W2-8-6
EX255-EX285

NOTES:
EX255-EX285
W2-9-1
SHOCKLESS VALVE
REMOVE AND INSTALL SHOCKLESS VALVE
WARNING
Preparation


pressure.

while working.
Removal
Installation
IMPORTANT - Attach labels or tags to hoses to aid in

assembly.
1. Apply LOCTITE to bolts (10), then install

shockless valve with bolts (10).
1. Disconnect hoses (1 to 9, 13 to 20).
2. Install pressure switch (11) and pressure sensor

(12).
: 19, 22 mm
3. Connect hoses (1 to 9, 13 to 20).
2. Remove pressure switch (11) and pressure sensor

(12).
Wrench
Size
: 24 mm
Tightening
Torque
(mm)
3. Remove bolts (10) to remove shockless valve.

: 17 mm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Hose (To left swing control valve)

Hose (To right swing control valve)
Hose (To bucket roll-out control valve)
Hose (To bucket roll-in control valve)
Hose (To boom raise control valve)
Hose (To boom lower control valve)
Hose (To arm roll-in control valve)
Hose (To arm roll-out control valve)
Hose (From pilot shut-off valve)
Bolt
Pressure switch (for boom raise)
Pressure sensor (for arm roll-in)
Hose (From arm roll-in pilot valve)
Hose (From arm roll-out pilot valve)
Hose (From boom lower pilot valve)
Hose (From boom raise pilot valve)
Hose (From bucket roll-in pilot valve)
Hose (From bucket roll-out pilot valve)
Hose (From right swing pilot valve)
Hose (From left swing pilot valve)
16
17
Nm
Remark
kgf m lbf ft
: 17
20
14.5
Bolt
: 19
29
21.7
Hose
: 22
39
29
Hose
: 24
78
58
Pressure sensor
and Switch
18
19
20
11
15
14
13
12
3
4
10
5
9
6
SM1314
W2-9-2
EX255-EX285
SHOCKLESS VALVE
DISASSEMBLE AND ASSEMBLE
SHOCKLESS VALVE
14
2
11
3
4
10
13
7
15
9
7
4
8
3
2
1
10
10
11
11
12
12
SM1315
EX255-EX285
W2-9-3
SHOCKLESS VALVE
Section V
Section X
1
1
2
2
4
10
11 10 9 15 7 10
11
12
14
1
A4
X
Section W
11 10 9
7 10
11
12
14
13
1
Section Z-Z
Section Y
SM1316
W2-9-4
EX255-EX285
SHOCKLESS VALVE
Item
Part Name
Q.ty
Wrench Size
(mm)
Torque Specification
Remark
Nm
kgf m
lbf ft
:5
10
7.2
PF 1/8
Plug
O-ring
Spring
Steel Ball
Body
Steel Ball
Ring
Orfice
Plunger
10
Spring
11
O-ring
12
Plug
:8
49
36
PF 3/8
13
Orifice
:5
10
7.2
PF 1/8
14
Plug
:8
49
36
PF 3/8
15
Orifice
EX255-EX285
W2-10-1
SOLENOID VALVE UNIT

REMOVE AND INSTALL SOLENOID VALVE UNIT
WARNING
Preparation
pressure.

while working.
Removal
1
2
1. Remove all wire harnesses for solenoid valves

from connectors.
2. Disconnect pilot lines (1 to 6, 8 to 11, 16).
3
4
5
16
: 17, 19, 22 mm
15
3. Remove bolts (7) to remove solenoid valve unit.
14
: 8 mm
11
10
Installation
13
1. Install solenoid valve unit with bolts (7).
12
7
SM1037
2. Connect pilot lines (1 to 6, 9, to 11, 16).

3. Connect all wire harnesses for solenoid valves to
connectors.
Wrench Size
(mm)
Tightening Torque
Remark
Nm
kgf m
lbf ft
: 17
44
4,5
32.5
Hose
: 19
29
22
Pipe
: 22
59
43
Hose
:8
20
16
Bolt
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Hose PE: (To pump control valve (4-spool))

Pipe DE: (From bucket flow control valve)
Pipe PH: (To pump control valve (5-spool))
Hose PG: (To swing parking brake)
Pipe DP: (From pilot shut-off valve)
Hose DS: (To hydraulic oil tank)
Socket Bolt
Hose SG: (To main relief valve)
Hose SI: (To travel speed change)
Pipe SD: (To pump regulator valve (Pump 1 and 2))
Pipe SC: (To arm regenerative valve)
Solenoid Valve (SG)
Solenoid Valve (SI)
Solenoid Valve (SD)
Solenoid Valve (SC)
Hose F: (From pilot shut-off valve)
W2-10-2
EX255-EX285
SOLENOID VALVE UNIT

DISASSEMBLE PROPORTIONAL SOLENOID VALVE
1
2
4
5
6
7
8
9
10
13
11
14
12
15
16
17
18
SM1038
1
2
3
4
5

Lock Nut
O-Ring
Adjusting Screw
Spring
6
7
8
9
10
Solenoid
Spring
O-Ring
Diaphragm
Spool
11
12
13
14
15
Washer
Spring
O-Ring
O-Ring
O-Ring
16 - Sleeve
17 - Plate
18 - Washer
EX255-EX285
W2-10-3
SOLENOID VALVE UNIT

Disassemble Proportional Solenoid Valve
1. Loosen socket bolts (1) and remove solenoid (6).
IMPORTANT - Take care not to lose spring (7) provided in the groove of solenoid (6) when removing
solenoid (6). Do not remove pressure control lock nut
(2) and adjusting screw (4).
: 3 mm
2. Pull out spool (10) and remove washer (11), spring

(12) and diaphragm (9) from spool (10).
3. Pull sleeve (16) out of the housing and remove
O-rings (13), (14) and (15) from sleeve (16), and
then take washer (18), plate (17) out of the housing.
W2-10-4
EX255-EX285
SOLENOID VALVE UNIT

ASSEMBLE PROPORTIONAL SOLENOID
VALVE
16
13
14
11
12
10
15
18
17
SM1039
1
2
3
4
5

Lock Nut
O-Ring
Adjusting Screw
Spring
6
7
8
9
10
Solenoid
Spring
O-Ring
Diaphragm
Spool
11
12
13
14
15
Washer
Spring
O-Ring
O-Ring
O-Ring
16 - Sleeve
17 - Plate
18 - Washer
EX255-EX285
W2-10-5
SOLENOID VALVE UNIT

Assemble Proportional Solenoid Valve
16
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.
15
14
13
1. Install washer (18) and plate (17) into the housing.

Install O-rings (13), (14) and (15) onto sleeve (16)
and insert into the housing.
IMPORTANT - Take care not to damage the bore

edges of sleeve (16) when inserting the spool assembly.
After inserting spool (10) to check that spool (10)
slides in and out smoothly without any restriction
about 3 to 5 mm (0.12 to 0.20 in).
SM1040
10
16
2. Install diaphragm (9), washer (11) and spring (12) to

spool (10). Apply a film of hydraulic oil to the spool
12
SM1041
11
10
SM1042
3. Install solenoid (6) with tightening socket bolts (1).

6
IMPORTANT - Lock nut (2) and adjusting screw (4)
should not be removed during disassembly, so they
are not required to be reassembled.
IMPORTANT - Be careful not to allow spring (7) to fall

out when installing solenoid (6).
: 3 mm
: 3 N m (0.3 kgf m, 2.2 lbf ft)
SM1043
W2-10-6
EX255-EX285
SOLENOID VALVE UNIT

NOTES
EX255-EX285
W2-11-1
PILOT RELIEF VALVE UNIT

REMOVE AND INSTALL PILOT RELIEF VALVE UNIT
WARNING
Preparation
pressure.

while working.
Removal
1
1. Disconnect hoses (1, 2, 3 and 6).
: 22 mm, 27 mm
2
2. Remove bolts (4) to remove relief valve unit.
6
: 17 mm
5
3
Installation
1. Install relief valve unit with bolts (4).
2. Connect hoses (1, 2, 3 and 6).
SM4225
Wrench Size Tightening Torque

mm
Remark
Nm
kgf m
lbf ft
: 17
49
36
Bolt
: 22
39
29
Hose
: 27
70
50
Hose
: 19
39
29
Hose
1
2
3
4
5
6
Hose TA: (To hydraulic oil tank)

Hose PI: (To control valve (4-Spool)
Hose PD:(To Pilot shut-off valve)
Bolt
Pilot Relief Valve
Hose PA:(From pilot pump)
W2-11-2
EX255-EX285

DISASSEMBLE PILOT RELIEF VALVE
2
Port A
Port P
Port PI
4
Port T
SM4226
1 - Plug
2 - O-Ring
3 - Body
4 - Poppet
5 - Spring
6 - Shim
7 - O-Ring
8 - Plug
EX255-EX285
W2-11-3

Disassemble Pilot Relief Valve
1. Loosen plug (1) and remove O-ring (2) from body
(3).
: 8 mm
2. Loosen plug (8) and remove O-ring (7), shim (6),

spring (5), and poppet (4) from body (3).
: 36 mm
W2-11-4
EX255-EX285

ASSEMBLE PILOT RELIEF VALVE
2
3
4
PI
7
T
8
6
Section
A-A
Section
B-B
SM4277
1 - Plug
2 - O-Ring
3 - Body
4 - Poppet
5 - Spring
6 - Shim
7 - O-Ring
8 - Plug
EX255-EX285
W2-11-5

Assemble Pilot Relief Valve
1. Install poppet (4) and spring (5) into body (3).
IMPORTANT - Be sure to check if poppet (4) moves

smoothly.
2. Install shim (6) and O-ring (7) to plug (8) and tighten
plug (8) to body (3).
: 36 mm
: 49 N m (5 kgf m, 36 lbf ft)
3. Install O-ring (2) to plug (1) and tighten plug (1) to

body (3).
: 8 mm
: 49 N m (5 kgf m, 36 lbf ft)
W2-11-6
EX255-EX285

IMPORTANT - When pilot filter (3) for pilot relief valve
unit (1) is replaced or disassembled, correctly tighten
socket bolt (2).
: 6 mm
: 202 N m (20.2 kgf m, 14.51.5 lbf ft)
SM4225
1 - Pilot Relief Valve Unit

2 - Socket Bolt
3 - Pilot Filter
SECTION 3
EX255-EX285
UNDERCARRIAGE
CONTENTS
Group 1 -
Swing Bearing
Remove and Install

Swing Bearing ...................................... W3-1-1
Group 2 -
Travel Device
Remove and Install Travel Device ......... W3-2-1

Travel Device Components (EX255) ...... W3-2-2
Travel Motor Removal (EX255) .............. W3-2-3
Disassemble Travel
Reduction Gear (EX255) ....................... W3-2-4
Reassembly (EX255) ............................ W3-2-9
Assemble Travel
Reduction Gear (EX255) ..................... W3-2-10
Travel Motor Installation (EX255) ........ W3-2-16
Disassemble Travel Device (EX285) ... W3-2-18
AssembleTravel Device (EX285) ......... W3-2-24
Disassemble Travel Motor (EX255) ..... W3-2-30
Assemble Travel Motor (EX255) .......... W3-2-34
Disassemble Brake Valve (EX255) ..... W3-2-42
Assemble Brake Valve (EX255) .......... W3-2-44
Disassemble Travel Motor (EX285) ..... W3-2-46
Assemble Travel Motor (EX285) .......... W3-2-50
Disassemble Brake Valve (EX285) ...... W3-2-58
Assemble Brake Valve (EX285) .......... W3-2-60
Maintenance Standard ........................ W3-2-62
Group 3 -
Center Joint
Remove and Install Center Joint .......... W3-3-1

Disassemble Center Joint .................... W3-3-2
Assemble Center Joint ......................... W3-3-4
Maintenance Standard ......................... W3-3-7
Group 4 -
Track Adjuster
Remove and Install

Track Adjuster ...................................... W3-4-1
Disassemble Track Adjuster ................. W3-4-2
Assemble Track Adjuster ................... W3-4-10
Group 5 -
Front Idler
Remove and Install Front Idler ............. W3-5-1

Disassemble Front Idler (EX255) .......... W3-5-2
Assemble Front Idler (EX255) .............. W3-5-6
Disassemble Front Idler (EX285) .......... W3-5-8
Assemble Front Idler (EX285) ............ W3-5-12
Group 6 -
Upper and Lower Roller
Remove and Install Upper Roller .......... W3-6-1

Remove and Install Lower Roller .......... W3-6-4
Disassemble Upper Roller .................... W3-6-7
Disassemble Lower Roller .................... W3-6-8
Assemble Lower Roller ...................... W3-6-10
Gruppo 7 -
Tracks
Remove and Install Tracks ................... W3-7-1

Maintenance Standard ......................... W3-7-7
EX255-EX285
W3-1-1
SWING BEARING
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstructure
must be removed first. For removal and installation of
the upperstructure, refer to Remove and Install Main
Frame section. In this section, the procedure starts
on the premise that the upperstructure has already
been removed.
Mark
Removal
1. Put alignment marks on swing bearing (1) and track
frame (2).
2
SM1307
2. Remove bolts (3) (36 used).

: 32 mm
SM1308
WARNING
Swing bearing weight: 331 kg (730 lb)
3. Attach lifting tools (75298793), hoist swing bearing

(4) and remove it.
SM1309
W3-1-2
EX255-EX285
SWING BEARING
Installation
Clean the matching surfaces of swing bearing and the
frame.
1. Apply THREEBOND 1102 to the matching surfaces of swing bearing and track frame.
WARNING
Swing bearing weight: 331 kg (730 lb)
SM1309
Front
Frontside
Side
IMPORTANT - Inner race soft zone (S) and the ball

filler port should be placed on the same position (right
side of the frame).
S S
Soft Zone
Soft Zone
Marking
MarkingPosition
Position
10.5
2. Hoist the swing bearing.

Align the swing bearing with the alignment mark on
the track frame and install the swing bearing.
PositionofofPlug
Plug
Position
SM3517
3. Install bolts (3) (36 used) and tighten to specification.

: 32 mm
: 700 N m (71 kgf m, 514 lbf ft)
SM1308
EX255-EX285
W3-2-1
TRAVEL DEVICE
REMOVE AND INSTALL TRAVEL DEVICE
WARNING
Preparation
pressure.

while working.
Installation
Removal
The procedure starts on the premise that the track
link has already been removed.
1. Loosen bolts (7) to remove cover (6). Disconnect
hoses (2) to (5).
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
: 22 mm
: 177 N m (18 kgf m, 130 lbf ft)
: 27 mm
: 93 N m (9.5 kgf m, 69 lbf ft)
: 36 mm
: 157 N m (16 kgf m, 116 lbf ft)
NOTE - Install caps on all disconnected hose and line
ends.
1. Install the travel device using bolts (1).

3. Install cover (6) using bolts (7).
IMPORTANT - After completing travel motor installation, be sure to fill the travel motor with hydraulic oil.
After completing installation of the travel motor or the
travel device, be sure to perform test driving to prevent
motor seizure. Test drive as follows:
1. Run the engine with the engine control dial in the
slow idle position.
2. Turn the travel speed mode switch to the slow
speed position.
3. Test drive the machine back-and-forth for 0.5 m to
1 m (19.7 to 39.37 in) in each direction five times
or more.
2. Attach the travel device to a crane using a wire

rope. Remove any slack from the wire rope so as
to secure the travel device when the mounting
bolts are removed.
4
3
WARNING
Travel device weight:
EX255: Approx. 315 kg (694 Ib)
EX285: Approx. 441 kg (972 lb)
3. Remove bolts (1). Remove the travel device using

the crane.
: 30 mm
: 590 N m (60 kgf m, 434 lbf ft)
7
6
SM5500
W3-2-2
EX255-EX285
EX255
TRAVEL DEVICE
TRAVEL DEVICE COMPONENTS (EX255)
SM3022
EX255-EX285
EX255
W3-2-3
TRAVEL DEVICE
TRAVEL MOTOR REMOVAL
Oil draining
Unscrew the plugs (2) and let the oil flow.
SM1270
1. Unscrew the 4 socket head screws M16x80

(22) grade 12.9, which fix the hydraulic motor to
the gearbox.
22
SM1271
2. Remove the hydraulic motor from the gearbox.
SM1272
3. Remove the O-ring (21) from the hydraulic

motor seat.
21
SM1273
EX255
EX255-EX285
W3-2-4
TRAVEL DEVICE
DISASSEMBLE TRAVEL REDUCTION GEAR (EX255)
1
7
W3-2-20PGS
10
14
15
16
3
5
6
17
18
4
11
19
20
12
21
13
SM3515
22
1
2
3
4
5
6
Screw (10 used)

Plug (2 used)
Washer (2 used)
Cover
O-ring
Plug
7
8
9
10
11
12
1st stage sun gear

1st reduction assembly
2nd reduction assembly
Circlip
Planetary gear (5 used)
Spacer (5 used)
13 - Ring nut
14 - Screw (18 used)
15 - Spring washer
(18 used)
16 - Sprocket
17 - Gearbox housing
18
19
20
21
22
Half seal
Centering ring
Hub
O-ring
Screw (4 used)
EX255-EX285
EX255
W3-2-5
TRAVEL DEVICE
1. Loosen screws (14). Remove sprocket (16) from
gearbox housing (17) using a craine.
: 30 mm
WARNING
Sprocket weight: approx. 47 kg (104 lb)
2. Turn the gearbox upside down, unscrew and remove the 2 plugs M22x1,5 (2) and the 2 washers (3)
from the end cover (4).
SM1275
3. Unscrew and remove the 10 socket head screws

M10x25 (1), grade 12.9, from the end cover (4).
1
SM1276
4. Remove the end cover (4) using 2 screws M22x1.5

tightened to the oil plugs holes.
4
SM1277
W3-2-6
EX255-EX285
EX255
TRAVEL DEVICE
5. Remove the O-ring (5) from its seat in the end cover
(4).
5
SM1278
6. Remove the 1st stage sun gear (7).
SM1279
8
7. Remove the 1st reduction assembly (8).
SM1280
8. Remove the 2nd reduction assembly (9).
SM1281
EX255-EX285
EX255
W3-2-7
TRAVEL DEVICE
9. Using pliers remove the 5 circlips (10) from their
seats placed in the pins of the flanged hub (20).
10
SM1282
10. Use a puller to remove the 5 planet assemblies of

the 3rd reduction (11) from the flanged hub (20).
11
SM1283
11. Remove the 5 spacer (12).
12
SM1284
12. By means of a punch, remove the riveting in the

edge of the ring nut (13).
Using the tool 75301526, unscrew the nut M230x2
(13).
13
SM1285
EX255
EX255-EX285
W3-2-8
TRAVEL DEVICE
13. Remove the centering ring from (19) from the
flanged hub (20).
NOTE - The above operation must be executed only in

case the hub must be replaced.
19
SM1286
14. Using a press and a metal stopper, remove the

flanged hub (20) from the gearbox housing (17).
17
WARNING
In case of oil leakages, it might be necessary to
check and eventually replace the lifetime seal (18),
which means both the metal rings parts and the
O-rings.
20
SM1287
15. Use a screwdriver to remove the 1st half-seal (18)

from the flanged hub (20).
18
SM1288
16. Use a screwdriver to remove the 2nd half-seal (18)

from the gearbox housing (17).
18
SM1289
EX255
EX255-EX285
W3-2-9
TRAVEL DEVICE
REASSEMBLY (EX255)
1. Important notes before reassembly
When proceeding with the gearbox reassembly, it is
necessary to follow the rules listed below:
a) In case of damaged gears, for example a planet, do
not replace the single gear, but the whole reduction
stage.
b) Replace always the O-rings of the part to be
reassembled after having carefully cleaned the
seats and having butterd some grease on the seats
themselves and on the O-rings to make easier the
reassembly.
2. Instructions for the installation of the half seals

To follow these instructions at the time of fitting, in
order to obtain the correct seal:
a) Carefully clean the seats (1) and (2) using, if necessary, metal brushes or solvent (surfaces in contact
with or (3) must be perfectly clean and dry).
b) Make sure that sealing surface (4) of metal rings (5)

are free from scratches, dinges or foreign substances; metal ring surfaces (6) must be perfectly
clean and dry.
c) Carefully clean the lapped surface (4) of metal rings

(5) and remove dust or fingersprints. Then
lubrificate them with a thin oil film, taking care not
to oil the other components.
4
SM1290
EX255
EX255-EX285
W3-2-10
TRAVEL DEVICE
ASSEMBLE TRAVEL REDUCTION GEAR (EX255)
W3-2-25PGS
16
13
15
12
11
19
21
14
10
9
18
20
22
23
4
8
7
6
3
2
5
17
SM3023
1
2
3
4
5
6
Screw (10 used)

Plug (2 used)
Washer (2 used)
Cover
O-ring
Plug
7
8
9
10
11
12
1st stage sun gear

1st reduction assembly
2nd reduction assembly
Circlip
Planetary gear (5 used)
Spacer (5 used)
13 - Ring nut
14 - Screw (18 used)
15 - Spring washer
(18 used)
16 - Sprocket
17 - Gearbox housing
18
19
20
21
22
23
Half seal
Centering ring
Hub
O-ring
Screw (4 used)
Travel motor
EX255-EX285
EX255
W3-2-11
TRAVEL DEVICE
1. Assemble the 1st half seal (18) on the tool
75301527.
75301527
18
SM1291
2. Assemble the 1st half seal (18) on the gearbox

housing (17).
SM1292
3. Assemble, by using the same tool 75301527, the

2nd half seal (18) on the flanged hub (20).
Clean carefully the metal faces of the half-seals.
SM1293
4. Lube the metallic face of the half seal (18) with a

thin oil film.
SM1294
W3-2-12
EX255-EX285
EX255
TRAVEL DEVICE
5. Fit the lower ball row (d) into the gearbox housing
(17), holding the inner ring (c) with spacers (a, b).
c
a
b
SM1295
6. Remove the spacer (b).

Place the bearing spacer (e).
Drop the upper ball row (f).
Assemble the inner raceway (g).
f
e
a
b
SM1296
7. Place the flanged hub (20) inside the gearbox

housing (17).
Using a press and a metallic stopper, push the
flanged hub (20) against the shoulder of the gearbox housing (17) until assembly of the unit is
complete.
20
17
SM1297
8. Turn the gearbox upside down. Place the centering

ring (19) on the flanged hub (20) and using a press
and a metal stopper push it against the shoulder
until assembly is complete.
SM1298
EX255-EX285
EX255
W3-2-13
TRAVEL DEVICE
9. Using the tool 75301526 screw-in a new ring nut
M230x2 (13) at a torque of 375-425 da N m.
13
SM1285
10. Deform the ring nut (13) next to a space on the

flanged hub (20).
SM1311
SM1299
11. Assemble correctly the 5 spacers (12) on the pins

of the flanged hub (20).
12
SM1312
SM1284
WARNING
12.Place correctly the 5 planet assemblies of the
3rd reduction (11) on the pins of the flanged hub
(20), checking that the groove side is turned to
the end cover (see figure).
SM1313
W3-2-14
EX255-EX285
EX255
TRAVEL DEVICE
13. Use a press and the metal stopper 75301528, to
push the 5 planet assemblies of the 3rd reduction
(11) against the flanged hub shoulder (20) until
assembly is complete.
SM1304
14. Use pliers to assemble the 5 circlips (10) in the

flanged hub pin seats (20).
10
SM1282
9
15. Assemble the 2nd reduction assembly (9).
SM1281
8
16. Assemble the 1st reduction assembly (8).
SM1280
EX255-EX285
EX255
W3-2-15
TRAVEL DEVICE
17. Insert the 1st stage sun gear (7).
SM1279
18. Mount the O-ring (5) into its seat in the end cover
(4).
SM1278
4
19. Place the end cover (4) on the gearbox housing
(17).
SM1305
20. Fix the end cover (4) to the gearbox housing (17)
throught 10 socket head screws M10x25 (1),
grade 12.9, tightened by a torque wrench at
7.5 daN m torque.
21. Install sprocket (16) onto gearbox housing (17).

Tighten screws (14) with spring washer (15).
: 30 mm
: 470 N m (48 kgf m, 346 lbf ft)
SM1276
EX255
EX255-EX285
W3-2-16
TRAVEL DEVICE
TRAVEL MOTOR INSTALLATION (EX255)
IMPORTANT - Before mounting the hydraulic motor,
verify, use a depth slide gauge to measure the axial
distance from the input side of the flanged hub (20) to
the 1st stage sun gear (7).
Axial dimension = 115 2 mm.
SM1306
1. Fit the O-ring (21) into the seat of the hydraulic

motor.
21
SM1273
2. Place the hydraulic motor on the gearbox.
SM1272
3. Fix the hydraulic motor to the gearbox through 4

socket head screws M16x80 (22), grade 12.9,
tightened by a torque wrench at 27 da N m torque.
22
SM1271
EX255-EX285
EX255
W3-2-17
TRAVEL DEVICE
4. Fill the gearbox with the lubricant oil.
Loosen the filling oil plug and put fill with proper oil.
Approximate oil capacity 4,5 liters 10 %.
Insert the washers (3) and the plugs M22x1.5 (2)
into the oil draing-filling holes of the end cover (4).
Tighten the plugs by a torque wrench at
3-4 daNm torque.
SM1276
EX285
EX255-EX285
W3-2-18
TRAVEL DEVICE
DISASSEMBLE TRAVEL DEVICE (EX285)
36
31
32
31
30
45
44
29
46
42
35
37
43
10
9
8
23
18
2
8
1
7
33
34
19
24
3
25
26
28
26
27
22
19
20
21
6
17
41
40
14
12
27
16
11
15
38
SM5107
13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Third Stage Carrier

Second Stage
Planetary Gear (3 Used)
Pin (3 Used)
Spring Pin (3 Used)
Spacer (2 Used)
First Stage Carrier
Propeller Shaft
Ring Gear
Bolt (24 Used)
Stopper Pin
Cover
Bolt (12 Used)
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
- Plug (3 Used)
- Spring Pin (3 Used)
- Thrust Plate (6 Used)
- Needle Bearing (3 Used)
- First Stage Planetary
Gear (3 Used)
- Pin (3 Used)
- Second Stage Carrier
- Pin (3 Used)
- Third Stage Planetary
Gear (3 Used)
- Motor
- Floating Seal
- Roller Bearing (2 Used)
32
33
34
35
36
37
38
40
41
42
43
44
45
46
Drum
Bolt (20 Used)
Bearing Nut
Bolt (4 Used)
Sprocket
Retaining Ring
Bearing
O-Ring
Spacer
Housing
Lock Plate
Bolt (2 Used)
EX285
EX255-EX285
W3-2-19
TRAVEL DEVICE
Disassemble Travel Device
WARNING
Pressure may remain in the travel device. Slowly
loosen the air bleed plug to completely release the
residual pressure. Then, remove the drain plug to
drain gear oil into a container. If the air bleed plug
is loosened quickly, the plug may fly off and/or gear
oil may spout. Position your face and body away
from the plug.
29
1. Stand the travel device upright with the motor on

the top. Install spacer (75301498) on the frame
mounting surface on motor (29) using two bolts
(M20, Pitch 2.5).
: 30 mm
75301498
WARNING
Travel device weight: 441 kg (972 lb)
SM1079
2. Turn over the travel device. (Stand the travel

device upright with the spacer (75301498) side on
a work bench.)
NOTE - If the spacer (75301498) is not available, use
a device to stand the travel device securely so that the
brake valve does not come into contact with the work
bench.
3. Remove bolts (16) to remove cover (15).
: 19 mm
NOTE- For easy separation of cover (15), apply a
chisel between cover (15) and ring gear (12) and
lightly tap on the end of the chisel.
Do not remove stopper pin (14) unless it is damaged
or excessively worn.
4. Remove propeller shaft (11) and first stage carrier
(10) assembly.
stage carrier (23) as an assembly. Remove third
stage sun gear (2).
75301485
13
WARNING
Ring gear weight: 50 kg (110 Ib)
6. Remove bolts (13). Attach eye bolt (75301485) to
ring gear (12). Remove ring gear (12) using a crane.
: 24 mm
SM1080
W3-2-20
EX255-EX285
EX285
TRAVEL DEVICE
36
31
32
31
30
45
44
29
46
42
35
37
10
18
1
17
SM5107
EX255-EX285
EX285
W3-2-21
TRAVEL DEVICE
WARNING
Weight of third stage carrier assembly:
Approx. 45 kg (99 lb)
46
45
7. Remove third stage carrier (1) assembly.
36
8. Remove lock bolt (46), and lock plate (45), from

bearing nut (36).
9. Remove bearing nut (36) using special tools.

Special Tools: 75301495, 75301496, 75301497
Bolt: M16 (60 to 90 mm in length): 2 pieces
SM5109
WARNING
Weight of drum and sprocket combined:
130 kg (290 lb)
75301496
75301497
75301495
10. Attach eye bolt (75301486) to drum (32). Remove

drum (32) from housing (44) using a crane.
11. Remove the inner race of roller bearing (31) from
drum (32).
36
SM1082
12. Remove the half of floating seal (30) from drum

(32).
13. Remove the other half of floating seal (30) from
housing (44).
75301486
NOTE - Do not attempt to remove the inner race of
roller bearing (31) which remained in housing (44) side
unless it is to be replaced.
14. Apply a metal bar to the outer race of roller bearing

on drum (32) side, and tap the bar end with a
hammer to drive the outer race out.
SM1083
15. Apply a round bar to spring pin (18), and tap the end
of the bar to drive spring pin (18) out of first stage
carrier (10) assembly.
EX285
EX255-EX285
W3-2-22
TRAVEL DEVICE
32
44
10
43
8
23
18
8
1
33
34
19
21
22
19
20
38
SM5107
EX255-EX285
EX285
W3-2-23
TRAVEL DEVICE
16. Remove pin (22). Remove first stage planetary
gears (21), needle bearings (20), and thrust plates
(19).
17. Remove spacer (43) from first stage carrier (10)
assembly.
following steps 16 to 18 above.
19. Disassemble third stage carrier (1) assembly following steps 16 to 18 above.
WARNING
Sprocket weight: Approx. 65 kg (143 lb)
20. Loosen bolts (34). Remove sprocket (38) from

drum (32) using a crane.
: 30 mm
EX285
EX255-EX285
W3-2-24
TRAVEL DEVICE
ASSEMBLE TRAVEL DEVICE (EX285)
29
42
44
8 13 12 1 2 23 8 9 10
43
17
11
15
14
41
40
21
20
22
18
19
16
30 31 32
45 46 28 27 25 26 24
36
38
3 4
33-34
SM5108
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Third Stage Carrier

Second Stage
Planetary Gear (3 Used)
Pin (3 Used)
Spring Pin (3 Used)
Spacer (2 Used)
First Stage Carrier
Propeller Shaft
Ring Gear
Bolt (24 Used)
Stopper Pin
Cover
16
17
18
19
20
21
22
23
24
25
26
27
28
29
- Bolt (12 Used)

- Plug (3 Used)
- First Stage Planetary
Gear (3 Used)
- Pin (3 Used)
- Second Stage Carrier
- Pin (3 Used)
- Third Stage Planetary
Gear (3 Used)
- Motor
30
31
32
33
34
35
36
37
38
40
41
42
43
44
45
46
Floating Seal
Roller Bearing (2 Used)
Drum
Bolt (20 Used)
Bearing Nut
Bolt (4 Used)
Sprocket
Retaining Ring
Bearing
O-Ring
Spacer
Housing
Lock Plate
Bolt (2 Used)
EX255-EX285
EX285
W3-2-25
TRAVEL DEVICE
Assemble Travel Device
1. If replacing roller bearing (31), warm the inner race
50 to 70 C (122 to 158 F) using a heater, then
install it into housing (44). Wait for the inner race to
cool. Then, drive it in position completely using a
metal bar and a hammer.
7. Install bearing nut (36) to housing (44), with the

uneven surface side towards the hub and tighten
manually.
8. Secure the travel device immovable. Attach the
special tools to bearing nut (36). Then, tighten it
using a torque wrench.
Special Tools: 75301495, 75301496, 75301497
2. Install one half of floating seal (30) on housing (29).

Bolt:
M16 (60 to 90 mm in length): 2 pieces

: 785 N m (80 kgf m, 580 lbf ft)
NOTE - For easier insertion of floating seal O-ring, use

wooden spatula to guide it along the periphery.
3. Install the outer race of roller bearing (31) on drum

(32) in position completely using a metal bar and a
hammer.
Install the halt floating seal (30) into drum (32).
75301496
75301497
75301495
WARNING
Sprocket weight: Approx. 65 kg (143 lb)
36
4. Mount sprocket (38) on drum (32). Apply LOCTITE
262 to bolts (34). Tighten bolts (34) and spring
washer (33).
: 30 mm
: 470 N m (48 kgf m, 350 lbf ft)
WARNING
Weight of drum and sprocket combined:
5. Attach eyebolt (75301486) to drum (32) then install

drum (32) onto housing (44) with motor (29), using
a hoist.
6. Warm the inner race of roller bearing (31) 50 to
70 C (122 to 158 F) using a heater. Install it
between drum (32) and housing (44). Wait for the
inner race to cool. Then, drive it into position
completely using a metal bar and a hammer.
SM1082
EX285
EX255-EX285
W3-2-26
TRAVEL DEVICE
44
8 13 12 1
30 31 32
45 46 28 27 25 26 24
36
38
SM5108
EX255-EX285
EX285
W3-2-27
TRAVEL DEVICE
9. Tap on drum (32) using a plastic hammer to secure
appropriate play. Then, rotate sprocket (38) three
turns clockwise and then counterclockwise.
10. Repeat step 9 above. Then, tighten bearing nut
(36) to specification.
75301496
75301497
Special Tools: 75301495, 75301496, 75301497

Bolt: M16 (60 to 90 mm in length): 2 pieces
75301495
: 785 N m (80 kgf m, 580 lbf ft)

36
11. Install lock plate (45). Apply LOCTITE 262 to the
thread of bolts (46) (2 used), then tighten them to
specification.
SM1082
: 19 mm
: 88 N m (9 kgf m, 65 lbf ft)
12. Install two needle bearings (27) into each third
stage planetary gear (28).
46
13. Putting thrust plates (26) on both ends of each

third stage planetary gears (28), install them into
third stage carrier (1). Install thrust plates (8) into
third stage carrier (1).
45
36
14. Drive pin (25) into third stage carrier (1), aligning
the spring pin holes.
15. Drive spring pin (24) into the spring pin hole on third
stage carrier (1) and pin (25).
upwards in relation to the end of pin (25), as shown.
WARNING
Third stage carrier assembly weight:
SM5109
25
24
Spaccatura
SM1085
16. Install third stage carrier (1) assembly, aligning

splines with housing (44).
17. Install third stage sun gear (2) into third stage
carrier (1). Be sure that the lower tooth end faces
upwards.
18. Clean (decrease) ring gear mounting surface of
drum (32). Apply THREEBOND 1215 to the
mounting surface.
W3-2-28
EX255-EX285
EX285
TRAVEL DEVICE
29
42
44
8 13 12 1 2 23 8 9 10
43
17
11
15
14
41
40
21
20
22
18
19
16
30 31 32
SM5108
EX255-EX285
EX285
W3-2-29
TRAVEL DEVICE
WARNING
Ring gear weight: Approx. 50 kg (110 lb)
18. Install ring gear (12) onto drum (32) using a crane.
Tighten bolts (13).
WARNING
Travel device weight: Approx. 441 kg (972 lb)
30. Turn over the travel device. Remove spacer

(75301498).
: 24 mm
: 265 N m ( 27 kgf m, 195 lbf ft)
19. Install spacer (8) into second stage carrier (23).
20. Assemble second stage carrier (23) referring to
steps 12 to 15.
21. Install second stage carrier (23) assembly into ring
gear (12).
stage carrier (23).
23. Install spacer (43) into first stage carrier (10).
24. Assemble first stage carrier (10) referring to steps
12 to 15.
25. Install first stage carrier (10) assembly into ring
gear (12), aligning splines between first stage
carrier (10) and second stage sun gear (9).
26. Add lubricant oil to gear box. (Refer to the Operators Manual for the type of lubricant oil to be used.)
Oil capacity:
7.8 L (2.1 US gal)
27. Insert propeller shaft (11). Be sure that the propeller shaft correctly meshes with first stage planetary gears (21) and the shaft of motor (29).
28. Clean (degrease) the cover mounting surface of
ring gear (12). Apply THREEBOND 1215 to the
mounting surface. Install cover (15). Tighten bolts
(16).
: 19 mm
: 108 N m (11 kgf m, 80 lbf ft)
29. Wrap seal tape around plugs (17). Install plugs (17)
into cover (15).
: 10 mm
: 49 N m (5 kgf m, 36 lbf ft)
IMPORTANT - Be sure to fill the travel device with the

specified amount of gear oil after installing it on the
machine.
EX255
EX255-EX285
W3-2-30
TRAVEL DEVICE
DISASSEMBLE TRAVEL MOTOR (EX255)
13
14
12
11
10
9
8
7
6
5
4
3
2
1
15
16
17
18
19
20
21
25
22
26
27
23
28
24
29
30
31
32
40 39
38 37
33
36
SM3513
34
35
1
2
3
4
5
6
7
8
9
10
11
12
13
14
O-Ring
Disc Spring
D-Ring
Piston
D-Ring
Plate (5 Used)
Spacer
Drive Disc
Bearing
Spacer
Bearing
Housing
Oil Seal
Retaining Ring
15
16
17
18
19
20
21
22
23
24
25
26
27
28
O-Ring
Baring Nut
Plunger (7 Used)
Rotor
Plug (2 Used)
Link
Reamer Bolt
Plug
O-Ring
Pin
Center Shaft
Center Spring
Bushing
29
30
31
32
33
34
35
36
37
38
39
40
Valve Plate
Plate
Knock Pin (2 Used)
Brake Valve
O-Ring
Plug
Servo Piston
Piston Ring (2 Used)
O-Ring
Cover
EX255-EX285
EX255
W3-2-31
TRAVEL DEVICE
Disassemble Travel Motor
WARNING
Brake valve weight: 30 kg (66 lb)
1. Loosen socket bolts (32), and remove brake valve

(33) using hoist from the motor.
: 14 mm
2. Loosen socket bolts (40) and remove cover (39)

and O-ring (38).
22
: 10 mm
3. Turn over brake valve (33).

Remove drain plug (23). Insert a hexagon wrench
from drain plug hole to remove reamer bolt (22).
SM1087
: 8, 10 mm
4. Remove servo piston (36) to remove valve plate

(29) and link (21).
IMPORTANT - Remove plug (19), only necessary.

19
5. Remove O-rings (1, 15) from housing (12).
SM1088
6. Remove rotor (18) from housing (12).

Make matching mark on rotor (18) and plungers
(17).
7. Remove center spring (27) and center shaft (26).
8. Remove plungers (17) one by one. First, grab

plunger (17) upright against drive disc (8). Then,
turn it at an angle against the drive disc while
slightly raising the bottom of the plunger to remove
the plunger. (to disconnect the joint).
IMPORTANT - Make matching mark on the plungers

(17) and drive disc (8).
9. Remove disc spring (2).
W3-2-32
EX255-EX285
EX255
TRAVEL DEVICE
13
14
12
11
10
9
8
7
6
5
4
3
16
20
SM3513
EX255-EX285
EX255
W3-2-33
TRAVEL DEVICE
WARNING
Be sure to reduce air pressure to 98 to 196 kPa
(1 to 2 kgf/cm2, 14 to 28 psi) when using compressed air. Cover piston (4) with cloths when
removing the piston using compressed air to avoid
sudden flying off.
12
10. Remove piston (4) from housing while supplying

98 to 196 kPa (1 to 2 kgf/cm2, 14 to 28 psi) air
pressure to the brake releasing hydraulic circuit
using an air pump.
11. Remove D-rings (3, 5) from piston (4).
12. Remove plates (6), friction plates (20) and spacer
SM1089
WARNING
Housing+drive disc+etc weight: 50 kg (110 lb)
13. Turn over housing (12), then tap with plastic

hammer to remove drive disc (8) assembly.
75301492
75301499
14. Remove retaining ring (14) from housing (12). Pull

out oil seal (13).
15. Attach drive disc (8) assembly to special tool

(75301492 and 75301499). Remove bearing nut
(16).
16. Place support wooden blocks under the outer
race, as illustrated. Press drive disc (8) using a
press to pull out bearing (11) and spacer (10).
17. Remove the outer race of bearing (11) from spacer
(10).
SM1090
10
11
Pista
18. Place support wooden blocks under the inner race

of bearing (9). Push drive disc (8) out using a
press.
IMPORTANT - If the inner race of bearing (9) is
removed, do not reuse it.
SM1091
W3-2-34
EX255-EX285
EX255
TRAVEL DEVICE
ASSEMBLE TRAVEL MOTOR (EX255)
35
30
28
29
15
18
27
25
26
Cross Section A-A
A
33
22
21
19
A
14
B
C
12
A
23
13
37
16
39
40
11
38
1
2
3
4
5
6
7
8
9
10
11
12
13
14
O-Ring
Disc Spring
D-Ring
Piston
D-Ring
Plate (5 Used)
Spacer
Drive Disc
Bearing
Spacer
Bearing
Housing
Oil Seal
Retaining Ring
36
32 17
15
16
17
18
19
20
21
22
23
24
25
26
27
28
20
O-Ring
Baring Nut
Plunger (7 Used)
Rotor
Plug (2 Used)
Link
Reamer Bolt
Plug
O-Ring
Pin
Center Shaft
Center Spring
Bushing
9 10
SM3519
29
30
31
32
33
34
35
36
37
38
39
40
Valve Plate
Plate
Knock Pin (2 Used)
Brake Valve
O-Ring
Plug
Servo Piston
O-Ring
Cover
EX255-EX285
EX255
W3-2-35
TRAVEL DEVICE
Assemble Travel Motor
1. Warm the inner race of bearing (9) to 70 to 90 C
(160 to 194 F) in an oil bath or using a dryer. Then,
install it onto drive disc (8) using special tool
75298960 and a press.
10
9
2. Put the outer race on the inner race of bearing (9).

3. Install the outer race of bearing (11) onto spacer
(10) by tapping with a plastic hammer.
4. Put spacer (10) on the outer race of bearing (9).
Confirm that the oil groove side of the spacer faces
bearing (9).
Oil groove
SM1093

install it onto drive disc (8) using special tool and a
press. Apply a metal bar to the inner race. Tap the
end of the bar to completely install it in position (or
to confirm that it has been completely installed in
position).
6. Fix drive disc (8) in special tool (75301499).
Tighten bearing nut (16) while applying lubricants
until the specified shaft starting torque is obtained.
7. Measure shaft starting torque.
16
75301499
8
: 2 0.5 N m (0.2 0.05 kgf m,

1.5 0.4 lbf ft)
SM1090
IMPORTANT - Take care not to damage oil seal (13).
8. Install oil seal (13) into housing (12) using a press.

Install retaining ring (14).
WARNING
9. Turn over housing (12). Install drive disc (8) assembly into housing (12) by tapping with a plastic
hammer.
SM1094
EX255
EX255-EX285
W3-2-36
TRAVEL DEVICE
30
15
18
27
25
26
Cross Section A-A
33
23
17
20
10
SM3519
EX255-EX285
EX255
W3-2-37
TRAVEL DEVICE
10. Install spacer (7) into housing (12) with the oil
groove side facing downward, aligning the oil
groove and the hole on housing (12).
11. Install plates (6) (5 used) and friction plates (20) (4
used) one by one alternately, aligning notches of
each plate and friction plate. Be sure to install
plates (6) to housing (12) side and friction plates
(20) to drive disc (8) side.
12. Attach D-rings (3) and (5) onto piston (4). Install
piston (4) into housing (12).
NOTE - Tap the end of piston (4) with a plastic hammer

for easy insertion.
17
13. Install disc spring (2) onto housing (12) with the
larger diameter side facing upward.
14. Aligning matching marks, install plungers (17) into
the spherical joints on drive disc one by one.
Confirm that plungers (17) move smoothly in the
joints.
SM1095
15. Install center shaft (26) onto drive disc (8). Attach
center spring (27) onto center shaft (26).
16. Insert the top part of center shaft (26) into the
center hole on rotor (18), aligning pin (25) on center
shaft (26) with the groove on rotor (18).
18
17. Insert plungers (17) into rotor (18) one by one,

aligning the matching marks. Be sure that the
groove on rotor (18) comes over pin (25) on shaft
(26).
19. Add hydraulic oil into housing (12).
Hydraulic oil:1.2 L (1.27 US qt)
20. Remove plug (23) from brake valve (33).
21. Install plate (30) on brake valve (33).
26
25
SM1096
EX255
EX255-EX285
W3-2-38
TRAVEL DEVICE
35
30
28
29
Cross Section A-A
A
33
22
21
19
A
23
37
39
40
38
36
SM3519
EX255-EX285
EX255
W3-2-39
TRAVEL DEVICE
22. Attach piston rings (37) onto servo piston (36).
Then, attach them to special tool (75301530).
36
23. Insert servo piston (36) into brake valve (33).

24. If replacing bushing (28), drive it into valve plate
(29) using special tool (75301494).
NOTE - Note the facing direction of the oil groove side

when removing the bushing.
25. Apply LOCTITE 262 to plugs (19). Install link (21)

on valve plate (29) using plugs (19).
75301530
SM1097
: 6 mm
: 49 N m (5 kgf m, 36 lbf ft)
29
21
26. Install link (21) and valve plate (29) to fit into the
groove on plate (30). Align the groove of link (21)
with servo piston (36).
27. Align the holes on link (21) and on servo piston (36)
by inerting the aligning tool (75301500) through
plug (23) hole.
28. Apply extreme-pressure grease to the tip of
reamer bolt (22) to prevent seizure between parts.
Install reamer bolt (22) into link (21) and servo
piston (36) through the other plug (23) hole on the
opposite side.
19
SM1098
: 8 mm
36
: 49 N m (5 kgf m, 36 lbf ft)
75301500
21
29. Remove plug (35) from brake valve (33). Secure

valve plate (29) using a fastening device.
30. Install O-ring (38) on cover (39). Install cover (39)
on brake valve (33) using socket bolts (40).
: 10 mm
: 88 N m (9 kgf m, 65 lbf ft)
22
SM1099
EX255
EX255-EX285
W3-2-40
TRAVEL DEVICE
35
26
Cross Section A-A
A
33
A
B
C
12
A
23
32
SM3519
EX255-EX285
EX255
W3-2-41
TRAVEL DEVICE
31. Attach special tool (75301501) to the top of center
shaft (26).
32. Remove plug (A) from brake valve (33). Remove
spool (B) and spring (C).
: 8 mm
75301501
26
WARNING
Brake valve weight: 30 kg (66 Ib)
33. Attach brake valve (33) to a crane. Lift brake valve

(33) and align special tool (75301501) with plug (A)
hole. Then, install brake valve (33) onto housing
(12).
34. Remove special tool (75301501) and the fastening
device from brake valve (33).
35. Install plugs (23) and (35), spool (B), spring (C),
and plug (A) to brake valve (33).
: 5 mm
: 15 N m (1.5 kgf m, 11 lbf ft)
: 8 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
: 10 mm
: 118 N m (12 kgf m, 90 lbf ft)
36. Install socket bolts (32).
: 12 mm
: 215 N m (22 kgf m, 160 lbf ft)
SM1092
12
W3-2-42
EX255-EX285
EX255
TRAVEL DEVICE
DISASSEMBLE BRAKE VALVE (EX255)
4
8
1- 2
10
11
12
21
20
19
13
7
18
12
14
15
11
16
17
1- 2
4
10
SM1101
1
2
3
4
5
6
7
O-Ring (2 Used)
Overload Relief Valve (2 Used)
Casing
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Poppet (2 Used)
8
9
10
11
12
13
14
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Spring (2 Used)
Stopper (2 Used)
Spool
Ball (2 Used)
15
16
17
18
19
20
21
Seat (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Plug
O-Ring
Spool
Spring
EX255-EX285
EX255
W3-2-43
TRAVEL DEVICE
Disassemble Brake Valve
Parking Brake Release Valve

9. Remove plug (17) and O-ring (16) from casing
(3).
: 6 mm
10. Remove seat (15) and tilt casing (3) to remove

ball (14).
: 5 mm
1. Remove plug (8) and O-ring (9) from casing (3).

: 36 mm
2. Remove springs (10), (11) and stopper (12).
3. Remove spool (13) from casing (3).
Reducing Valve
(3).
: 8 mm

12. Remove spool (20) and spring (21).
4. Remove overload relief valve (2) from casing
(3).
: 27 mm
Check Valve
5. Remove plug (4) and O-ring (5) from casing (3).
: 12 mm
6. Remove spring (6) and poppet (7).
Servo Piston Operating Shuttle Valve

(3).
: 6 mm
8. Remove seat (15) and tilt casing (3) to remove
ball (14).
: 5 mm
W3-2-44
EX255-EX285
EX255
TRAVEL DEVICE
ASSEMBLE BRAKE VALVE (EX255)
Cross Section C-C
2
14 19
20
21
15
5
18
16
17
C
10
11
8
9
12
3
B
13
A
Cross Section A-A
14
15
Cross Section B-B
17
1
2
3
4
5
6
7
O-Ring (2 Used)
Casing
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Poppet (2 Used)
8
9
10
11
12
13
14
SM1102
16
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Spring (2 Used)
Stopper (2 Used)
Spool
Ball (2 Used)
15
16
17
18
19
20
21
Seat (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Plug
O-Ring
Spool
Spring
EX255-EX285
EX255
W3-2-45
TRAVEL DEVICE
Assemble Brake Valve
5. Install O-ring (16) to plug (17), then install it

to casing (3).
Reducing Valve
: 6 mm
: 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).
: 8 mm
: 69 N m (7 kgf m, 51 lbf ft)
Check Valve
6. Insert poppet (7) with spring (6) into casing (3),
(3).
Parking Brake Relief Valve

(Cross Section C-C)
: 12 mm
: 235 N m (24 kgf m, 175 lbf ft)
2. Tilt casing (3) and insert ball (14). Apply

LOCTITE 262 to seat (15) and tighten it to
casing (3).
: 5 mm

7. Install overload relief valve (2) to casing (3).
: 14.5 N m (1.5 kgf m, 11 lbf ft)
: 27 mm
: 540 N m (55 kgf m, 400 lbf ft)
IMPORTANT - Before inserting ball (14), put ball (14)

on seat (15) and tap on the ball with a hammer to obtain
tight fitting between ball (14) and seat (15). Also, after
inserting ball (14) and before tightening seat (15),
insert a metal bar into the plug hole to apply its end to
ball (14), then tap the other end of the bar to obtain tight
fitting between ball (14) and the casing.
3. Install O-ring (16) to plug (17), then install it to

casing (3).
: 6 mm
: 34 N m (3.5 kgf m, 25 lbf ft)

(Cross Section B-B)
casing (3).
: 5 mm
: 14.5 N m (1.5 kgf m, 11 lbf ft)

8. Insert spool (13) into casing (3).
IMPORTANT - Apply film of hydraulic oil to spool

(13).
9. Install springs (10), (11) to stopper (12), then
insert it into casing (3).
10. Install O-ring (9) to plug (8), then install to
casing (3).
: 36 mm
: 215 N m (22 kgf m, 160 lbf ft)
IMPORTANT - Be sure to fill the travel device with

EX285
EX255-EX285
W3-2-46
TRAVEL DEVICE
DISASSEMBLE TRAVEL MOTOR (EX285)
12
10
9
8
7
13 14
20
4
3
1
11 16
15
25
26
27
17
18
19
28
21
29
22
19
23
32 24
30
31
40
39 38 37
33
36
SM5110
34
35
1
2
3
4
5
6
7
8
9
10
11
12
13
14
O-Ring
Disc Spring
D-Ring
Piston
D-Ring
Plate (5 Used)
Spacer
Drive Disc
Bearing
Spacer
Bearing
Housing
Oil Seal
Retaining Ring
15
16
17
18
19
20
21
22
23
24
25
26
27
28
O-Ring
Bearing Nut
Plunger (7 Used)
Rotor
Plug (2 Used)
Link
Reamer Bolt
Plug
O-Ring
Pin
Center Shaft
Center Spring
Bushing
29
30
31
32
33
34
35
36
37
38
39
40
Valve Plate
Plate
Knock Pin (2 Used)
Brake Valve
O-Ring
Plug
Servo Piston
O-Ring
Cover
EX255-EX285
EX285
W3-2-47
TRAVEL DEVICE
Disassemble Travel Motor
WARNING
Brake valve weight: 43 kg (95 lb)
1. Loosen socket bolts (32), and remove brake valve

(33) using hoist from the motor.
: 14 mm
2. Loosen socket bolts (40) and remove cover (39)

and O-ring (38).
22
: 10 mm
3. Turn over brake valve (33).

Remove drain plug (23). Insert a hexagon wrench
from drain plug hole to remove reamer bolt (22).
SM1087
: 8, 10 mm
4. Remove servo piston (36) to remove valve plate

(29) and link (21).
IMPORTANT - Remove plug (19), only necessary.

19
5. Remove O-rings (1), (15) from housing (12).
SM1088
6. Remove rotor (18) from housing (12).

Make matching mark on rotor (18) and plungers
(17).
7. Remove center spring (27) and center shaft (26).
IMPORTANT - Make matching mark on the plungers

(17) and drive disc (8).
8. Remove plungers (17) one by one. First, grab

plunger (17) upright against drive disc (8). Then,
turn it at an angle against the drive disc while
slightly raising the bottom of the plunger to remove
the plunger. (to disconnect the joint)
9. Remove disc spring (2).
EX285
EX255-EX285
W3-2-48
TRAVEL DEVICE
12
10
8
7
13 14
20
4
3
11 16
SM5110
EX285
EX255-EX285
W3-2-49
TRAVEL DEVICE
WARNING
Be sure to reduce air pressure to 98 to 196 kPa
(1 to 2 kgf/cm2, 14 to 28 psi) when using compressed air. Cover piston (4) with cloths when
removing the piston using compressed air to avoid
sudden flying off.
12
10. Remove piston (4) from housing while supplying

98 to 196 kPa (1 to 2 kgf/cm2, 14 to 28 psi) air
pressure to the brake releasing hydraulic circuit
using an air pump.
11. Remove D-rings (3, 5) from piston (4).
12. Remove plates (6), friction plates (20) and spacer
SM1089
WARNING
Housing+drive disc+etc weight: 50 kg (110 lb)
13. Turn over housing (12), then tap with plastic

hammer to remove drive disc (8) assembly.
14. Remove retaining ring (14) from housing (12). Pull
out oil seal (13).
75301492
75301499
8
15. Attach drive disc (8) assembly to special tool

75301492 and 75301499. Remove bearing nut
(16).
16. Place support wooden blocks under the outer
race, as illustrated. Press drive disc (8) using a
press to pull out bearing (11) and spacer (10).
17. Remove the outer race of bearing (11) from spacer
(10).
SM1090
10
11
Pista
18. Place support wooden blocks under the inner race

of bearing (9). Push drive disc (8) out using a
press.
IMPORTANT - If the inner race of bearing (9) is
removed, do not reuse it.
SM1091
W3-2-50
EX255-EX285
EX285
TRAVEL DEVICE
ASSEMBLE TRAVEL MOTOR (EX285)
34,35 28
15
Cross Section A
30
29
31
10
33
11
12
13
22 21 19
14
18
25
16
17
37
20
39
SM5111
36 38 40
1
2
3
4
5
6
7
8
9
10
11
12
13
14
O-Ring
Disc Spring
D-Ring
Piston
D-Ring
Plate (5 Used)
Spacer
Drive Disc
Bearing
Spacer
Bearing
Housing
Oil Seal
Retaining Ring
24,23 32
27
26
15
16
17
18
19
20
21
22
23
24
25
26
27
28
O-Ring
Bearing Nut
Plunger (7 Used)
Rotor
Plug (2 Used)
Link
Reamer Bolt
Plug
O-Ring
Pin
Center Shaft
Center Spring
Bushing
29
30
31
32
33
34
35
36
37
38
39
40
Valve Plate
Plate
Knock Pin (2 Used)
Brake Valve
O-Ring
Plug
Servo Piston
O-Ring
Cover
EX285
EX255-EX285
W3-2-51
TRAVEL DEVICE
Assemble Travel Motor
install it onto drive disc (8) using special tool
75298960 and a press.
10
9
2. Put the outer race on the inner race of bearing (9).

3. Install the outer race of bearing (11) onto spacer
(10) by tapping with a plastic hammer.
4. Put spacer (10) on the outer race of bearing (9).
Confirm that the oil groove side of the spacer faces
bearing (9).
Oil groove
SM1093

install it onto drive disc (8) using special tool and a
press. Apply a metal bar to the inner race. Tap the
end of the bar to completely install it in position (or
to confirm that it has been completely installed in
position).
6. Fix drive disc (8) in special tool (75301499).
Tighten bearing nut (16) while applying lubricants
until the specified shaft starting torque is obtained.
7. Measure shaft starting torque.
16
75301499
8
: 3 0.5 N m (0.3 0.05 kgf m,

2.2 0.4 lbf ft)
SM1090
IMPORTANT - Take care not to damage oil seal (13).
8. Install oil seal (13) into housing (12) using a press.

Install retaining ring (14).
WARNING
9. Turn over housing (12). Install drive disc (8) assembly into housing (12) by tapping with a plastic
hammer.
SM1094
W3-2-52
EX255-EX285
EX285
TRAVEL DEVICE
34,35 28
15
Cross Section A
30
29
31
10
33
11
12
13
14
18
25
16
17
20
SM5111
36 38 40
24,23 32
27
26
EX285
EX255-EX285
W3-2-53
TRAVEL DEVICE
10. Install spacer (7) into housing (12) with the oil
groove side facing downward, aligning the oil
groove and the hole on housing (12).
11. Install plates (6) (5 used) and friction plates (20) (4
used) one by one alternately, aligning notches of
each plate and friction plate. Be sure to install
plates (6) to housing (12) side and friction plates
(20) to drive disc (8) side.
12. Attach D-rings (3) and (5) onto piston (4). Install
piston (4) into housing (12).
NOTE - Tap the end of piston (4) with a plastic hammer

for easy insertion.
17
13. Install disc spring (2) onto housing (12) with the
larger diameter side facing upward.
14. Aligning matching marks, install plungers (17) into
the spherical joints on drive disc one by one.
Confirm that plungers (17) move smoothly in the
joints.
SM1095
15. Install center shaft (26) onto drive disc (8). Attach
center spring (27) onto center shaft (26).
16. Insert the top part of center shaft (26) into the
center hole on rotor (18), aligning pin (25) on center
shaft (26) with the groove on rotor (18).
18
17. Insert plungers (17) into rotor (18) one by one,

aligning the matching marks. Be sure that the
groove on rotor (18) comes over pin (25) on shaft
(26).
19. Add hydraulic oil into housing (12).
Hydraulic oil:1.3 L (1.37 US qt)
20. Remove plug (23) from brake valve (33).
: 10 mm
21. Install plate (30) on brake valve (33).
26
25
SM1096
EX285
EX255-EX285
W3-2-54
TRAVEL DEVICE
34,35 28
Cross Section A
30
29
31
33
22 21 19
37
39
SM5111
36 38 40
24,23
EX255-EX285
EX285
W3-2-55
TRAVEL DEVICE
22. Attach piston rings (37) onto servo piston (36).
Then, attach them to special tool (75301530).
36
23. Insert servo piston (36) into brake valve (33).

24. If replacing bushing (28), drive it into valve plate
NOTE - Note the facing direction of the oil groove side

when removing the bushing.
25. Apply LOCTITE 262 to plugs (19). Install link (21)

on valve plate (29) using plugs (19).
75301530
SM1097
: 6 mm
: 49 N m (5 kgf m, 36 lbf ft)
29
21
26. Install link (21) and valve plate (29) to fit into the
groove on plate (30). Align the groove of link (21)
with servo piston (36).
27. Align the holes on link (21) and on servo piston (36)
by inerting the aligning tool (75301500) through
plug (23) hole.
28. Apply extreme-pressure grease to the tip of
reamer bolt (22) to prevent seizure between parts.
Install reamer bolt (22) into link (21) and servo
piston (36) through the other plug (23) hole on the
opposite side.
19
SM1098
: 8 mm
36
: 49 N m (5 kgf m, 36 lbf ft)
75301500
21
29. Remove plug (35) from brake valve (33). Secure

valve plate (29) using a fastening device.
30. Install O-ring (38) on cover (39). Install cover (39)
on brake valve (33) using socket bolts (40).
: 10 mm
: 88 N m (9 kgf m, 65 lbf ft)
22
SM1099
W3-2-56
EX255-EX285
EX285
TRAVEL DEVICE
34,35 28
15
Cross Section A
30
29
31
10
33
11
12
13
14
18
25
16
17
20
SM5111
36 38 40
24,23 32
27
26
EX255-EX285
EX285
W3-2-57
TRAVEL DEVICE
31. Attach special tool (75301501) to the top of center
shaft (26).
32. Remove plug (A) from brake valve (33). Remove
spool (B) and spring (C).
: 8 mm
75301501
26
WARNING
Brake valve weight: 43 kg (95 Ib)
33. Attach brake valve (33) to a crane. Lift brake valve

(33) and align special tool (75301501) with plug (A)
hole. Then, install brake valve (33) onto housing
(12).
34. Remove special tool (75301501) and the fastening
device from brake valve (33).
35. Install plugs (23) and (35), spool (B), spring (C),
and plug (A) to brake valve (33).
: 5 mm
: 15 N m (1.5 kgf m, 11 lbf ft)
: 8 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
: 10 mm
: 118 N m (12 kgf m, 90 lbf ft)
36. Install socket bolts (32).
: 14 mm
: 390 N m (40 kgf m, 290 lbf ft)
SM1092
12
EX285
EX255-EX285
W3-2-58
TRAVEL DEVICE
DISASSEMBLE BRAKE VALVE (EX285)
8
9
A
10
12
17
16
15
14
13
6
1,2
12
21
10
20
14
15
16
17
19
18
5
1,2
8
4
SM5112
A
B
1
2
3
4
5
6
Parking Brake Shuttle Valve

Servo Piston Shuttle Valve
O-Ring (2 Used)
Casing
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
7
8
9
10
12
13
14
15
Poppet (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Stopper (2 Used)
Spool
Ball (2 Used)
Seat (2 Used)
16
17
18
19
20
21
O-Ring (2 Used)
Plug (2 Used)
Plug
O-Ring
Spool
Spring
EX285
EX255-EX285
W3-2-59
TRAVEL DEVICE
Disassemble Brake Valve
(3).
: 41 mm
2. Remove spring (10) and stopper (12).
3. Remove spool (13) from casing (3).

4. Remove overload relief valve (2) from cas
ing (3).
: 27 mm
Check Valve
(3).
: 12 mm
6. Remove spring (6) and poppet (7).

7. Remove plug (17) and O-ring (16) from
casing (3).
: 6 mm
8. Remove seat (15) and tilt casing (3) to
remove ball (14).
: 5 mm
Parking Brake Release Shuttle Valve

casing (3).
: 6 mm
10. Remove seat (15) and tilt casing (3) to
remove ball (14).
: 5 mm
Reducing Valve
casing (3).
: 8 mm
12. Remove spool (20) and spring (21).
W3-2-60
EX255-EX285
EX285
TRAVEL DEVICE
ASSEMBLE BRAKE VALVE (EX285)
14
15
16
14
17
15
Section B
17
16
Section C
19
20
21
18
3
4
5
8
9
13
12
Section A-A
10
SM5113
1
2
3
4
5
6
7
O-Ring (2 Used)
Casing
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Poppet (2 Used)
8
9
10
12
13
14
15
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Stopper (2 Used)
Spool
Ball (2 Used)
Seat (2 Used)
16
17
18
19
20
21
O-Ring (2 Used)
Plug (2 Used)
Plug
O-Ring
Spool
Spring
EX285
EX255-EX285
W3-2-61
TRAVEL DEVICE
Assemble Brake Valve
5. Install O-ring (16) to plug (17), then install it to

casing (3).
Reducing Valve
: 6 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
1. Insert spring (21) and spool (20) into casing (3),

(3).
: 8 mm
: 69 N m (7 kgf m, 51 lbf ft)
Check Valve
6. Insert poppet (7) with spring (6) into casing (3),
(3).
Parking Brake Relief Valve

(Cross Section C-C)
: 12 mm
: 235 N m (24 kgf m, 175 lbf ft)

casing (3).
: 5 mm

7. Install overload relief valve (2) to casing (3).
: 14.5 N m (1.5 kgf m, 11 lbf ft)
: 27 mm
: 540 N m (55 kgf m, 400 lbf ft)

8. Insert spool (13) into casing (3).
IMPORTANT - Apply film of hydraulic oil to spool (13).

3. install O-ring (16) to plug (17), then install it to
casing (3).
: 6 mm
9. Install spring (10) to stopper (12), then insert it

into casing (3).
: 34 N m (3.5 kgf m, 25 lbf ft)

(Cross Section B-B)
casing (3).
: 5 mm
: 14.5 N m (1.5 kgf m, 11 lbf ft)

10. Install O-ring (9) to plug (8), then install to

casing (3).
: 41 mm
: 340 N m (35 kgf m, 250 lbf ft)
IMPORTANT - Be sure to fill the travel device with

W3-2-62
EX255-EX285
TRAVEL DEVICE
Sprocket
B
C
D
SM1103
IMPORTANT - Consult FIAT-HITACHI for any inqueries concerning welding procedures.
Standard (mm)
mm (in)
EX255
A
B
72.0 (2.83)
Allowable Limit
mm (in)
EX285
EX255
EX285
93.0 (3.66)
64 (2.52)
75 (2.95)
579.6 (22.82) 616.5 (24.27) 570 (22.42)
PCD644.6
(25.38)
658.4 (25.92)
190.0 (7.48)
PCD689.4
(27.50)
704.0
(27.72)
203.2
(8.0)
602 (23.70)
648 (25.51)
694 (27.32)
Remedy
Build up and
finishing
EX255-EX285
W3-2-63
TRAVEL DEVICE
Parking Brake
Part Name
SM1104
Standard (Thickness)
of Height
mm (in)
EX255
Allowable Limit
(Thickness)
mm (in)
EX285
Friction Plate
Spacer
8.5 (0.33)
9.0 (0.35)
Disk Spring
6.2 (0.24)
6.5 (0.26)
6.10 (0.24)
Piston
*41.5 (1.63)
*46.0 (1.81)
Plate
Remark
Remedy
3.3 (3.25)
1.8 (0.070)
3.25
1.75 (0.069)
The spacer and piston do not wear down. New friction plates are
made with a marginal tolerance of plus (+) 0.1 mm in thickness.
NOTA - * Piston thickness (D) is the distance (width) between the disc spring (C) contacting left end of the piston
and the brake plate (E) contacting right end of the piston.
W3-2-64
EX255-EX285
TRAVEL DEVICE
NOTES
EX255-EX285
W3-3-1
CENTER JOINT
REMOVE AND INSTALL CENTER JOINT
WARNING
Preparation


pressure.
NOTE - Be sure to run the vacuum pump continuously while working.
Removal
Installation
NOTE - Attach labels or tags to hoses and adapters,

to aid in assembly.
NOTE - Refer to Removal section above for wrench

sizes and tightening torque.
1. Disconnect hoses (1), (2), and (5) to (16).

Remove the adapters.
Loosen bolts (3) and remove lock plate (4).
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
1. Install the center joint and lift it, then tighten bolts
(17).
2. Install adapters and hoses (1), (2), (5) to (16).
3. Install lock plate (4) and tighten bolts (3).
1
: 22 mm
: 39 N m (4.0 kgf m, 29 lbf ft)
: 27 mm
: 93 N m (9.5 kgf m, 69 lbf ft)
: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)
SM1141
NOTE - Plug all disconnected ends.
6
9
2. Attach the center joint to a hoist.

17
3. Remove bolts (17) and lower the hoist to remove
the center joint.
: 19 mm
: 34 N m (3.5 kgf m, 25 lbf ft)
WARNING
Weight of center joint: 26.5 kg (58.5 lb)
10
16
11
15
14
12
13
SM1148
W3-3-2
EX255-EX285
CENTER JOINT
DISASSEMBLE CENTER JOINT
1
12
10
11
SM1149
1
2
3
4
Plug
Spindle
Dust Seal
O-Ring
5
6
7
8
Bushing
Body
Oil Seal (6 Used)
Bolt (4 Used)
9
10
11
12
Cover
Retaining Ring
O-Ring
Ring
EX255-EX285
W3-3-3
CENTER JOINT
Disassemble Center Joint
IMPORTANT - Put a matching mark on body (6) and
spindle (2).
WARNING
75301505
Weight of center joint: 26.5 kg (58.5 Ib)

8
1. Remove two bolts (8) and install two eyebolts
(M10, Pitch1.5, Length18 mm). Attach hoist to the
center joint, then secure it on workbench
(75298324).
2. Remove eyebolts and bolts (8) to remove cover

(9) from body (6).
SM1150
: 17 mm
3. Remove O-ring (11), retaining ring (10) and ring
(12) from body (6).
4. Attach the special tool (75301505) to body (6),
using bolts (8) (2 Used) and remove body (6) from
spindle (2).
: 17 mm
IMPORTANT - Take care not to damage the spindle.

5. Remove oil seals (7) from body (6).
6
IMPORTANT - Use two picks to pry out oil seals (7),
for easy removal, as illustrated.
Take care not to damage the seal groove with the pick.
7
6. Remove dust seal (3) and O-ring (4) from body
(6).
SM1151
W3-3-4
EX255-EX285
CENTER JOINT
ASSEMBLE CENTER JOINT
3
4
5
6
12
SM1152
11
1
2
3
4
Plug
Spindle
Dust Seal
O-Ring
10
5
6
7
8
Bushing
Body
Oil Seal (6 Used)
Bolt (4 Used)
9
10
11
12
Cover
Retaining Ring
O-Ring
Ring
EX255-EX285
W3-3-5
CENTER JOINT
Assemble Center Joint
1. Install O-ring (4) and dust seal (3) into body (6).
NOTE - If bushing is removed, be sure to reinstall

bushing (5) before installing dust seal (3).
2. Install oil seals (7) (6 Used) into body (6).

3. Secure spindle (2) to workbench (75298324).
Mount body (6) on spindle (2).
NOTE - Align with the matching mark on the spindle

and body.
IMPORTANT - Take care not to damage the seals

when installing.
Clearance between body (6) and spindle (2) is about
0.1 mm (0.004 in), so that body (6) must be straight
to spindle (2).
0,1 mm
4. Tap body (6) with a soft hammer until it touches

the edge of spindle (2).
IMPORTANT - Be sure to install ring (12) with the

chamfered side down.
5. Install ring (12) and O-ring (11) to body (6).
IMPORTANT - Be sure to install retaining ring (10)

with the chamfered side down.
6. Install retaining ring (10) to spindle (2).

7. Install cover (9) and tighten bolts (8) (4 Used).
: 17 mm
: 49 N m (5 kgf m, 36 lbf ft)
SM1153
W3-3-6
EX255-EX285
CENTER JOINT
When replacing the body or spindle with new one, the
following procedures are required.
75301507
Replacing Body (6)

1. Clean body (6) and bushing (5).
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
Replacing Spindle (2)
1. Clean spindle (2).

2. Insert plugs (1) into spindle (2) using pressing
tools (75301506) so that the top of the plug sleeve
is lower than the top surface of spindle (2).
3. Insert the balls into the plug sleeves so that the top
of each ball (A) is 0.4 mm ( 0.016 in ) or more lower
than the respective sleeve edge, as illustrated in
the detail D.
Sleeve
Detail D
SM1155
75301506
Balls
SM1156
EX255-EX285
W3-3-7
CENTER JOINT
Item
Bushing
Allowable Limit (basis of judgment) Remedy

1. Wear more than 0.2 mm (0.008 in)
Replace
2. Scored, abnormal wear.
Replace
3. Uneven wear.
(wear range is less than 180).
Replace
Wear area
Body, Spindle
Sliding Surface and

Sealed Part
Scored or something hurt it
Replace
1. Scored more than 0.1 mm (0.004 in). Replace

Sliding Surface
Except Sealed Part
Sliding Surface
Ring
Cover
Sliding Surface
Ring
2. Scored less than 0.1 mm (0.004 in)

deep.
Repair with
oil stone
1. Wear more than 0.5 mm (0.02 in)

deep. Abnormal wear.
Replace
2. Wear less than 0.5 mm (0.02 in)

deep.
Repair

deep and able to repair.
Repair
1. Wear more than 0.5 mm (0.02 in).
Replace
2. Wear less than 0.5 mm (0.02 in).
Repair

deep and able to repair.
Repair
W3-3-8
EX255-EX285
CENTER JOINT
NOTES:
EX255-EX285
W3-4-1
TRACK ADJUSTER
REMOVE AND INSTALL TRACK
ADJUSTER
Before removing the track adjuster, the tracks and the
front idler must be removed first. For removal and
installation of the tracks and the front idler, refer to
applicable removal/installation sections. In this section, the procedure starts on the premise that the
tracks and the front idler have already been removed.
Removal
WARNING
Track adjuster weight:
EX255: 118 kg (260 lb)
EX285: 161 kg (355 lb)
1. After removing the front idler and yoke, remove

track adjuster (1) from track frame (2) by prying it
out, using a pry bar.
Installation
SM1157
1. As illustrated, install track adjuster (1) into spring

guide (3) on track frame (2). Check that the end
face of track adjuster (1) comes into contact with
the face of plate (4).
SM1175
SM1158
W3-4-2
EX255-EX285
TRACK ADJUSTER
DISASSEMBLE TRACK ADJUSTER
3
4
6
9
10
11
17
12
16
15
14
13
SM1159
3
4
6
8
9
Wiper Ring
Piston Rod
U-Ring
Rod
O-Ring
10
11
12
13
14
Cylinder
Plug
Valve
Nut
Washer
15 - Spacer
16 - Spring
17 - Seal
EX255-EX285
W3-4-3
TRACK ADJUSTER
Disassemble Track Adjuster
Be sure to use special tool (75301508) for assembly / disassembly of the track adjuster.
75301508
WARNING
Prevent personal injury. The spring force of the
track adjuster is extremely large.Thoroughly inspect the special tool for any damage. Carefully
perform assembly work referring to the procedure
below.
SM1160
WARNING
Approximate weight of the track spring holder
assembly: 225 kg (496 lb)
Plate
1. Place a jack on the bottom of the track spring

holder assembly (75301508).
2. Loosen four nuts to remove the plate.
: 46 mm
WARNING
EX255: 118 kg (260 lb)
EX285: 161 kg (355 lb)
SM1161
3. Connect the track adjuster to a hoist using a lifting

strap.
Put the track adjuster in the track spring holder
assembly (75301508), using the hoist.
Remove the lifting strap.
SM1162
W3-4-4
EX255-EX285
TRACK ADJUSTER
11
17
12
14
13
SM1159
EX255-EX285
W3-4-5
TRACK ADJUSTER
4. Install the plate on the spring holder.
Remove valve (12) with grease fitting.
Plate
SM1163
5. Set an oil jack as illustrated.

Jack up the specified amount below to compress
the spring.
NOTE
EX255 - Specified Amount: A - B = 112 mm (4.41 in).
A = Free length: 689 mm (27.13 in);
B = Set length: 577 mm (22.72 in).
EX285 - Specified Amount: A - B = 120 mm (4.72 in).
A = Free length: 677 mm (26.65 in);
B = Set length: 557 mm (21.93 in).
SM1164
13
6. Tighten nuts to secure the track adjuster.

: 46 mm
Operate the oil jack to compress the track adjuster
approximately 10 mm (0.4 in) until a clearance is
observed between washer (14) and nut (13).
SM1165
13
11
7. Remove plug (11) and nut (13).

: 5 mm
: 75 mm
SM1166
W3-4-6
EX255-EX285
TRACK ADJUSTER
3
4
10
16
15
14
SM1159
EX255-EX285
W3-4-7
TRACK ADJUSTER
8. Lower jack to release the spring force.
SM1167
9. Loosen the nuts to remove the plate.

Remove washer (14).
Plate
14
WARNING
Spring assembly weight:
EX255: 110 kg (242 lb)
EX285: 148 kg (326 lb)
SM1168
10. Remove the track adjuster, using an eyebolt (M16,

Pitch1.5) and hoist.
Remove the hoist and eyebolt.
WARNING
Spring weight:
EX255: 70 kg (154 lb)
EX285: 87 kg (192 lb)
11. Remove spring (16) from rod (8).

12. Remove spacer (15) from rod (8).
SM1169
13. Pull out piston rod (4) from cylinder (10).
W3-4-8
EX255-EX285
TRACK ADJUSTER
4
6
9
10
SM1159
EX255-EX285
W3-4-9
TRACK ADJUSTER
14. Remove rod (8) and O-ring (9) from cylinder (10).
3
6
15. Remove wear ring (3), and U-ring (6) from cylinder
(10).
10
SM1170
W3-4-10
EX255-EX285
TRACK ADJUSTER
ASSEMBLE TRACK ADJUSTER
EX255
12 11 13
14
15
16
10
577 mm (free length, 689 mm)

718 mm
SM1171
EX285
12 11 13
14
15
16
10

707 mm
SM1171
1
2
3
4
Idler
Flange
Wiper Ring
Piston Rod
6
8
9
10
U-Ring
Rod
O-Ring
Cylinder
11
12
13
14
Plug
Valve
Nut
Washer
15 - Spacer
16 - Spring
EX255-EX285
W3-4-11
TRACK ADJUSTER
Assemble Track Adjuster
1. Clean all parts.
Install U-ring (6), and wiper ring (3) to cylinder (10).
2. Apply a film of grease to O-ring (9) and install it into
cylinder (10).
Install rod (8) into cylinder (10).
3
6
10
3. Apply grease to U-ring (6), wiper ring (3), cylinder

(10), and to piston rod (4). Install piston rod (4) into
cylinder (10).
IMPORTANT - Fill part (B) on cylinder (10) and insert

piston rod (4) to completely bleed air from part (B) and
from the inside of rod (8).
4. Install spacer (15) on rod (8).
SM1170
WARNING
Spring weight:
EX255: 70 kg (154 lb)
EX285: 87 kg (192 lb)
5. Install spring (16) on rod (8).
WARNING
Spring assembly weight:
EX255: 110 kg (242 lb)
EX285: 148 kg (326 lb)
6. Put the track adjuster in the spring holder, using an

eyebolt (M16, Pitch1.5) and hoist. Remove the
hoist and eyebolt.
SM1169
W3-4-12
EX255-EX285
TRACK ADJUSTER
EX255
11
13
14
16

718 mm
SM1171
EX285
11
13
14
16

707 mm
SM1171
EX255-EX285
W3-4-13
TRACK ADJUSTER
7. Install washer (14) on spring (16).
Install the plate.
Plate
14
16
SM1168
8. Align the jack and track adjuster with the hole in

plate.
Tighten the nuts to secure the track adjuster.
: 46 mm
SM1165
9. Operate the jack to compress spring (16) to

specification.
Compressed Length: 577 mm (1 ft 10.7 in)
16
SM1172
13
11
10. Apply LOCTITE 242 to plug (11). Install nut (13)

and plug (11) to rod (8).
: 75 mm
: 5 mm
: 14.5 N m (1.5 kgf m, 11 lbf m)
SM1166
W3-4-14
EX255-EX285
TRACK ADJUSTER
EX255
12

718 mm
SM1171
EX285
12

707 mm
SM1171
EX255-EX285
W3-4-15
TRACK ADJUSTER
11. Install valve (12) to rod (8).
: 24 mm
: 147 N m (15 kgf m, 110 lbf ft)
12. Lower the jack.
SM1164
13. Remove the nuts and plate.
Plate
: 46 mm
SM1163
WARNING
EX255: 118 kg (260 lb)
EX285: 161 kg (355 lb)
14. Remove the track adjuster from the spring holder,

using a lifting strap and a hoist.
SM1173
15. If only the spring assembly is to be transported, be

sure to use a special tool, such as the one
illustrated, to carry the spring assembly safely.
: 24 mm
SM1174
W3-4-16
EX255-EX285
TRACK ADJUSTER
NOTES
EX255-EX285
W3-5-1
FRONT IDLER
REMOVE AND INSTALL FRONT IDLER
Before removing the front idler, the tracks must be
removed first. For removal and installation of the
tracks, refer to Remove and Install Tracks section.
In this section, the procedure starts on the premise
that the tracks has already been removed.
SM1176
Removal
WARNING
Front idler weight:
EX255: 123 kg (271 lb)
EX285: 203 kg (448 lb)
3
1. Slide the front idler forward, using a pry bar.
2. Attach the front idler to a hoist, then remove front
idler (1) from track frame (3).
2
SM1177
3. To keep the front idler (1) for a time, place it on

blocks as shown.
SM1178
1
Installation
1. Attach front idle (1) to a hoist, then install it to track
frame (3).
Apply a film of grease to the sliding surface
between track frame (3) and yoke bearing (2).
2
SM1190
W3-5-2
EX255-EX285
EX255
FRONT IDLER
DISASSEMBLE FRONT IDLER (EX255)
2
1
3
4
7
6
5
4
3
2
1
9
10
8
SM1179
1
2
3
4
Bearing (2 Used)
Elastic pin (2 Used)
O-Ring (2 Used)
Floating Seal (2 Used)
5
6
7
8
Axle
Bushing (2 Used)
Idler
Plug (2 Used)
9 - Yoke
10 - Bolt (4 Used)
EX255-EX285
EX255
W3-5-3
FRONT IDLER
Disassemble Front Idler
1. Loosen bolts (10) to remove yoke (9). Remove

plug (8) from bearing (1) to drain oil into a container.
: 24 mm
: 6 mm
2. Remove elastic pin (2).
: 16 mm
WARNING
Total weight including idler:
3. Set the idler assembly in a press as illustrated.

Apply the press on the axle end. Push axle (5) out
of bearing (1) using the press. Axle (5) will come
off idler (7), and the upper side bearing (1) will also
be separated from idler (7).
SM1180
1
4
4. Remove floating seal (4) from bearing (1) and idler

(7).
IMPORTANT - For handling of floating seal (4), refer

to the section Floating seal precautions on page
W1-1-3.
4
3
5
1
SM1181
W3-5-4
EX255-EX285
EX255
FRONT IDLER
6
5
SM1179
EX255-EX285
EX255
W3-5-5
FRONT IDLER
5. Press out axle (5) to remove bearing (1) and
O-ring (3).
3
1
SM1182
6. Remove bushings (6), using special tool.

Special Tool: 75301510
75301510
SM1183
EX255
EX255-EX285
W3-5-6
FRONT IDLER
ASSEMBLE FRONT IDLER (EX255)
10
SM1184
1
2
3
4
Bearing (2 Used)
O-Ring (2 Used)
5
6
7
8
Axle
Bushing (2 Used)
Idler
Plug (2 Used)
9 - Yoke
10 - Bolt (4 Used)
EX255-EX285
EX255
W3-5-7
FRONT IDLER
Assemble Front Idler
2
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).
IMPORTANT - The elastic pin (2) has to be fitted with

the slit oriented to the internal side of the idler.
3
3. Install floating seal (4) (one pair) into idler (7) and
into bearing (1).
SM1185

W1-1-3.
4. Insert axle (5) into idler (7) from the floating seal
installed side. Install O-ring (3) onto axle (5).
5
SM1186
5. Install the other floating seal (4) (one pair) into

idler (7) and into the other bearing (1).
6. Install bearing (1) onto axle (5), aligning the pin
holes. Secure them using elastic pin (2).
1
7
1

7. Add engine oil via plug (8) hole on bearing (1).

Apply sealant (LOCTITE 503 or equivalent) to
plug (8). Tighten plug (8).
SM1187
: 6 mm
: 20 N m (2 kgf m, 15 lbf ft)
SAE 30 oil quantity: 265 cm3 (0.28 US qt)
2
8. Install yoke (9) and tighten bolts (10).
: 24 mm
: 206 N m (21 kgf m, 152 lbf ft)
5
1
SM1188
EX285
EX255-EX285
W3-5-8
FRONT IDLER
DISASSEMBLE FRONT IDLER (EX285)
7
12
6
5
4
1
11
10
SM5115
1
2
3
4
Bearing (2 Used)
O-Ring (2 Used)
5
6
7
8
Axle
Bushing (2 Used)
Idler
Plug
9 -Yoke
10 - Bolt (4 Used)
11 - Washer (4 Used)
12 - O-Ring
EX285
EX255-EX285
W3-5-9
FRONT IDLER
Disassemble Front Idler
1. Loosen bolts (10) to remove yoke (9). Remove

plug (8) from bearing (1) to drain oil into a container.
: 24 mm
: 6 mm
2. Remove elastic pin (2).
: 16 mm
CAUTION
Total weight including idler:
3. Set the idler assembly in a press as illustrated.

Apply the press on the axle end. Push axle (5) out
of bearing (1) using the press. Axle (5) will come
off idler (7), and the upper side bearing (1) will also
be separated from idler (7).
SM1180
1
4
4. Remove floating seal (4) from bearing (1) and idler

(7).

W1-1-3.
4
3
5
1
SM1181
EX285
EX255-EX285
W3-5-10
FRONT IDLER
1
6
6
5
3
1
SM5115
EX285
EX255-EX285
W3-5-11
FRONT IDLER
5. Press out axle (5) to remove bearing (1) and
O-ring (3).
3
1
SM1182
6. Remove bushings (6), using special tool.

75301509
SM1183
W3-5-12
EX255-EX285
EX285
FRONT IDLER
ASSEMBLE FRONT IDLER (EX285)
8-12
10-11
SM5116
1
2
3
4
Bearing (2 Used)
O-Ring (2 Used)
5
6
7
8
Axle
Bushing (2 Used)
Idler
Plug
9
10
11
12
Yoke
Bolt (4 Used)
Washer (4 Used)
O-Ring
EX255-EX285
EX285
W3-5-13
FRONT IDLER
Assemble Front Idler
2
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).

3
3. Install floating seal (4) (one pair) into idler (7) and
into bearing (1).
SM1185

W1-1-3.
4. Insert axle (5) into idler (7) from the floating seal
installed side. Install O-ring (3) onto axle (5).
5. Install the other floating seal (4) (one pair) into

idler (7) and into the other bearing (1).
SM1186
6. Install bearing (1) onto axle (5), aligning the pin

holes. Secure them using elastic pin (2).
1
7
1

7. Add engine oil via plug (8) hole on bearing (1).

Apply sealant (LOCTITE 503 or equivalent) to
plug (8). Tighten plug (8).
: 6 mm
SM1187
: 20 N m (2 kgf m, 15 lbf ft)

SAE 30 oil quantity: 380 cm3 (0.41 US qt)
2
8. Install yoke (9) and tighten bolts (10).
: 24 mm
: 225 N m (23 kgf m, 166 lbf ft)
5
1
SM1188
W3-5-14
EX255-EX285
FRONT IDLER
Front Idler
C D
E
A
B
Standard
(mm) (in)
SM1189
Allowable Limit
(mm) (in)
Remedy
EX255
EX285
EX255
EX285
84 (3.31)
101 (3.98)
66 (2.60)
92 (3.62)
159 (6.26)
203 (7.99)
Buildup weld
and
500 (19.69)
530 (20.87)
482 (18.98)
520 (20.47)
540 (21.26)
574 (22.60)
20 (0.79)
22 (0.87)
finishing
Axle and Bushing

Standard
Allowable Limit
(mm) (in)
(mm) (in)
EX255
EX285
EX255
Remedy
EX285
Axle
Outside Dia.
75 (2.95)
85 (3.35) 74.2 (2.92) 84.2 (3.31)
Bushing
Inside Dia.
75 (2.95)
85 (3.35) 76 (2.99) 86 (3.39)
Bushing
Flange Thickness
Replace
2 (0.08)
1.2 (0.05)
EX255-EX285
W3-6-1
UPPER AND LOWER ROLLER

REMOVE AND INSTALL UPPER ROLLER
Removal
WARNING
Do not loosen valve (1) quickly or loosen it too
much as high-pressure grease in the adjusting
cylinder may spout out. Loosen carefully, keeping
body parts and face away from valve (1).
Never loosen grease fitting (2).
SM1228
IMPORTANT - When gravel or mud is packed between

sprockets and tracks, remove it before loosening.
1. Loosen valve (1) to drain grease.

: 24 mm
2
Grease Outlet
SM0100
WARNING
Use a nonskid cloth between track frame (5) and oil
jack to prevent slipping.
2. Jack up tracks (3) heigh enough to permit upper

roller (4) removal.
5
3. Insert a wooden block between tracks (3) and track
frame (5).
SM1230
5
SM1231
W3-6-2
EX255-EX285

4. Remove bolts (2) from upper roller (1).
: 24 mm
1
2
SM1233
WARNING
Upper roller weight:
EX255: 14 kg (31 lb)
EX285: 16 kg (35 lb)
1
5. Remove upper roller (1) from track frame (3).
SM1233
Installation
WARNING
Upper roller weight:
EX255: 14 kg (31 lb)
EX285: 16 kg (35 lb)
1
1. Install upper roller (1) and bolts (2).
: 24 mm
: 265 N m (27 kgf m, 195 lbf ft)
3
SM1233
2. Remove the wooden block and jack.
SM1230
EX255-EX285
W3-6-3

3. Supply grease to valve (1) to adjust tracks tension.
Grease Outlet
SM0100
Check the track tension measuring the track sag

(A) as indicated in the TRACKS section.
Track sag specifications (A):
EX255: 300 to 335 mm (11.8 to 13.2 in)
EX285: 340 to 380 mm (13.4 to 15.0 in)
: 24 mm
: 147 N m (15 kgf m, 108 lbf ft)
NOTE - Check track sag after thoroughly removing soil

stuck on the track area by washing.
SM1234
4. Add engine oil via plug (4) hole on cover (5). Apply
sealant (LOCTITE 503 or equivalent) to plug (4).
Tighten plug (4).
5
SAE 30 oil quantity:
EX255: 85 cm3 (0.09 US qt)
EX285: 75 cm3 (0.08 US qt)
: 6 mm
: 9.8 to 19.6 N m
(1 to 2 kgf m, 7.5 to 15 lbf ft)
SM1235
W3-6-4
EX255-EX285

REMOVE AND INSTALL LOWER ROLLER
Removal
1. Remove the roller guard and loosen bolts (5).
5
EX255
: 27 mm
EX285
: 30 mm
SM1236
2. Lift the one side of the track frame high enough to

remove the lower roller.
Insert wooden blocks under track frame (2).
2
SM1237
WARNING
Do not loosen valve (3) quickly or loosen it too
much as high-pressure grease in the adjusting
cylinder may spout out. Loosen carefully, keeping
body parts and face away from valve (3).
SM1228
3
3. Loosen valve (3) to drain grease enough to permit
the roller removal.
: 24 mm
4
Grease Outlet
SM0100
EX255-EX285
W3-6-5
WARNING
Lower roller weight:
EX255: 35 kg (77 lb)
EX285: 56 kg (123 lb)
4. Securely hold the lower roller using a fork lift.

Remove lower roller (1).
1
Installation
SM1238
1. Securely hold the lower roller using a fork lift.

Put lower rollers (1) on the tracks as illustration.
SM1239
2. Lower track frame (2) enough to allow bolts (4) to be

installed into track frame (2).
SM1240
3. Align tapped holes in track frame (2).

Tighten bolt (4).
EX255
: 27 mm
: 400 N m (41 kgf m, 295 lbf ft)

EX285
: 30 mm
: 500 N m (51 kgf m, 369 lbf ft)
SM1236
W3-6-6
EX255-EX285

4. Supply grease to valve (3) to adjust tracks tension.
3
Grease Outlet
SM0100

(A) as indicated in the TRACKS section.
Track sag specifications (A):
EX255: 300 to 335 mm (11.8 to 13.2 in)
EX285: 340 to 380 mm (13.4 to 15.0 in)
: 24 mm
: 147 N m (15 kgf m, 108 lbf ft)
SM1234
NOTE - Check track sag after thoroughly removing soil

stuck on the track area by washing.
EX255-EX285
W3-6-7

DISASSEMBLE UPPER ROLLER
NOTE - Replace the upper roller as an assembly.
SM1241
W3-6-8
EX255-EX285

DISASSEMBLE LOWER ROLLER
8
6
5
4
3
2
1
SM1242
1 - Plug (2 Used)
2 - Collar ( 2 Used)
3 - Elastic pin (2 Used)
4 - O-ring (2 Used)
5 - Floating Seal (2 Used)
6 - Bushing (2 Used)
7 - Roller
8 - Axle
EX255-EX285
W3-6-9

Disassemble Lower Roller
5
1. Remove plug (1) and elastic pins (3) from collars

(2), and drain oil.
: 6 mm
: 14 mm
2. Press down axle (8) until O-ring (4) comes out of

collar (2).
Remove collar (2) from axle (8).
SM1243
3. Remove O-ring (4) from axle (8).

Remove axle (8) from roller (7).
8
4. Remove floating seal (5) from roller (7) and collar
(2).
5. Press out axle (8), and remove collar (2) and O-ring
(4) from axle (8)
SM1244
6. In case of replacing bushings (6), remove the

bushings using a press and the special tool.
75301509
SM1245
W3-6-10
EX255-EX285

ASSEMBLE LOWER ROLLER
8
SM1246
1 - Plug (2 Used)
2 - Collar ( 2 Used)
3 - Elastic pin (2 Used)
4 - O-ring (2 Used)
5 - Floating Seal (2 Used)
6 - Bushing (2 Used)
7 - Roller
8 - Axle
EX255-EX285
W3-6-11

Assemble Lower Roller
3
8
1. Install bushings (6) (2 used) onto roller (7) using a
press. Take care not to dent the flange surface of
bushings (6). Apply a coat of grease to O-ring (4)
and install onto axle (8).
2. Install collar (2) onto axle (8), aligning the pin holes.
Secure them using elastic pin (3). Take care not to
damage O-ring (4).
SM1247
IMPORTANT - The elastic pin has to be fitted with the

slit oriented to the internal side of the roller.
IMPORTANT - For handling of floating seal (5), refer to the

section "Floating seal precautions on page W1-1-3.
3. Install floating seal (5) to roller (7) and to collar (2).

SM1248
4. Insert axle (8) into roller (7). Install the other floating
seal (5) to roller (7) and to collar (2). Install O-ring
(4) the other collar (2). Secure them using elastic
pin (3).
IMPORTANT - The elastic pin has to be fitted with the

slit oriented to the internal side of the roller.
5. Add oil via plug (1) hole on collar (2). Apply sealant
(LOCTITE 503 or equivalent) to plug (1). Tighten
plug (1).
SM1249
SAE 30 oil quantity:

3
EX255: 278 cm (0.29 US qt)
3
EX285: 555 cm (0.59 US qt)
: 6 mm
: 9.8 to 19.6 N m
(1 to 2 kgf m, 7.5 to 15 lbf ft)
SM1250
W3-6-12
EX255-EX285

Upper Roller
SM1251
Standard
Allowable Limit
(mm) (in)
(mm) (in)
EX255
EX285
EX255
84 (3.31)
98 (3.86)
150 (5.91)
165 (6.50)
Remedy
EX285
Replace
120 (4.72)
110 (4.33)
Lower Roller
SM1252
Standard
Allowable Limit
(mm) (in)
(mm) (in)
EX255
EX285
EX255
Remedy
EX285
172 (6.77)
203 (7.99) 181.5 (7.15) 213 (8.39)
218 (8.58) 256 (10.08)
23 (0.91)
26.5 (1.04) 11.5 (0.45) 18.5 (0.73)
155 (6.10)
175 (6.89)
Buildup weld
and
finishing
139 (5.47) 165 (6.50)
IMPORTANT - Consult FIAT-HITACHI for any inqueries concerning welding procedure.
EX255-EX285
W3-6-13

Axle and Bushing
Standard
Allowable Limit
(mm)
(mm)
EX255
EX285
EX255
Remedy
EX285
Axle
Outside Dia.
65 (2.56) 75 (2.95) 64.2 (2.53) 74.2 (2.92)
Bushing
Inside Dia.
65 (2.56) 75 (2.95)
Bushing
Flange Thickness
Replace
2 (0.08)
66 (2.60)
76 (2.99)
1.2 (0.047)
W3-6-14
EX255-EX285

NOTES:
EX255-EX285
W3-7-1
TRACKS
REMOVE AND INSTALL TRACKS
Removal
1. Move the tracks so that master pin (3) is positioned
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 cylinder
may spout out.
Loosen carefully, keeping body parts and face
away from valve (1).
SM1253
2. To loosen the track tension, slowly turn valve (1)

counterclockwise one turn; grease will escape
from grease outlet.
: 24 mm
SM1255
Grease
outlet
SM0100
W3-7-2
EX255-EX285
TRACKS
WARNING
The front idler may jump out of position due to strong
spring force when the tracks is disconnected.
Especially, the strong spring force is always applied
to the bolt part of the rod. If the rod and/or the bolt
are damaged, metal fragments may fly off when the
tracks is disconnected.
Take the necessary precautions to prevent personal injuries.
SM1256
Spacer
3. Remove master pin (3) by using a special tool.
Bushing
SM1257
EX255
EX285
75294946
75294946
75294947
75295630
75294964
75298429
75294963
75298430
75295757
75298428
75297580
75297580
A
SM1258
4. Slowly drive the machine in reverse until the whole

length of the removing track comes on the ground.
SM1259
5. Rotate the upperstructure 90 degrees toward the

removing track side, perpendicular to the tracks.
Operate the boom and arm so that the angle
between them is 90 to 110 degrees. Lower the
boom with the bucket rolled-in to jack up the
machine as illustrated.
90 110
SM1260
EX255-EX285
W3-7-3
TRACKS
Installation
1. Jack up the machine and put the track under the
lower roller.
Be sure to position the track in correct direction, as
illustrated.
Idler side
Sprocket
side
SM1261
2. Lift the track, and place it on sprocket (1).
SM1262
3. Slowly turn the sprocket in forward direction.
SM1263
4. Turn sprocket (1) until end of track (4) comes on

front idler (3).
Lower the machine and put a wooden block as
illustrated.
4
SM1264
W3-7-4
EX255-EX285
TRACKS
IMPORTANT - Hole surfaces, link holes and
counterbore surfaces, bushing ends, shall be free from
dust and rust.
5. Install master pin (5), using a hammer and special
tool.
EX255
EX285
75294946
75294946
75294947
75295630
75294964
75298429
75294963
75298430
75295757
75298428
75297580
75297580
Spacer
Bushing
SM1257
A
SM1258
IMPORTANT - Inject rust preventive protective (ex.

TECTYL165 G) between pin and bushing clearance.
IMPORTANT - If any links have been removed from

the track, be sure to charge the grease (es. AMBRA
MG2) into the clearance between the pin and bushing
when reconnecting the links. Also, apply a coat of
grease to the ends of the bushing.
Grease Charging Method:
- Stand the bushing on a flat plate.
- Fill the bushing bore with the grease.
- Insert the pin into the bushing while pushing the
bushing onto the plate (so that the bushing end
stays on the plate).
- Wipe off excess grease.
6. Supply grease to the cylinder through the grease

fitting to adjust the track tension.
: 24 mm
(A) as indicated in the pages to follow.
SM1265
EX255-EX285
W3-7-5
TRACKS
Checking track sag
Turn the upperstructure 90 and lower the bucket to
raise one track off the ground as shown.
Keep the angle between boom and arm 90 to 110
and rest the bucket round side (outer) onto the
ground.
90 110
Place blocks under the frame to support the machine.

Rotate the raised track in reverse two full rotations,
then forward two full rotations.
S0012
Measure track sag (A) at the middle of the frame and

from the bottom of the track frame to the back face
of the track shoe. Distance (A) should be:
EX255: 300 to 335 mm (11.8 to 13.2 in)
EX285: 340 to 380 mm (13.4 to 15.0 in)
NOTE: Check track sag after thoroughly removing dirt

stuck on the track by pressure-washing.
Precautions for adjusting track sag

If track sag is not within specification, loosen or
tighten the track following the procedures detailed
below.
When adjusting track sag, lower the bucket to the
ground to raise one track off the ground. Repeat this
procedure to raise the other track. Place blocks
under the frame on the side of the raised track to
support the machine.
After adjusting track sag of both tracks, move the
machine back and forth several times. Check track
sag again. If, after settling, this is not within
specifications repeat the above procedures until
correct sag is obtained.
SM1234
W3-7-6
EX255-EX285
TRACKS
Loosening the track
2
WARNING
- Do not loosen the valve (1) quickly or too much as
grease pressure inside the cylinder might dangerously eject it off its seat.
- Loosen the valve with care, keeping the body
parts and face away from the valve (1).
- Never loosen the grease fitting (2).
IMPORTANT: remove any matter such as mud or

gravel possibly stuck between sprockets and track
links before loosening.
To loosen the track, slowly turn valve (1) anticlockwise using a 24 mm long socket. The grease will
escape from the valve base.
1 to 1.5 turns of the valve (1) are sufficient to loosen
the track.
If grease does not come out evenly, slowly rotate the
raised track.
When proper track sag is obtained, turn valve (1)
clockwise and tigthen to 14 daNm.
Tightening the track
WARNING
It is abnormal if the trac remains tight after turning
valve (1) anticlockwise or if the track is still loose
after charging grease through the grease fitting (2).
In such cases NEVER ATTEMPT TO DISASSEMBLE the track or the track adjuster due to dangerous high-pressure grease inside the track adjuster.
Contact your authorised FIAT-HITACHI Dealer immediately.
To tighten the track, inject grease from a grease gun

into fitting (2) until sag is within specification.
1
OM0142
EX255-EX285
W3-7-7
TRACKS
Link Pin and Track Bushing
Measure the length of four links, as illustrated, with

the tension on the track.
Do not measure the master-pin included part of the
track.
SM1266
Standard
(mm) (in)
EX255
A
Allowable Limit
(mm) (in)
EX285
EX255
760.6 (29.95) 812 (31.97) 785.8(30.94)
EX285
830 (32.68)
Remedy
Buildup weld
and finishing
or replace
Master Pin
SM1269
Standard
(mm) (in)
Allowable Limit
(mm) (in)
EX255
EX285
EX255
212 (8.35)
251 (9.88)
37.72 (1.48) 44.2 (1.74) 35.5 (1.39) 41.5 (1.63)
Remedy
EX285
Replace
Replace
W3-7-8
EX255-EX285
TRACKS
Master Bushing
SM1267
Standard
(mm) (in)
EX255
EX285
129.2 (5.09)
154 (6.06)
Allowable Limit
(mm) (in)
EX255
Remedy
EX285
Replace
38.7 (1.52)
44.45 (1.75)
41.5 (1.63)
47,3 (1.86)
59 (2.32)
66.675 (2.625)
54 (2.13)
63 (2.48)
Suola
SM1268
Standard
(mm) (in)
EX255
A
EX285
217.5 (8.56) 240 (9.45)
Allowable Limit
(mm) (in)
EX255
Remedy
EX285
Replace
10 (0.39)
13 (0.51)
26 (1.02)
26.5 (1.04)
15 (0.59)
SECTION 4
EX255-EX285
FRONT ATTACHMENT
CONTENTS
Group 1 -
Front attachment
Remove and install front attachment

(monobloc version) ................................ W4-1-1
Maintenance Standard
(monobloc version) ................................ W4-1-6
Bucket teeth ......................................... W4-1-8
Standard dimensions for arm and
bucket connection ................................. W4-1-9
Remove and install front attachment
(triple articulation version) ................... W4-1-11
Maintenance Standard
(triple articulation version) ................... W4-1-16
Group 2 -
Cylinders
Remove and install cylinders ................. W4-2-1

Hydraulic circuit pressure
release procedure ................................ W4-2-12
Cylinder air bleeding procedure ............ W4-2-13
Disassemble cylinders ......................... W4-2-14
Assemble cylinders ............................. W4-2-20
Maintenance Standard ........................ W4-2-26
Special Tools (EX255) ......................... W4-2-27
Special Tools (EX285) ......................... W4-2-28
EX255-EX285
W4-1-1
FRONT ATTACHMENT
REMOVE AND INSTALL FRONT ATTACHMENT
(monobloc version)
WARNING
Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.
The hydraulic oil tank cap may fly off if removed without releasing internal pressure first.
Push the air release valve on top of the hydraulic oil tank to release any remaining pressure.
Preparation
1. Park the machine on firm, level ground.
Position the front attachment as illustated and
lower the bucket to the ground.
SM1317
Removal
12
1. Disconnect lubrication pipes (12) from both boom

cylinder rod ends.
: 19 mm
2. Loosen lock nuts (1), remove bolt (2) and stoppers (3) from both boom cylinder rod ends.
: 30 mm
SM1318
WARNING
Boom cylinder weight:
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)
4
4
2
WARNING
Prevent personal injury. Metal fragments may fly
off when a hammer is used to remove pins. Be
sure to wear necessary protection, such as goggles, hardhat, etc.
3. Attach each boom cylinder to a crane.

Remove cylinder rod end pin (5) and thrust plate
(4) using a hammer and bar.
SM3502
W4-1-2
EX255-EX285
FRONT ATTACHMENT
IMPORTANT - Avoid boom cylinder damage. A
grease fitting is located on the boom cylinder. Be sure
to position a wooden block so that the grease fitting
does not come in contact with the wooden block when
the boom cylinder is lowered.
4. Position a wooden block between the main frame

and the boom cylinder bottom, as illustrated.
Slowly lower the boom cylinder using the crane
onto the wooden block.

pressure.
Completely release the residual pressure from the
hydraulic circuit by performing the Hydraulic Circuit Pressure Release Procedure Refer to page
W4-2-12.
SM1320
Wooden Block
6. Disconnect hoses (8) and (7) of arm cylinder and

bucket cylinder.
Close all openings with plugs to keep clean.
: 36, 41 mm
8
SM3504
7. Remove bolts (10) and lock plate (9) from main

frame.
: 30 mm
10
9
11
SM3503
EX255-EX285
W4-1-3
FRONT ATTACHMENT
WARNING
EX255: 4550 kg (10 031 lb)
EX285: 5600 kg (12 346 lb)
8. Attach the boom to a crane.

Slighty hoist the boom to take out any wire rope
slack.
SM1323
9. Pull the boom foot pin with special tool

(75301511).
75301511
SM1350
10. Lift the front attachment. Drive the base machine

away from the front attachment and the crane.
SM1325
W4-1-4
EX255-EX285
FRONT ATTACHMENT
Installation
WARNING
EX255: 4550 kg (10 031 lb)
EX285: 5600 kg (12 346 lb)
1. Install the front attachment

Install dust seals to boom foot.
Align the boom foot boss with the main frame
boss. Insert a thrust plate to both right and left
sides of the boom foot boss to take out clearance
between the boom foot boss and the main frame
boss the remaining clearance should be less than
1 mm.
SM1325
2. Install boom foot pin (11) using a hammer and bar.

Install bolt (10) (2 used) and lock plate (9).
10
: 30 mm
9
: 540 N m (55 kgf m, 398 lbf ft)

11
SM3503
3 Remove the plugs from the pipes or hoses.

Connect the arm and bucket hoses (7), (8) to the
pipes.
: 41 mm
: 295 N m (30 kg m, 218 lbf ft)

: 36 mm
: 235 N m (24 kgf m, 173 lbf ft)
WARNING
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)
SM3504
4. Attach the boom cylinder to a crane. Lift the boom

cylinder and align the boom cylinder rod with the
pin hole on the boom.
NOTE - For easy alignment, start the engine and use

the boom control lever.
SM1326
EX255-EX285
W4-1-5
FRONT ATTACHMENT
NOTE - Fill the hydraulic oil tank with hydraulic oil to
the specified level.
Run the engine at idle. Check hose connections for
any oil leakage
IMPORTANT - Bleed air from hydraulic circuit.
WARNING
off when a hammer is used to insert pins. Be sure
to wear necessary protection, such as goggles,
hardhat, etc.
4
4
2
5
3
5. Install thrust plate (4). Drive pin (5) into the pin
hole.
1
6. Install thrust plate (4), stopper (3), tighten bolt (2)
and lock nuts (1).
SM3502
: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)
Install the other boom cylinder following the same
procedures.
12
7. Connect lubrication pipes (12) to each boom

cylinder rod. Tighten the connection to specification.
: 19 mm
: 29 N m (3 kgf m, 22 lbf ft)
SM1318
8. Remove the pipes, with pipe fittings located in the

holes (14), from the boom foot boss.
9. Remove plug (13) and install an adeguate grease

fitting into plug (13) removed hole.
Plug tapered thread: 3/8 GAS - UNI339
10. Fill grease via grease fitting.

Remove grease fitting and re-install the plug (13)
in the original position.
11. Connect the pipes, with pipe fittings, on the boom

foot boss.
SM5521
W4-1-6
EX255-EX285
FRONT ATTACHMENT
(monobloc version)
E
G
C
H
J
D
A
I
K
B
SM1328
Unit: mm (in)
Parts Name
Standard
EX255
EX285
Allowable Limit
EX255
Remedy
EX285
Pin
100 (3.94)
99,0 (3.90)
Bushing
100 (3.94)
101,5 (4.00)
Pin
90 (3.54)
100 (3.94)
89.0 (3.50)
99.0 (3.90)
Boss (Main Frame)
90 (3.54)
100 (3.94)
91.5 (3.60)
101.5 (4.00)
Bushing (Boom Cylinder)
90 (3.54)
100 (3.94)
91.5 (3.60)
101.5 (4.00)
Pin
90 (3.54)
100 (3.94)
89.0 (3.50)
99.0 (3.90)
90 (3.54)
100 (3.94)
91.5 (3.60)
101.5 (4.00)
Boss (Boom)
90 (3.54)
100 (3.94)
91.5 (3.60)
101.5 (4.00)
Pin
90 (3.54)
100 (3.94)
89.0 (3.50)
99.0 (3.90)
Bushing
90 (3.54)
100 (3.94)
91.5 (3.60)
101.5 (4.00)
Pin
80 (3.15)
90 (3.54)
79.0 (3.11)
89.0 (3.50)
Boss (Arm)
80 (3.15)
90 (3.54)
81.5 (3.21)
91.5 (3.60)
Bushing (Arm Cylinder)
80 (3.15)
90 (3.54)
81.5 (3.21)
91.5 (3.60)
Pin
80 (3.15)
90 (3.54)
79.0 (3.11)
89.0 (3.50)
Boss (Boom)
80 (3.15)
90 (3.54)
81.5 (3.21)
91.5 (3.60)
80 (3.15)
90 (3.54)
81.5 (3.21)
91.5 (3.60)
Replace
EX255-EX285
W4-1-7
FRONT ATTACHMENT
Unit: mm (in)
Parts Name
Standard
EX255
EX285
Allowable Limit
EX255
Remedy
EX285
Pin
80 (3.15)
79.0 (3.11)
Boss (Arm)
80 (3.15)
81.5 (3.21)
Bushing (Bucket Cylinder)
80 (3.15)
81.5 (3.21)
Pin
90 (3.54)
89.0 (3.50)
Bushing
90 (3.54)
91.5 (3.60)
90 (3.54)
91.5 (3.60)
Replace
Pin
80 (3.15)
79.0 (3.11)
Bushing
80 (3.15)
81.5 (3.21)
Pin
90 (3.54)
89.0 (3.50)
Bushing
90 (3.54)
91.5 (3.60)
Pin
90 (3.54)
89.0 (3.50)
Bushing
90 (3.54)
91.5 (3.60)
IMPORTANT - Be sure to install front attachment

bushings using a press.
W4-1-8
EX255-EX285
FRONT ATTACHMENT
BUCKET TEETH
Replacement
WARNING
Keep people not involved in the maintenance work
outside the working area.
Wear adequate personal clothes and glasses with
side shields as a protection against flying debris.
Ensure the machine is parked on a level surface.

5
Rest the bucket to the ground.

Switch off the auto-idle, fully turn the engine speed
manual control anticlockwise, stop the engine,
remove the ignition key and move the safety lever
in the locked position (LOCK).
Using a hammer (3) and a drift (2), as shown, drive

the lock pin (1) from its seat and remove the tooth.
4
NOTE: Hit the lock pin (1) with the drift (2) on the pin
tapered portion to drive it out of its seat.
Clean shank (5) surface and install a new tooth (4)

onto the shank.
Install the lock pin (1) into its seat and drive it in
using a drift (2) and a hammer (3) until it is fully
seated.
SM1329
EX255-EX285
W4-1-9
FRONT ATTACHMENT
STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION
d
e
c
b
a
j
p
n
h
g
q
m
l
Cross-section A
Cross-section B
SM1330
Unit: mm (in)
EX255
EX285
a (*)
460 (181.1)
475 (187)
b (*)
5 (2)
0 (0)
620 (244.1)
622 (244.9)
580 (228.3)
600 (236.2)
475 (187)
475 (187)
1547 (609)
1588 (625.7)
549 (216.1)
555 (218.5)
430 (169.3)
430 (169.3)
90 (35.4)
90 (35.4)
470 (185)
470 (185)
69 (27.1)
69 (27.1)
549 (216.1)
555 (218.5)
410 (161.4)
410 (161.4)
90 (35.4)
90 (35.4)
90
90
20
45
565 (222.4)
571 (224.8)
(*) Arm: 2 950 mm (1161.4 in) (EX255), 3 750 mm (1476.4 in) (EX285)
W4-1-10
EX255-EX285
FRONT ATTACHMENT
NOTES:
EX255-EX285
W4-1-11
FRONT ATTACHMENT
REMOVE AND INSTALL FRONT ATTACHMENT
WARNING
Preparation
Position the front attachment as illustated and
SM1357
Removal
12
1. Disconnect lubrication pipes (12) from both boom

cylinder rod ends.
: 19 mm
2. Loosen lock nuts (1), remove bolt (2) and stoppers

(3) from both boom cylinder rod ends.
: 30 mm
SM1318
WARNING

EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)
4
2
3
WARNING
off when a hammer is used to remove pins. Be
sure to wear necessary protection, such as goggles, hardhat, etc.
SM3502
3. Attach each boom cylinder to a crane.

Remove cylinder rod end pin (5) and thrust plate
(4) using a hammer and bar.
W4-1-12
EX255-EX285
FRONT ATTACHMENT
IMPORTANT - Avoid boom cylinder damage. A
grease fitting is located on the boom cylinder. Be sure
to position a wooden block so that the grease fitting
does not come in contact with the wooden block when
the boom cylinder is lowered.
4. Position a wooden block between the main frame

and the boom cylinder bottom, as illustrated.
Slowly lower the boom cylinder using the crane
onto the wooden block.
SM1320

pressure.
hydraulic circuit by performing the Hydraulic Circuit Pressure Release Procedure. Refer to page
W4-2-12.
Wooden Block
6. Disconnect hoses (8), (7) and (31) of arm cylinder

and bucket cylinder and positioning cylinder.
Close all openings with plugs to keep clean.
: 36, 41 mm
: 12 mm
31
SM1358
7. Remove bolts (10) and lock plate (9) from main

frame.
: 30 mm
10
9
11
SM3503
EX255-EX285
W4-1-13
FRONT ATTACHMENT
WARNING
Front assembly weight:
EX255: 4890 kg (10 781 lb)
EX285: 5900 kg (13 007 lb)
WARNING
Avoid wire rope damage. Be sure to position a
necessary protection between the wire rope and
boom pin hole surfaces.
8. Attach the boom to a crane.

Using the boom pin hole for front attachment sling.
WARNING
To secure the top arm with an other crane, when
remove the front attachment.
9. Slighty hoist the boom to take out any wire rope

slack.
10. Pull the boom foot pin with special tool

(75301511).
75301511
SM1350
11. Lift the front attachment. Drive the base machine

away from the front attachment and the crane.
SM1325
W4-1-14
EX255-EX285
FRONT ATTACHMENT
Installation
WARNING
Front assembly weight:
EX255: 4890 kg (10 781 lb)
EX285: 5900 kg (13 007 lb)
WARNING
To secure the top arm with an other crane, when
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. Insert a thrust plate to both right and left
sides of the boom foot boss to take out clearance
between the boom foot boss and the main frame
boss the remaining clearance should be less than
1 mm.
10
9
11
SM3503
2. Install boom foot pin (11) using a hammer and bar.

Install bolt (10) (2 used) and lock plate (9).
7
: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)
8
3 Remove the plugs from the pipes or hoses.
Connect positioning arm and bucket hoses (31)
(7), and (8) to the pipes.
: 41 mm
: 295 N m (30 kg m, 218 lbf ft)
31
: 36 mm
: 235 N m (24 kgf m, 173 lbf ft)
SM1358
WARNING
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)
4. Attach the boom cylinder to a crane. Lift the boom
cylinder and align the boom cylinder rod with the
pin hole on the boom.

SM1326
EX255-EX285
W4-1-15
FRONT ATTACHMENT
any oil leakage
WARNING
hardhat, etc.
4
4
2
5
3
5. Install thrust plate (4). Drive pin (5) into the pin
hole.
6. Install thrust plate (4), stopper (3), tighten bolt (2)

and lock nuts (1).
SM3502
: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)
12
7. Connect lubrication pipes (12) to each boom
cylinder rod. Tighten the connection to specification.
: 19 mm
: 29 N m (3 kgf m, 22 lbf ft)
8. Remove the pipes, with pipe fittings located in the

holes (14), from the boom foot boss.
SM1318
9. Remove plug (13) and install an adeguate grease

fitting into plug (13) removed hole.
Plug tapered thread: 3/8 GAS - UNI339
10. Fill grease via grease fitting.

Remove grease fitting and re-install the plug (13)
in the original position.
11. Connect the pipes, with pipe fittings, on the boom

foot boss.
SM5521
W4-1-16
EX255-EX285
FRONT ATTACHMENT
M
G
D
F
A
N
H
B
I
K
SM1357
Unit: mm (in)
Parts Name
Standard
EX255
EX285
Allowable Limit
EX255
Remedy
EX285
Pin
100 (3.94)
99.0 (3.90)
Bushing
100 (3.94)
101.5 (4.00)
Pin
90 (3.54)
100 (3.94) 89.0 (3.50) 99.0 (3.90)
Boss (Main Frame)
90 (3.54)
100 (3.94) 91.5 (3.60) 101.5 (4.00)
90 (3.54)
100 (3.94) 91.5 (3.60) 101.5 (4.00)
Pin
90 (3.54)
100 (3.94) 89.0 (3.50) 99.0 (3.90)
90 (3.54)
100 (3.94) 91.5 (3.60) 101.5 (4.00)
Boss (Boom)
90 (3.54)
100 (3.94) 91.5 (3.60) 101.5 (4.00)
Pin
100 (3.94)
99.0 (3.90)
Bushing
100 (3.94)
101.5 (4.00)
Pin
90 (3.54)
89.0 (3.50)
Boss (Arm)
90 (3.54)
91.5 (3.60)
Bushing (Positioning Cylinder)
90 (3.54)
91.5 (3.60)
Pin
90 (3.54)
89.0 (3.50)
Boss (Boom)
90 (3.54)
91.5 (3.60)
Bushing (Positioning Cylinder)
90 (3.54)
91.5 (3.60)
Replace
EX255-EX285
W4-1-17
FRONT ATTACHMENT
Unit: mm (in)
Parts Name
Standard
EX255
EX285
Allowable Limit
EX255
Remedy
EX285
Pin
80 (3.15)
79.0 (3.11)
Boss (Arm)
80 (3.15)
81.5 (3.21)
80 (3.15)
81.5 (3.21)
Pin
90 (3.54)
89.0 (3.50)
Bushing
90 (3.54)
91.5 (3.60)
90 (3.54)
91.5 (3.60)
Pin
80 (3.15)
79.0 (3.11)
Bushing
80 (3.15)
81.5 (3.21)
Pin
90 (3.54)
89.0 (3.50)
Bushing
90 (3.54)
91.5 (3.60)
Replace
Pin
90 (3.54)
89.0 (3.50)
Bushing
90 (3.54)
91.5 (3.60)
Pin
80 (3.15)
90 (3.54)
79.0 (3.11) 89.0 (3.50)
Boss (Positioning)
80 (3.15)
90 (3.54)
81.5 (3.21) 91.5 (3.60)
80 (3.15)
90 (3.54)
81.5 (3.21) 91.5 (3.60)
Pin
80 (3.15)
90 (3.54)
79.0 (3.11) 89.0 (3.50)
Boss (Arm)
80 (3.15)
90 (3.54)
81.5 (3.21) 91.5 (3.60)
80 (3.15)
90 (3.54)
81.5 (3.21) 91.5 (3.60)
Pin
90 (3.54)
100 (3.94)
89.0 (3.50) 99.0 (3.90)
Bushing
90 (3.54)
100 (3.94)
91.5 (3.60) 101.5 (4.00)
IMPORTANT - Be sure to Install front attachment

bushings using a press.
W4-1-18
EX255-EX285
FRONT ATTACHMENT
NOTES
EX255-EX285
W4-2-1
CYLINDERS
REMOVE AND INSTALL CYLINDERS
WARNING
Preparation
Position the front attachment as illustrated and
2. Push the air release valve on top of the hydraulic
SM1317
Remove Bucket Cylinder

1. Insert wooden block (15) between bucket cylinder
(1) and arm (8).
1
2. Completely release the residual pressure from the
W4-2-12.
15
IMPORTANT - Pin (6) end of the link will drop when pin
(6) is removed, possibly resulting in personal injury. Be
sure to secure the link using a piece of wire before
removing pin (6).
8
15
SM1331
3. Loosen nuts (4) and bolt (5), in that order.

Pull out pin (6). Then, remove thrust plates (16).
16
5
: 30 mm
SM3506
W4-2-2
EX255-EX285
CYLINDERS
13
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
14
WARNING
Bucket cylinder weight:
EX255: 172 kg (379 lb)
EX285: 209 kg (461 lb)
SM1333
17
10
12
6. Use a crane to slightly hoist bucket cylinder (1).
Loosen lock-nuts (11), remove screw (12) and
stopper (18) then pull-out pin (10) using a hammer
and a bar, so that the end of the cylinder gets free.
Recover adjusting shims (17).
: 30 mm
18
11
1
SM5522
7. Remove bucket cylinder (1).

9
9
EX255-EX285
W4-2-3
CYLINDERS
Install Bucket Cylinder
WARNING
Bucket cylinder weight:
EX255: 172 kg (379 lb)
EX285: 209 kg (461 lb)
17
10
12
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.
2. Install thrust plates (17).
Insert pin (10). Then, install bolt (12) into stopper
(18). Tighten lock nuts (11).
18
11
1
SM5522
: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)
9
3. Connect two hoses (9) to bucket cylinder (1).
: 10 mm
: 88 N m (9.0 kgf m, 65 lbf ft)

: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)

any oil leakage.
4. Align the bucket cylinder rod with bucket links (2),

(3).
Install thrust plates (16) and pin (6).
18
16

the arm control lever.
6
5. Install bolt (5), onto pin (6) and stopper (18); tighten
lock nuts (4).
: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)
IMPORTANT - If link (3) has been disconnected from

the arm, be sure to insert thrust plate (16) when
connecting it. Bleed air from hydraulic circuit.
SM3506
W4-2-4
EX255-EX285
CYLINDERS
Remove Arm Cylinder
1
1. Insert a wooden block between arm cylinder (1) and

boom (12).

pressure.
W4-2-12.
SM1347
12
13
3. Disconnect lubricant supply pipe from pin (9).
Loosen lock nuts (10) and remove bolt (11).
11
: 30 mm
9
1
4. Remove pin (9) and thrust plate (13).

10
SM3508
5. Use wire to secure cylinder rod (2) as illustrated.

2
SM1337
1
6. Disconnect arm cylinder hoses (7), (16).
Put plugs on the pipe on arm cylinder (1) and hoses.
: 36 mm
7. Disconnect Iubricant supply pipe (8).

: 19 mm
16
SM3509
EX255-EX285
W4-2-5
CYLINDERS
WARNING
Arm cylinder weight:

EX255: 300 kg (661 lb)
EX285: 310 kg (683 lb)
8. Use a crane to slightly hoist arm cylinder (1).

SM1335
15
3
9. Loosen lock nuts (4). Remove bolt (5) and pin (3).
Then remove thrust plate (15) from arm cylinder (1).
: 30 mm
SM3510
W4-2-6
EX255-EX285
CYLINDERS
Install Arm Cylinder
WARNING
EX255: 300 kg (661 lb)
EX285: 310 kg (683 lb)
1. Use a crane to install arm cylinder (1) to the boom

bracket.
2. Install thrust plates (15) stopper (18) and pin (3).
Then, install bolts (5) and lock nuts (4) into stopper
(18).
: 30 mm
15
3
8
: 540 N m (55 kgf m, 398 lbf ft)

3. Attach lubricant supply pipe (8) and arm cylinder
hoses (7) and (16).
: 10 mm
7
18
4
: 88 N m (9 kgf m, 65 lbf ft)

16
: 19 mm
SM3509
: 29 N m (3 kgf m, 21 lbf ft)

: 36 mm
: 175 N m (18 kgf m, 129 lbf ft)
NOTE - Fill hydraulic oil tank with hydraulic oil to the

specified level.
any oil leakage.
4. Remove wire (6) from arm cylinder (1).

Slightly hoist arm cylinder (1) and align the arm
cylinder rod with arm (14).
6
2
SM1337

the arm control lever.
11
5. Install thrust plate (13), pin (9) and stopper (18).

Then, install bolt (11) into stopper (18) and pin (9).
Tighten lock nuts (10).
13
18
: 30 mm
: 540 N m (55 kgf m, 398 lbf ft)
10
SM3508
EX255-EX285
W4-2-7
CYLINDERS
Remove Boom Cylinder
1. Park the machine on firm, level surface and lower
the bucket teeth and arm top to the ground with the
arm and bucket cylinders fully retracted as illustrated.
SM1317
2. Disconnect lubricant supply pipes (1).

: 19 mm
1
WARNING
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)
3. Use a crane to hoist the boom cylinder.
4. Loosen lock nuts (2), remove bolt (3) and stopper

(4). Using bar and hammer, tap pin (5) until the
boom cylinder is free. Remove thrust plate (6).
: 30 mm
4
2
6
SM3511
5. Use a wire to secure the boom cylinder rod as

illustrated.
Lower cylinder on proper stand.
pressure.
W4-2-12.
SM1342
7. Disconnect boom cylinder hoses (11) (4 used). Put

plugs on cylinder pipes.
: 36 mm
10
8. Loosen lock nuts (7), Remove bolt (8), pins (9), and
thrust plates (10).
: 30 mm
11
8
WARNING
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)
9
7
9. Hoist the boom cylinder with a crane.

Remove the other boom cylinder following the
same procedures.
9
SM3512
W4-2-8
EX255-EX285
CYLINDERS
Install Boom Cylinder
WARNING
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)
1. Use a crane to install the boom cylinders to the
main frame.
2. Install thrust plate (10) and pin (9). Then, install bolt
(8) and lock nuts (7). Tighten lock nuts (7).
: 30 mm
: 540 N m (55 kgf m, 400 lbf ft)
SM1342
11
10
3. Install the other side boom cylinder.

4. Connect the boom cylinder hoses (11) (4 used).
: 36 mm
: 175 N m (18 kgf m, 130 lbf ft)
9
any oil leakage.
7
9
SM3512
5. Hoist the boom cylinder, and align the rod side with
the boom.

WARNING
hardhat, etc.
4
2
6
6. Install pin (5) using a bar and hammer, then install

thrust plates (6).
7. Install bolt (3), stopper (4), and lock nuts (2).
Tighten lock nuts (2).
: 30 mm
6
SM3511
: 540 N m (55 kgf m, 398 lbf ft)

8. Install lubricant supply pipes (1).
: 19 mm
: 29 N m (3 kgf m, 21 lbf ft)
9. Install other boom cylinder following the same
procedure.
SM1346
EX255-EX285
W4-2-9
CYLINDERS
Remove positioning cylinder
PREPARATION
Position the front attachment as illustrated and
2. Push the air release valve on top of the hydraulic
SM1357
REMOVAL
6
1. Insert a wooden block between positioning cylinder

and boom.
2. Completely release the residual pressure from the

W4-2-12.
3. Disconnect lubrication pipe from positioning cylinder (rod side).
4
SM1360
4. Loosen lock nuts (4), remove bolt (5) and stopper

(7).
Using bar and hammer, tap pin (6) until the positioning cylinder is free and remove thrust plate.
14
: 30 mm
13
5. Use wire (14) to secure cylinder rod (13) as illustrated.
SM1337
6. Disconnected hoses (9) (2 used) from positioning

cylinder. Put plugs on cylinder hoses.
: 12 mm
7. Disconnect lubrication pipe (A) from positioning

cylinder (bottom side).
A
SM1358
W4-2-10
EX255-EX285
CYLINDERS
WARNING
Positioning cylinder weight:

EX255-EX285: 242 kg (534 lb)
8. Use a crane to slightly hoist positioning cylinder

(1).
Loosen lock nuts (11), remove bolt (12), stopper
(15) and pin (10).
Remove thrust plate.
SM1361
12
10
9. Remove positioning cylinder (1).
15
11
SM1362
EX255-EX285
W4-2-11
CYLINDERS
Install positioning cylinder
12
10
WARNING
EX255-EX285: 242 kg (534 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.
15
11
SM1362
2. Install thrust plates and insert pin (10). Then install

stopper pin (15) and bolt (12) into pin (10). Tighten
lock nuts (11).
3. Connect lubrication pipe (A) to positioning cylinder

(bottom side).
4. Connect two hoses (9) to positioning cylinder (1).

A
: 12 mm

the specified level. Run the engine at idle. Check hose
connections for any oil leakage.
SM1358
5. Remove wire (14) from positioning cylinder (13).
6. Slightly hoist positioning cylinder and align the

positioning cylinder rod with positioner.
Install thrust plate and insert pin (6).
14
13

the positioner control lever.
SM1337
5
7. Install stopper (7) and bolt (5) onto pin (6). Tighten
lock nuts (4).
8. Connect lubrication pipe to positioning cylinder

(rod side).
7
NOTE - Bleed air from hydraulic circuit.

4
SM1360
W4-2-12
EX255-EX285
CYLINDERS
HYDRAULIC CIRCUIT PRESSURE RELEASE 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 loosening the overload relief valve(s) for the line(s) or hose(s)
to be disconnected.
: 32 mm
: 835N m (8.50.5 kgf m, 623.6 lbf ft)
IMPORTANT - Be sure to loosen the valve body, not

the adjusting screw. Also, be sure to re-tighten the
overload relief valve after releasing the residual circuit
pressure.
SM1348
2
7
1
2
3
4
5
6
7
8
Boom Cylinder (Bottom Side)

Boom Cylinder (Rod Side)
Arm Cylinder (Bottom Side)
Arm Cylinder (Rod Side)
Bucket Cylinder (Bottom Side)
Bucket Cylinder (Rod Side)
Positioning Cylinder (Rod Side)
Positioning Cylinder (Bottom Side)
1
8
5
SM1349
EX255-EX285
W4-2-13
CYLINDERS
CYLINDER AIR BLEEDING PROCEDURE
WARNING
After installing the cylinder, be sure to do the work
air bleeding procedure.
Move in the horizontal direction for boom cylinder
and arm cylinder.
Air bleeding procedure
1. Install cylinder.
2. Start engine and run at low speed (about low idle
speed + 200 min-1).
Extend and retract slowly 5 times.
(Do not extend and retract to the stroke end dur-ing
the first 4 times. On the last time extend and retract
to the stroke end.)
3. Be sure that cylinder moves smoothly.
SM6293
Air Bleeding Figure
W4-2-14
EX255-EX285
CYLINDERS
DISASSEMBLE CYLINDERS
Boom Cylinder
11
1 2 3 4
6 9 10
8
13 20
15
16
21 23
14 19 16 17 18 20 19
22
12
SM1350A
24
Bucket Cylinder
11
1 2 3 4
6 9 10
8
13 20
15
16 20 21
22
12
19 16 17 18 19
24
23
SM1351
1
2
3
4
5
6
Wiper Ring
Backup Ring
U-Ring
Buffer Ring
Bushing
Snap Ring
7
8
9
10
11
12
Cylinder Head
Backup Ring
O-Ring
Cylinder Rod
Cylinder Tube
13
14
15
16
17
18
Cushion Bearing
Cushion Seal
Piston
Backup Ring (2 Used)
Seal Ring
O-Ring
19
20
21
22
23
24
Slide Ring (2 Used)

Slide Ring (2 Used)
Shim
Set Screw
Steel Ball
Nut
EX255-EX285
W4-2-15
CYLINDERS
Disassemble Boom and Bucket Cylinders
Be sure to thoroughly read all the Precautions for
Disassembly and Assembly on page W1-1-1 before
starting the disassembly procedure.
The disassembly procedure below starts on the
premise that the hydraulic lines and the line securing
bands have been removed.
WARNING
Boom cylinder:
EX255: 203 kg (448 lb)
EX285: 233 kg (514 lb)
Bucket cylinder:
EX255: 172 kg (379 lb)
EX285: 209 kg (461 lb)
4. Pull-out cylinder rod (11) and secure it on special

tool (75298623). Put matching marks between
cylinder rod (11) and nut (24).
75298623
SM1365
5. Remove set screw (22) and steel ball (23).

NOTE - Cut away its mushroomed portion using a drill
first, as set screw (22) was mushroomed with a punch
and hammer at two places after it had been screwed
in.
1. Lift and securely place the cylinder on a workbench

using a crane. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from the cylinder.
: 6 mm
6. Loosen nut (24) using special tool (75298623).

Remove shim (21), piston (15) and cushion bearing
(13).
For the boom cylinder, also remove and cushion
seal (14).
SM1364
2. Fully extend cylinder rod (11). Secure the rod end

using a crane. Remove socket bolts (8) from
cylinder head (7).
Nut (24) turning special tool:

EX255
- (bucket and boom cylinders): 95 mm (75294752)
EX285
- (bucket and boom cylinders): 100 mm (75297716)
: 14 mm
3. Pull out cylinder head (7) from cylinder tube (12) by
tapping with a plastic hammer.
IMPORTANT - Be sure to pull cylinder rod (11) straight

so as not to damage the sliding surfaces.
SM1366
7. Remove slide rings (19), (20), backup rings (16),

seal ring (17) and O-ring (18) from piston (15).
8. Remove cylinder head (7) from cylinder rod (11).
9. Remove O-rings (10), backup rings (9) and (2) from

cylinder head (7). Then remove wiper ring (1), Uring (3), buffer ring (4), snap ring (6), and bushing
(5).
W4-2-16
EX255-EX285
CYLINDERS
Arm Cylinder
11
1 2 3 4
6 9 10
8
13 20
14 19 16
1
2
3
4
5
6
7
8
9
10
15
16
25 26
28 24 22
12
17 18 20 19 27 21 23
Wiper Ring
Backup Ring
U-Ring
Buffer Ring
Bushing
Snap Ring
Cylinder Head
Backup Ring
O-Ring
11
12
13
14
15
16
17
18
19
20
Cylinder Rod
Cylinder Tube
Cushion Bearing (front)
Cushion Seal (front)
Piston
Seal Ring
O-Ring
Slide Ring (2 Used)
Slide Ring (2 Used)
SM1352
21
22
23
24
25
26
27
Shim
Set Screw
Steel Ball
Nut
Snap Ring
Cushion Seal (rear)
Cushion Bearing
(rear)
28 - Stopper (2 Used)
EX255-EX285
W4-2-17
CYLINDERS
Disassemble Arm Cylinder
Disassembly and Dissembly on page W1-1-1 before
WARNING

in.
: 6 mm

EX255: 300 kg (661 lb)
EX285: 310 kg (683 lb)
1. Place the cylinder horizontally on a workbench

using a crane and secure it.
Drain hydraulic oil from the cylinder.

Remove shim (21), piston (15), cushion bearing
(13) and cushion seal (14).
Nut (24) Turning Special Tool:
- EX255: 100 mm (75297716)
- EX285: 115 mm (75297549)
SM1366
SM1364

cylinder head (7).
7. Remove slide ring (19), (20), backup ring (16), seal

ring (17) and O-ring (18) from piston (15).
: 17 mm
IMPORTANT - Be sure to pull cylinder rod (11)

straight so as not to damage the sliding surfaces.
4. Pull out cylinder rod (11) and secure it on special

75298623
SM1365

(5).
10.Remove stopper (28) from cylinder rod (11) using a

screw driver. Remove cushion bearing (27), cushion seal (26), and snap ring (25).
W4-2-18
EX255-EX285
CYLINDERS
Positioning Cylinder
11
1 2 3 4
6 9 10
8
20
15
16
21 23
19 16 17 18 20 19
22
12
24
SM5523
1
2
3
4
5
6
7
8
Wiper Ring
Backup Ring
U-Ring
Buffer Ring
Bushing
Snap Ring
Cylinder Head
9
10
11
12
15
16
17
18
Backup Ring
O-Ring
Cylinder Rod
Cylinder Tube
Piston
Seal Ring
O-Ring
19
20
21
22
23
24
Slide Ring (2 Used)

Slide Ring (2 Used)
Shim
Set Screw
Steel Ball
Nut
EX255-EX285
W4-2-19
CYLINDERS
Disassemble Positioning Cylinder
Disassembly and Assembly on page W1-1-1 before

in.
: 6 mm
WARNING
EX255-EX285: 242 kg (534 lb)
1. Place the cylinder horizontally on a workbench

using a crane and secure it.
Drain hydraulic oil from the cylinder.

Remove shim (21) and piston (15).
Nut (24) Turning Special Tool:
EX255-EX285: 120 mm (75298684)
SM1366
SM1364

cylinder head (7).
: 17 mm
IMPORTANT - Be sure to pull cylinder rod (11)

straight so as not to damage the sliding surfaces.
4. Pull out cylinder rod (11) and secure it on special

75298623
SM1365
7. Remove slide ring (19), (20), backup ring (16), seal

ring (17) and O-ring (18) from piston (15).

(5).
W4-2-20
EX255-EX285
CYLINDERS
ASSEMBLE CYLINDERS
Boom Cylinder
Face the slit
toward the piston
Slit
Green
Black
1 2
18
11 12 13 14 15 16 17 19 20 21
3 4 5 6 7 8 9-10
22-23
24
SM1353
Be sure that oil groove faces the correct

direction when assembling
Bucket Cylinder
Slit
Green
1 2
3 4 5 6 7 8 9-10
11 12 13
18
15 16 17 19 20 21
22-23
24
Be sure that oil groove faces

the correct direction when assembling
1
2
3
4
5
6
7
8
9
Wiper Ring
Backup Ring
U-Ring
Buffer Ring
Bushing
Snap Ring
Cylinder Head
Backup Ring
10
11
12
13
14
15
16
17
18
O-Ring
Cylinder Rod
Cylinder Tube
Cushion Bearing
Cushion Seal
Piston
Seal Ring
O-Ring
SM5524
19
20
21
22
23
24
Slide Ring (2 Used)

Slide Ring (2 Used)
Shim
Set Screw
Steel Ball
Nut
EX255-EX285
W4-2-21
CYLINDERS
Assemble Bucket and Boom Cylinder
1. Install bushing (5) to cylinder head (7) using a
press.
Special tools for bushing (5) installation:
EX255
- boom cylinder: 90 mm (75301684)
- bucket cylinder: 85 mm (75301685)
EX285
- boom cylinder: 95 mm (75301654)
- bucket cylinder: 90 mm (75301646)
IMPORTANT - Be sure that the cushion seal slit faces

toward the piston and that the cushion bearing oil
groove faces the correct direction.
7. Install cushion bearing (13) to cylinder rod (11).

(For boom cylinder only, install cushion seal (14).)
Install piston (15) to cylinder rod (11).
8. Install shim (21) to cylinder rod (11). Tighten nut
IMPORTANT - Be sure that the rings are installed

correctly.
2. Install U-ring (3), backup ring (2), snap ring (6), and
buffer ring (4) to cylinder head (7).
75298623
3. Install wiper ring (1) to cylinder head (7) using a

plastic hammer.
Special tools for wiper ring installing:
EX255
- boom cylinder: (75301665)
- bucket cylinder: (75301534)
EX285
4. Install O-rings (10) and backup ring (9) to cylinder
head (7).
5. Install O-ring (18), backup ring (16) (2 used), seal
ring (17), slide ring (19) (2 used), (20) (2 used) to
piston (15).
Special tools for seals assembly:
EX255: bucket and boom cylinder (75301670)
EX285: bucket and boom cylinder (75301659)
SM1365
Be sure to align the machine mark on the rod with

that on the nut.
Nut (24) Turning Special Tools:
EX255: 95 mm (75294752)
: 5 440 N m (555 kgf m, 4012 lbf ft)
(boom cylinder)
8 150 N m (831 kgf m, 6011 lbf ft)
(bucket cylinder)
EX285: 100 mm (75297716)
: 6 800 N m (693 kgf m, 5015 lbf ft)
(boom cylinder)
10 200 N m (1040 kgf m, 7523 lbf ft)
(bucket cylinder)
9. Align the holes on cylinder rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
screw (22) into the hole.
Mushroom the head of set screw (22) at two places
using a punch and hammer.
: 6 mm
15
SM1367
6. Install cylinder head (7) to cylinder rod (11).

Special tools:
EX255
- boom cylinder (75301688)
- bucket cylinder (75301689)
EX285
: 56.910.7 N m (5.81.09 kgf m,

427,9 lbf ft)
IMPORTANT - Be sure to align cylinder rod (11) with
the center of cylinder tube (12) when inserting, in order
to avoid damaging the rings.
10. Secure cylinder tube (12) horizontally using a work
bench. Insert cylinder rod (11) into cylinder tube
(12).
11. Install cylinder head (7) to cylinder tube (12).
: 14 mm
: 267 N m (27.2 kgf m, 197 lbf ft) (EX255)
367 N m (37.4 kgf m, 271 lbf ft) (EX285)
W4-2-22
EX255-EX285
CYLINDERS
Arm Cylinder
Face the slit toward

the piston
Slit
Green
Black
1 2
3 4 5 6 7 8 9-10
18
11 12 13 14 15 16 17 19 20 21
22-23
24
25
26
27
28
Be sure that oil groove faces the

correct direction when assembling
SM5525
1
2
3
4
5
6
7
8
9
10
Wiper Ring
Backup Ring
U-Ring
Buffer Ring
Bushing
Snap Ring
Cylinder Head
Socket Bolt
Backup Ring
O-Ring
11
12
13
14
15
16
17
18
19
20
- Cylinder Rod
- Cylinder Tube
- Cushion Bearing (front)
- Cushion Seal (front)
- Piston
- Backup Ring
- Seal Ring
- O-Ring
- Slide Ring
- Slide Ring
21
22
23
24
25
26
27
28
Shim
Set Screw
Steel Ball
Nut
Snap Ring
Cushion Seal (rear)
Cushion Bearing (rear)
Stopper
EX255-EX285
W4-2-23
CYLINDERS
Assemble Arm Cylinder


press.
Special tools for bushing installation (5):
EX255: 100 mm (75301686)
EX285: 100 mm (75301651)
75298623
IMPORTANT - Be sure that the rings are installed

correctly.
2. Install U-ring (3), backup ring (2), buffer ring (4), and
snap ring (6) to cylinder head (7).
plastic hammer.
Special tools for wiper ring installation:
EX255-EX285: (75301676)
head (7).
5. Install O -ring (18) buckup ring (16) (2 used), seal
ring (17), slide ring (19) (2 used), (20) (2 used), to
piston (15).
Special tool for seals assembly:
EX255: (75301659)
EX285: (75301170)
SM1365
Be sure to align the machine mark on the rod with

that on the nut.
Nut Turning Special Tools (24):
EX255: 100 mm (75297716)
: 10 200 N m (1040 kgf m, 7523 lbf ft)
EX285: 115 mm (75297549)
: 13 500 N m (1375 kgf m, 9957 lbf ft)
: 6 mm
: 56.910.7 N m (5.81.09 kgf m,
427,9 lbf ft)
15
SM1367

Special tools for cylinder head installation:
EX255: (75301690)
EX285: (75301692)

7. Install cushion seal (14) to cylinder rod (11). Install

cushion bearing (13) and piston (15) to cylinder rod
(11).
10. Install snap ring (25) and cushion seal (26) to

cylinder rod (11). Install cushion bearing (27) and
stopper (28) to cylinder rod (11).
IMPORTANT - Be sure to keep cylinder rod (11)
aligned with the center of cylinder tube (12) when
inserting, in order to avoid damaging the rings.
11. Secure cylinder tube (12) horizontally using a vise.
Insert cylinder rod (11) into cylinder tube (12).
12. Install cylinder head (7) to cylinder tube (12).
EX255:
: 14 mm
: 367 N m (37.4 kgf m, 271 lbf ft)
EX285:
: 17 mm
: 520 N m (53 kgf m, 384 lbf ft)
W4-2-24
EX255-EX285
CYLINDERS
Positioning Cylinder
Green
Slit
Black
1 2
3 4 5 6 7 8 9-10
18
15 16 17 19 20 21
11 12
22-23
24
SM1368
1
2
3
4
5
6
Wiper Ring
Backup Ring
U-Ring
Buffer Ring
Bushing
Snap Ring
7
8
9
10
11
12
Cylinder Head
Socket Bolt
Backup Ring
O-Ring
Cylinder Rod
Cylinder Tube
15
16
17
18
19
20
Piston
Backup Ring
Seal Ring
O-Ring
Slide Ring
Slide Ring
21
22
23
24
Shim
Set Screw
Steel Ball
Nut
EX255-EX285
W4-2-25
CYLINDERS
Assemble Positioning Cylinder
press.
Special tools for bushing installation (5):
EX255-EX285: 90 mm (75301646)
IMPORTANT- Be sure that the rings are installed

correctly.

75298623
2. Install U-ring (3), backup ring (2), buffer ring (4), and
snap ring (6) to cylinder head (7).

plastic hammer.
Special tools for wiper ring installation:
EX255-EX285: (75301665)
SM1365
Be sure to align the machine mark on the rod with that

on the nut.
Nut Turning Special Tools (24):
EX255-EX285: 110 mm (75298684)
: 8 460 N m (863 kgf m, 6240 lbf ft)

head (7).
5. Install O -ring (18) buckup ring (16) (2 used), seal

ring (17), slide ring (19) (2 used), (20) (2 used) to
piston (15).
Special tool for seals assembly:
EX255-EX285: (75301170)

: 6 mm
: 56.9 10.7 N m (5.8 10.9 kgf m,
427,9 lbf ft)
IMPORTANT - Be sure to keep cylinder rod (11)

aligned with the center of cylinder tube (12) when
inserting, in order to avoid damaging the rings.
10.Secure cylinder tube (12) horizontally using a vise.

Insert cylinder rod (11) into cylinder tube (12).
15
SM1367

Special tools for cylinder head installation:
EX255-EX285: (75301536)
11.Install cylinder head (7) to cylinder tube (12).

: 17 mm
: 520 N m (53 kgf m, 384 lbf ft)
7. Install piston (15) to cylinder rod (11).
W4-2-26
EX255-EX285
CYLINDERS
Rod
EX255
Cylinders
Unit: mm (in)
STANDARD (A)
Boom
90 0.03
Arm
100 0.03
Bucket
85 0.03
Positioning (*)
90 0.03
Remedy
Replace or
plate with
chromium
EX285
Cylinders
Unit: mm (in)
STANDARD (A)
Boom
95 0.03
Arm
100 0.03
Bucket
90 0.03
Positioning (*)
90 0.03
Remedy
Replace or
plate with
chromium
EX255-EX285
EX255
W4-2-27
CYLINDERS
SPECIAL TOOLS (EX255)
Piston nut socket wrench:
75294752 for boom cylinders and bucket cylinder (95 mm)
75297716 for arm cylinder (100 mm)
75298684 for positioning cylinder (110 mm) (triple articulation version)
Use nut loosening/tightening workbench: 75298623
SM1366
Tools kit seals installation:
75301679 for boom cylinders and bucket cylinder

75301659 for arm cylinder
75301170 for positioning cylinder (triple articulation version)
SM1369
Wiper installation tool:

75301665 for boom cylinders
75301534 for bucket cylinder
SM1370
Bushing installation tool:

75301684 for boom cylinders ( 90 mm)
75301685 for bucket cylinder ( 85 mm)
75601686 for arm cylinder ( 100 mm)
75301646 for positioning cylinder ( 90 mm) (triple articulation version)
SM1371
Head installation tool:

SM1372
W4-2-28
EX255-EX285
EX285
CYLINDERS
SPECIAL TOOLS (EX285)
Piston nut socket wrench:

75297716 for boom cylinders and bucket cylinder (100 mm)
75297549 for arm cylinder (115 mm)
75298684 for positioning cylinder (110 mm) (triple articulation version)
Use nut loosening/tightening workbench: 75298623
SM1366
Tools kit seals installation:
75301659 for boom cylinders and bucket cylinder

75301170 for positioning cylinder
SM1369

75301533
75301665
75301676
75301665
for boom cylinders

for bucket cylinder
for arm cylinder
for positioning cylinder (triple articulation version)
SM1370
Bushing installation tool:

75301654
75301646
75301651
75301646
for boom cylinders ( 95 mm)

for bucket cylinder ( 90 mm)
for arm cylinder ( 100 mm)
for positioning cylinder ( 90 mm) (triple articulation version)
SM1371

SM1372
SECTION 5
EX255-EX285
ENGINE AND ACCESSORY
CONTENTS
Group 1 -
General Information
Group 4 -
General Repair instructions ................... W5-1-1
Engine Inspection and

Repair
Notes on the Format of this Manual ....... W5-1-1
Cylinder Head ...................................... W5-4-1
External View ....................................... W5-1-5
Valve Guide ......................................... W5-4-2
Main Data and Specifications ................ W5-1-6
Valve .................................................. W5-4-3
Angular Nut and Bolt Tightening

Method ............................................. W5-1-7
Valve seat insert .................................. W5-4-4
Torque Specifications ............................ W5-1-9
Tappet ................................................. W5-4-7
Standard Bolt Torque Specifications ..... W5-1-20
Rocket Arm Shaft and Rocker Arm ........ W5-4-8
Special Tools List ............................... W5-1-22
Push Rod ............................................ W5-4-9
Identifications .................................... W5-1-24
Idler Gear and Idler Gear Shaft .............. W5-4-9
Valve Spring ........................................ W5-4-6
Camshaft .......................................... W5-4-10

Cylinder Body and Liner ...................... W5-4-11
Piston and Piston Ring ....................... W5-4-15
Piston Pin ......................................... W5-4-16
Group 2 -
Maintenance
Connecting Rod ................................. W5-4-17
Lubricating System ............................... W5-2-1
Crankshaft ......................................... W5-4-19
Fuel System ........................................ W5-2-2
Flywheel and Flywheel Housing ........... W5-4-25
Cooling System .................................... W5-2-6
Timing Gear Case Cover ..................... W5-4-25
Valve Clearance Adjustment .................. W5-2-7

Injection Timing .................................... W5-2-8
Compression Pressure Measurement ... W5-2-12
Turbocharger Inspection ...................... W5-2-13
Engine Repair Kit ............................... W5-2-14
Recommended Lubricants ................... W5-2-15
Engine Oil Viscosity Chart .................. W5-2-15
Group 5 -
Engine Reassembly
Piston and Connecting Rod ................... W5-5-1

Cylinder Head ...................................... W5-5-3
Rocket Arm and Rocker Arm Shaft ........ W5-5-6
Major Components ............................... W5-5-7
External Parts .................................... W5-5-16
Engine Tuning Operation ..................... W5-5-22
Group 3 -
Engine Disassembly
External Parts ...................................... W5-3-1

Major Components ............................... W5-3-5
Group 6 -
Lubricating System
Rocker Arm and Rocker Arm Shaft ...... W5-3-10
General Description .............................. W5-6-1
Cylinder Head .................................... W5-3-11
Oil Pump ............................................. W5-6-2
Piston and Connecting Rod ................. W5-3-12
Oil Cooler ............................................ W5-6-4
SECTION 5
Group 7 -
Cooling System
EX255-EX285
Group 11 - Troubleshooting
Hard Starting ..................................... W5-11-1
Thermostat .......................................... W5-7-2
1) Starter Inoperative .......................... W5-11-1

2) Starter Operates but
Engine Does not Turn Over .............. W5-11-2
Group 8 -
Fuel System

Injection Nozzle ................................... W5-8-2
Inuection Pump Calibration Data ............ W5-8-6
3) Engine Turns Over but Does not

Start (Fuel is Being
Delivered to the Injection Pump) ...... W5-11-3
4) Engine Turns Over but Does
not Start (Fuel is not Being Delivered
to the Injection Pump) ..................... W5-11-4
Unstable Low Idling ............................ W5-11-5
Insufficient Power ............................... W5-11-7
Group 9 -
Turbocharger
Overheating ..................................... W5-11-10
White Exhaust Smoke ...................... W5-11-12
Turbocharger Identification .................... W5-9-2
Dark Exhaust Smoke ........................ W5-11-13
Inspection and Repair ........................... W5-9-3
Oil Pressure Does not Rise ............... W5-11-14

Excessive Fuel Consumption ............ W5-11-16
Excessive Oil Consumption .............. W5-11-18
Abnormal Engine Noise ..................... W5-11-19
Group 10 -
Starting and Charging
Starter motor ..................................... W5-10-1

Alternator .......................................... W5-10-4
1) Engine Knocking .......................... W5-11-19

2) Gas Leakage Noise ...................... W5-11-20
3) Continuous Noise ......................... W5-11-21
4) Slapping Noise ............................. W5-11-22
Group 12 - Repair Standards

General Rules .................................... W5-12-1
EX255-EX285
W5-1-1
GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS
1. Before performing any service operation with the engine mounted, disconnect the grounding cable from the
battery. This will reduce the chance of cable damage and burning due to short circuiting.
2. Always use the proper tool or tools ISUZU for the job at hand. Where specified, use the specially designed
tool or tools.
3. Use genuine parts referring FIAT KOBELCO PARTS CATALOG.
4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you remove
them. Replace them with new ones.
5. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation. It is
especially important to keep fastening parts separate. These parts vary in hardness and design, depending
on their installation position.
6. All parts should be carefully cleaned before inspection or reassembly. Oil ports and other openings should
be cleaned with compressed air to make sure that they are completely free of obstructions.
7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly.
8. If necessary, use a sealer on gaskets to prevent leakage.
9. Nut and bolt torque specifications should be carefully followed.
10. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine or
disconnecting pipes and hoses. To not do so is extremely dangerous.
11. Always check and recheck you work. No service operation is complete until you have done this.
12. Information contained in the "Main Data and Specifications" of the Workshop Manual and the Operation and
Maintenance Instruction Manual may differ. In this case, the information contained in the Operation and
Maintenance Instruction Manual should be considered applicable.
NOTES ON THE FORMAT OF THIS MANUAL

This Workshop Manual is applicable to the 6BG1 and 6BG1T family of industrial diesel engines. Unless otherwise
specified, these engines have common parts and components as well as data and specifications. Illustrations used
in this Workshop Manual are based on the AA-6BG1 and BB-6BG1T engines. The BB-6BG1T engine is
turbocharged with intercooler.
1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual.
2. Common technical data such as general maintenance items, service specifications and tightening torques
are included in the General Information section.
3. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and reassembly.
The section ENGINE ASSEMBLY is an exception. This part is divided into three sections to facilitates quick
indexing.
4. When the same servicing operation is applicable to several different units, the manual will direct you to the
appropriate page.
5. For the sake of brevity, self-explanatory removal and installation procedures are omitted. More complex
procedures are covered in detail.
W5-1-2
EX255-EX285
GENERAL INFORMATION
6. Each service operation section in this Workshop Manual begins with an exploded view of the applicable area.
A brief explanation of the notation used follows.
Parts marked with an asterisk (*) are

included in the repair kit.
Parts within a square frame are to be
removed and installed as a single unit.
All parts within an irregularly shaped
frame form a single assembly. They
are considered a "major component".
Individual parts within the irregularly
shaped frame are considered "minor
components".
The number tells you the service operation sequence.
Removal of unnumbered parts is unnecessary unless replacement is required.
The "*Repair Kit" indicates that a repair
kit is available.
Disassembly Steps - 2
1. Water by-pass hose
2. Thermostat housing
3. Water pump
4. Injection nozzle holder
5. Glow plug and glow plug connector
6. Cylinder head cover
7. Rocker arm shaft and rocker arm
8. Push rod
9. Cylinder head
10. Cylinder head gasket
11. Crankshaft damper pulley

with dust seal
12. Timing gear case cover
(Option)
13. Timing gear cover
14. Timing gear oil pipe
15. Idler gear B and shaft
16. Idler gear A
17. Idler gear shaft
The parts listed under "Reassembly

Steps" or "Installation Steps" are in the
service operation sequence.
Inverted Engine
SM7400
The removal or installation of parts

marked with a triangle () is an important operation. Detailed information is
given in the text.
EX255-EX285
W5-1-3
GENERAL INFORMATION
7.
Below is a sample of the text of the Workshop Manual.
This is the item shown in the

illustration. It is marked with a
triangle () on the Major Components page.
Valve Guide Installation

1. Lubricate the valve guide outer face with engine
oil.
2. Attach the installer to the valve guide.
3. Use a hammer to drive the valve guide into
position from the cylinder head upper face. Valve
Guide Installer: 1-85220-001-0
4. Measure the height of the valve guideuide upper
end from the upper face of the cylinder head.
Valve Guide Upper End
Height (H)
Special tools are identified by the

tool name and/or number.
The illustration shows how the
special tool is to be used.
14.1 (0.56)
Note:
If the valve guide has en removed, both the Iva and
the valve guide must be placed with new on as a set.
Be absolutely sure to discard the used valves and
valve guides.
Letters and numbers contained

in a circle refer to the illustration.
SM7401
Symbols indicate the type of

service operation or step to be
performed. A detailed explanation of these symbols follows.
Service data and specifications
are given in this table.
8.
The following symbols appear throughout this Workshop Manual. They tell you the type of service operation
or step to perform.
Removal
Adjustment
Installation
Cleaning
Disassembly
Important Operation Requiring Extra Care
Reassembly
Specified Torque (Tighten)
Alignment (Marks)
Special Tool Use Required or Recommended (Isuzu Tool or Tools)
Directional Indication
Commercially Available Tool Use Required

or Recommended
Inspection
Lubrication (Oil)
Measurement
Sealant Application
Lubrication (Grease)
W5-1-4
EX255-EX285
GENERAL INFORMATION
9. Measurement criteria are defined by the terms Standard and Limit.
A measurement falling within the Standard range indicates that the applicable part or parts are serviceable.
Limit should be thought of as an absolute value.
A measurement which is outside the Limit indicates that the applicable part or parts must be either repaired
or replaced.
10. Components and parts are listed in the singular from throughout the Manual.
11. Directions used in this Manual are as follows:
Front
The cooling fan side of the engine viewed from the flywheel.
Right
The injection pump side of the engine.
Left
The exhaust manifold side of the engine.
Rear
The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine.
The front most cylinder is No. 1 and rear most cylinder is No. 6.
The engines direction of rotation is counterclockwise viewed from the flywheel.
Right
Inj. pump
Rear
Front
Left
SM7402
12. Maintenance procedure call for use of Special or Commercial Tools, where necessary.
The Special Tools required or recommended are identified by an ISUZU Part Number.
Any Special Tools are available in Europe making a purchase order to the following:
IED MAESA
BOOMSESTENWEG 42B
2630 AARTSELAAR
BELGIUM
EX255-EX285
W5-1-5
GENERAL INFORMATION
EXTERNAL VIEW
Turbocharger
Oil filler cap
Turbocharger
Dipstick
Nozzle holder
Air breather
Injection
pump
Flywheel housing
Main
oil filter
Partial
oil filter
Alternator
Crank pulley
Starter motor
Flywheel
Oil filler cap

Fuel filter
Nozzle holder
Fan pulley
Cooling fan
Fuel filter
Water pump
Water
drain plug
Alternator
pulley
Injection pump
Oil pan
Flywheel
housing
Oil pan
Main oil filter

Partial oil filter
Turbocharger
Partial oil filter
Crank pulley
Exhaust manifold
Alternator
Oil drain plug
Flywheel housing
Cylinder
head cover
Nozzle
holder
NOTE: Engine details may vary depending on

the specifications.
Glow plug
Inlet manifold
Air duct
SM7403
Oil filler cap
W5-1-6
EX255-EX285
GENERAL INFORMATION
MAIN DATA AND SPECIFICATIONS
ENGINE MODEL
ITEM
Engine type
Combustion chamber type
Cylinder liner type
No. of cylinders - bore x stroke
mm (in)
Total piston displacement
cm3 (cid)
Compression ratio
* Engine dimensions
mm
Length x width x height
(in)
* Engine weight (Dry)
kg (Ib)
Fuel injection order
Specified fuel
Injection pump
* Governor
Injection nozzle
Injection starting pressure
MPa (kgf/cm2/psi)
Fuel filter type
Water sedimentor
Compression pressure
MPa (kgf/cm2/psi)
(At warm)
Valve clearances (At cold) Intake
mm (in)
Exhaust
mm (in)
Lubrication method
Oil pump
Main oil filter type
* Lubricating oil volume
L (US gal)
Oil cooler
Cooling method
Coolant volume (engine only)
L (US gal)
Water pump
Thermostat type
* Generator
V-A
* Starter
V-kW
* Turbocharger manufacturer
* Turbocharger model
CC-6BG1T
Water cooled, four cycle, vertical in-line overhead valve
Direct injection
Dry
6 - 105.0 x 125.0 (4.13 x 4.92)
6,494 (396)
18.0 to 1
1204 x 762 x 961
(47.4 x 30.0 x 37.8)
484 (1067)
1-5-3-6-2-4
Diesel fuel (ASTM D975 No. 2D)
In-line plunger, Bosch AD type
Mechanical, RSV type
Multi hole
18.1 (185/2,630)
Cartridge (spin-on)
Sedimenter/water level indicating type
3.0 (31/441) at 200 min-1, at sea level
0.40 (0.016)
0.40 (0.016)
Pressurized circulation
Gear type
Cartridge (spin-on)
21.5 (5.68)
Water cooled integral type
Pressurized forced circulation
12 (3.2)
Belt driven impeller type
Wax pellet type
24-40
24-4.5
IHI
RHG6
NOTE: 1. These specifications are based on the standard engine.

2. Specifications for items marked with an asterisk (*) will vary according to the type of equipment on
which the engine is installed. If you are unable to locate the data applicable to these specifications,
please contact Isuzu Motors LTD through your FIAT KOBELCO Dealer.
EX255-EX285
W5-1-7
GENERAL INFORMATION
ANGULAR NUT AND BOLT TIGHTENING
METHOD
1. Carefully wash the nuts and bolts to remove all oil and grease.
2. Apply a coat of molybdenum disulfide

grease to the threads and setting faces of
the nuts and bolts.
m
nu
d e ide
b
y lf
o l u se
M d i s rea
g
SM7404
3. Tighten the nuts and bolts to the specified

torque (snug torque) with a torque
wrench.
NUT
OR
BOLT
Snug torque
SM7405
4. Draw a line (A-B) across the center of each

bolt.
Center line
SM7406
W5-1-8
EX255-EX285
GENERAL INFORMATION
5. Draw another line (C-D) on the face of each
of the parts to be clamped. This line should
be an extension of the line (A-B).
Line
SM7407
6. Draw another line (F-G) on the face of each

of the parts to be clamped. This line will be
in the direction of the specified angle (Q)
across the center (E) of the nut or bolt.
Specified angle (Q)
Coinciding line
SM7408
7. Use a socket wrench to tighten each nut or

bolt to the point where the line (A-B) is
aligned with the line (F-G).
Tighten
SM7409
Example: Specified Angle and Tightening Rotation
30
1/12 of a turn
60
1/6 of a turn
90
1/4 of a turn
180
1 /2 of a torn
360
One full turn
SM7410
EX255-EX285
W5-1-9
GENERAL INFORMATION
TORQUE SPECIFICATIONS
Cylinder Head and Cover
Nm (kgfm/lb.ft)
7.89.8
(0.81.0/5.87.2)
69
88
90120
(9.0/65)
(7.0/5.1)
4262
(4.36.3/3146)
Apply MoS2 grease
2025
(2.02.5/1418)
Glow plug
4262
(4.36.3/3146)
SM7411
MoS2..........Molybdenum disulfide paste.
W5-1-10
EX255-EX285
GENERAL INFORMATION
Cylinder Body
Nm (kgfm/lb.ft)
4262
(4.36.3/3146)
2130
(2.13.1/1522)
2130
(2.13.1/1522)
2130
(2.13.1/1522)
226245
(2325/166181)
Apply engine oil
1625
(1.62.6/1219)
SM7412
EX255-EX285
W5-1-11
GENERAL INFORMATION
Oil Pan and Dipstick
Nm (kgfm/lb.ft)
2530
(2.63.1/1922)
2130
(2.13.1/1522)
6988
(79/5165)
SM7413
W5-1-12
EX255-EX285
GENERAL INFORMATION
Camshaft and Rocker Arm
Nm (kgfm/lb.ft)
2535 (2.63.6/1926)
2535 (2.63.6/1926)
2130
(2.13.1/1522)
2130
(2.13.1/1522)
142172
(14.517.5/105127)
Lubricate with engine oil
4464 (4.56.5/3347)
SM7414
EX255-EX285
W5-1-13
GENERAL INFORMATION
Crankshaft, Piston, and Flywheel
Nm (kgfm/lb.ft)
Apply MoS2 grease
197240
(20.124.5/145177)
Apply MoS2 grease
Apply engine oil
SM7415
W5-1-14
EX255-EX285
GENERAL INFORMATION
Thermostat and Thermostat Housing
Nm (kgfm/lb.ft)
2130
(2.13.1/1522)
4262
(4.36.3/3146)
4262
(4.36.3/3146)
SM7416
EX255-EX285
W5-1-15
GENERAL INFORMATION
Thermostat and Thermostat Housing
Nm (kgfm/lb.ft)
2130
(2.13.1/1522)
4262 (4.36.3/3146)
2130 (2.13.1/1522)
2531 (2.63.2/1923)
SM7417
W5-1-16
EX255-EX285
GENERAL INFORMATION
Timing Gear Case and Flywheel Housing
Nm (kgfm/lb.ft)
2130
(2.13.1/1522)
147-167
(15-17/108-123)
2130 (2.13.1/1522)
Outer side
147-167
(15-17/108-123)
2130
(2.13.1/1522)
Inner side
SM7418
EX255-EX285
W5-1-17
GENERAL INFORMATION
Oil Cooler, Oil Filter, and Oil Pump
Nm (kgfm/lb.ft)
Refer to the section MAINTENANCE
4262 (4.36.3/3146)
4262
(4.36.3/3146)
2130
(2.13.1/1522)
1424 (1.42.4/1017)
SM7419
W5-1-18
EX255-EX285
GENERAL INFORMATION
Fuel System
Nm (kgfm/lb.ft)
1618
(1.61.8/1213)
3349
(3.45.0/2536)
1721
(1.72.1/1215)
3349
(3.45.0/2536)
4262
(4.36.3/3146)
1618
(1.61.8/1213)
1618
(1.61.8/1213)
2832
(2.93.3/2124)
1618
(1.61.8/1213)
2130
(2.13.1/1522)
3.97.8
(0.40.8/2.95.8)
SM7420
EX255-EX285
W5-1-19
GENERAL INFORMATION
Turbocharger
Nm (kgfm/lb.ft)
1625
(1.62.6/1219)
4262 (4.36.3/3146)
2846
(2.94.7/2134)
1625
(1.62.6/1219)
SM7421
W5-1-20
EX255-EX285
GENERAL INFORMATION
STANDARD TORQUE SPECIFICATION
The tightening torque values given in the tables below are applicable to the bolts unless otherwise specified.
Standard Bolt
Nm (kgfm/Ib.ft)
Bolt
Identification
Bolt
Diameter
x pitch (mm)
M 6 x 1.0
3.9-7.8 (0.4-0.8/2.9-5.8)
4.9-9.8 (0.5-1.0/3.6-7.2)
M 8 x 1.25
7.8-17.7 (0.8-1.8/5.8-13.0)
11.8-22.6 (1.2-2.3/8.7-16.6)
16.7-30.4 (1.7-3.1/12.3-22.4)
M10 x 1.25
20.6-34.3 (2.1-3.5/5.2-25.3)
27.5-46.1 (2.8-4.7/20.3-33.4)
37.3-62.8 (3.8-6.4/27.5-46.3)
* M10 x 1.5
19.6-33.4 (2.0-3.4/14.5-24.6)
27.5-45.1 (2.8-4.6/20.3-33.3)
36.3-59.8 (3.7-6.1/26.8-44.1)
M12 x 1.25
49.1-73.6 (5.0-7.5/36.2-54.2)
60.8-91.2 (6.2-9.3/44.8-67.3)
75.5-114.0 (7.7-11.6/55.7-83.9)
* M12 x 1.75
45.1-68.7 (4.6-7.0/33.3-50.6)
56.9-84.4 (5.8-8.6/42.0-62.2)
71.6-107.0 (7.3-10.9/52.8-78.8)
M14 x 1.5
76.5-115.0 (7.811.7/56.4-84.6)
93.2-139.0 (9.5-14.2/68.7-103.0)
114.0-171.0 (11.6-17.4/83.9-126.0)
* M14 x 2.0
71.6-107.0 (7.3-10.9/52.8-78.8)
88.3-131.0 (9.0-13.4/65.1-96.9)
107.0-160.0 (10.9-16.3/78.8-118.0)
M16 x 1.5
104.0-157.0 (10.6-16.0/76.7-115.7)
135.0-204.0 (13.8-20.8/99.8-150.0)
160.0-240.0 (16.3-24.5/118.0-177.0)
* M16 x 2.0
100.0-149.0 (10.2-15.2/73.8-110.0)
129.0-194.0 (13.2-19.8/95.5-143.0)
153.0-230.0 (15.6-23.4/113.0-169.0)
M18 x 1.5
151.0-226.0 (15.4-23.0/111.0-166.0)
195.0-293.0 (19.9-29.9/144.0-216.0)
230.0-345.0 (23.4-35.2/169.0-255.0)
* M18 x 2.5
151.0-226.0 (15.4-23.0/111.0-166.0)
196.0-294.0 (20.0-30.0/145.0-217.0)
231.0-346.0 (23.6-35.3/171.0-255.0)
M20 x 1.5
206.0-310.0 (21.0-31.6/152.0-229.0)
270.0-405.0 (27.5-41.3/199.0-299.0)
317.0-476.0 (32.3-48.5/234.0-351.0)
* M20 x 2.5
190.0-286.0 (19.4-29.2/140.0-211.0)
249.0-375.0 (25.4-38.2/184.0-276.0)
293.0-440.0 (29.9-44.9/216.0-325.0)
M22 x 1.5
251.0-414.0 (25.6-42.2/185.0-305.0)
363.0-544.0 (37.0-55.5/268.0-401.0)
425.0-637.0 (43.3-64.9/313.0-469.0)
* M22 x 2.5
218.0-328.0 (22.2-33.4/161.0-242.0)
338.0-507.0 (34.5-51.7/250.0-374.0)
394.0-592.0 (40.2-60.4/291.0-437.0)
M24 x 2.0
359.0-540.0 (36.6-55.0/265.0-398.0)
431.0-711.0 (43.9-72.5/318.0-524.0)
554.0-831.0 (56.5-84.7/409.0-613.0)
* M24 x 3.0
338.0-507.0 (34.5-51.7/250.0-374.0)
406.0-608.0 (41.4-62.0/299.0-448.0)
521.0-782.0 (53.1-79.7/384.0-576.0)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such
as casting.
EX255-EX285
W5-1-21
GENERAL INFORMATION
Flanged head bolt
Nm (kgfm/Ib.ft)
Bolt
Identification
Bolt
Diameter
x pitch (mm)
M 6 x 1.0
4.6-8.5 (0.5-0.9/3.6-6.5)
6.6-12.2 (0.6-1.2/4.3-8.7)
-------------------
M 8 x 1.25
10.5-19.6 (1.1-2.0/8.0-14.5)
15.3-28.4 (1.6-2.9/11.6-21.0)
18.1-33.6 (2.1-3.4/15.2-25.0)
M10 x 1.25
23.1-38.5 (2.4-3.9/17.4-28.2)
35.4-58.9 (3.6-6.1/26.0-44.1)
42.3-70.5 (4.3-7.2/31.1-52.1)
* M10 x 1.5
22.3-37.2 (2.3-3.8/16.6-27.5)
34.5-57.5 (3.5-5.8/25.3-42.0)
40.1-66.9 (4.1-6.8/29.7-49.2)
M12 x 1.25
54.9-82.3 (5.6-8.4/40.1-60.8)
77.7-117.0 (7.9-11.9/57.1-86.1)
85.0-128.0 (8.7-13.0/62.9-94.0)
* M12 x 1.75
51.0-76.5 (5.2-7.8/37.6-56.4)
71.4-107.0 (7.3-10.9/52.8-78.8)
79.5-119.0 (8.1-12.2/58.6-88.2)
M14 x 1.5
83.0-125.0 (8.5-12.7/61.5-91.9)
115.0-172.0 (11.7-17.6/84.6-127.0)
123.0-185.0 (12.6-18.9/91.1-137.0)
* M14 x 2.0
77.2-116.0 (7.9-11.8/57.1-85.3)
108.0-162.0 (11.1-16.6/80.3-120.0)
116.0-173.0 (11.8-17.7/85.3-128.0)
116.0-173.0 (11.8-17.7/85.3-128)
171.0-257.0 (17.4-26.2/126.0-190.0)
177.0-265.0 (18.0-27.1/130.0-196.0)
109.0-164.0 (11.2-16.7/81.0-121.0)
163.0-244.0 (16.6-24.9/120.0-180.0)
169.0-253.0 (17.2-25.8/124.0-187.0)
M16 x 1.5
* M16 x 2.0
A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.
W5-1-22
EX255-EX285
GENERAL INFORMATION
SPECIAL TOOL LIST
ITEM NO.
ILLUSTRATION
PART NO.
PARTS NAME
PAGE
1.
5-85317-001-0
Compression gauge adaptor
W5-2-12
2.
1-85111-003-0
Cylinder head bolt wrench
W5-3-6
3.
9-8521-0122-0
Crankshaft taper bushing remover
W5-3-7
4.
5-8840-2360-0
Rear oil seal remover
W5-3-7
5.
1-85235-006-0
Valve spring compressor
W5-3-11
W5-5-4
6.
1-85232-001-0
9-85220-035-0
Valve guide remover and

installer
W5-4-2
7.
9-8523-1818-0
Camshaft bearing remover and

installer
W5-4-10
8.
9-8523-1169-0
Cylinder liner remover
W5-4-11
9.
5-8523-1004-0
Cylinder liner remover ankle
W5-4-11
10.
5-8522-1018-0
Cylinder liner installer
W5-4-13
EX255-EX285
W5-1-23
GENERAL INFORMATION
ITEM NO.
ILLUSTRATION
PART NO.
PARTS NAME
PAGE
11.
9-8523-1369-0
Connecting rod bushing installer
W5-4-18
12.
9-8521-0141-0
Crankshaft gear remover
W5-4-24
13.
9-8522-0033-0
Crankshaft gear installer
W5-4-24
14.
9-8522-0034-0
Crankshaft front oil seal installer
W5-4-25
15.
1-85221-005-0
Valve stem oil seal installer
W5-5-4
16.
9-8522-1251-0
Piston ring compressor
W5-5-10
17.
5-8840-9025-0
Rear oil seal installer
W5-5-11
W5-1-24
EX255-EX285
GENERAL INFORMATION
IDENTIFICATIONS
Engine Serial Number
The engine number is stamped on the front left hand
side of the cylinder body.
Engine serial number

SM7422
Injection Pump Number

Injection volume should be adjusted after referring to
the adjustment data applicable to the injection pump
installed.
The injection pump identification number (A) is
stamped on the injection pump identification plate.
NOTE: Always check the identification number before beginning a service operation.
Applicable service data will vary according to the
Identification number. Use of the wrong service data
will result in reduced engine performance and engine
damage.
Pump No.
NP-PE
(LICENCE BOSCH)
Identification number
SM7423
EX255-EX285
W5-2-1
MAINTENANCE
LUBRICATING SYSTEM
Main Oil Filter Replacement
Cartridge (Spin-On) Type
REMOVAL
Removal and Installer: Filter Wrench
1. Loosen the used oil filter by turning it
counterclockwise with the filter wrench.
2. Discard the used oil filter.
INSTALLATION
1. Wipe the oil filter mounting face with a
clean rag. This will allow the new oil filter to
seat properly.
2. Lightly oil the O-ring.
3. Turn in the new oil filter until the sealing
face is fitted against the O-ring.
4. Use the filter wrench to turn in the oil filter
an additional 3/4 of a turn or one turn.
5. Check the engine oil level and replenish to
the specified level if required.
6. Start the engine and check for oil leakage
from the oil filter.
Main oil filter
Partial filter
SM7424
W5-2-2
EX255-EX285
MAINTENANCE
FUEL SYSTEM
Fuel Filter Replacement
Cartridge (Spin-On) Type
REMOVAL
1. Loosen the fuel filter by turning it
counterclockwise with the filter wrench or
your hand. Discard the used filter.
2. Wipe the fuel filter fitting face clean with a
rag.
This will allow the new fuel filter to seat
properly.
SM7425
INSTALLATION
1. Apply a light coat of engine oil to the O-ring.
2. Supply fuel to the new fuel filter. This will
facilitate air bleeding.
3. Turn in the new fuel filter until the filter
O-ring is fitted against the sealing face.
4. Use the filter wrench to turn in the fuel filter
an additional 2/3 of a turn.
Overflow Valve
Check the overflow valve for clogging.
Check the ball side for suction leakage.
kPa (kgf/cm2/psi)
Overflow Valve Opening
Pressure (Reference)
147 (1.5/21)
SM7426
EX255-EX285
W5-2-3
MAINTENANCE
Injection Nozzle
INSPECTION PROCEDURE
1. Clamp the injection nozzle holder in a vise.
2. Use a wrench to remove the injection
nozzle holder cap.
3. Remove the injection nozzle holder from
the vise.
SM7427
ADJUSTING PROCEDURE
Injection Starting Pressure Check
1. Attach the injection nozzle holder to the
injection nozzle tester.
2. Loosen the adjusting screw (1).
3. Check the injection nozzle starting pressure and the spray condition by operating
the injection nozzle tester.
4. Adjust the injection nozzle starting pressure. Turn the adjusting screw clockwise
while operating the injection nozzle tester
handle.
SM7428
SM7429
MPa (kgf/cm2/psi)
Injection Starting
Pressure
18.1 (185/2630)
WARNING
TEST FLUID FROM THE NOZZLE
TESTER WILL SPRAY OUT UNDER
GREAT PRESSURE. IT CAN EASILY
PUNCTURE A PERSONS SKIN. KEEP
YOUR HANDS AWAY FROM THE NOZZLE TESTER AT ALL TIMES.
SM7430
W5-2-4
EX255-EX285
MAINTENANCE
Spray Condition Check (During Injection Nozzle Tester Operation)
1. Tighten the cap nut.
2. Check the injection nozzle starting pressure.
3. Check the injection nozzle spray condition. Operate the injection nozzle tester
hand lever 4 to 6 times a second while
looking for abnormal injection nozzle
spray conditions. Refer to the illustration
for different spray conditions
(1) Good
(2) Bad (Restrictions in orifice)
(3) Bad (Dripping)
SM7431
Feed Pump Strainer

1. Remove the joint bolt.
2. Use a screwdriver to remove the strainer.
3. Wash the strainer in clean diesel fuel.
SM7432
Strainer
SM7433
EX255-EX285
W5-2-5
MAINTENANCE
Water Separator (Water Sedimentor)
Check the water separator float (1) level.
If the float (1) has reached level (2), loosen the
drain plug (3) (at the bottom side of the water
separator) to drain the water.
Nm (kgfm/ft.lb)
Drain Plug Torque
9-15 (0.9-1.5/7-11)
SM7434
Air Bleeding
1. Loosen the feed pump cap (1) on the
injection pump.
2. Loosen the fuel filter fuel return eye bolt
(2).
3. Operate the feed pump until there are no
more bubbles visible in the fuel being
discharged from the fuel filter fuel return
eye bolt.
4. Retighten the fuel filter fuel return eye bolt.
5. Operate the feed pump several times and
check for fuel leakage around the injection
pump and the fuel filter.
SM7435
SM7436
W5-2-6
EX255-EX285
MAINTENANCE
COOLING SYSTEM
Cooling Fan Drive Belt
Depress here
98N (10kgf/22lb)
ADJUSTMENT
1. Check the cooling fan drive belt for cracking and other damage.
2. Check the drive belt tension by exerting a
force of 98N (10kgf/22lb) midway between the fan pulley (2) and the alternator
(3).
3. Adjust the belt tension by loosening the
alternator mounting bolt and the alternator
adjusting bolt and pivoting the alternator.
Be sure to retighten the bolts after adjusting the belt tension.
Deflection
SM7437
mm (in)
Cooling Fan Drive
Belt Deflection
7.0-10.0
(0.28-0.39)
Thermostat
INSPECTION
Visually inspect the thermostat.
Replace the thermostat if excessive wear or
damage is discovered during inspection.
Measure the valve lift.
Thremometer
Agitating rod
mm (in)
Amount of Valve Lift
at 95 C (203 F)
10.0 (0.39)
Wood piece
C(F)
Valve Opening
Temperature
80-84 (176-183)
SM7438
EX255-EX285
W5-2-7
MAINTENANCE
VALVE CLEARANCE ADJUSTMENT
NOTE: The cylinder head bolts were previously tightened with the Angular Tightening
Method. Therefore, it is not necessary to
retighten the cylinder head bolts before adjusting the valve clearance.
1. Bring the piston in either the No. 1 cylinder
or the No. 6 cylinder to Top Dead Center on
the compression stroke by turning the
crankshaft until the TDC notched line on
the crankshaft pulley is aligned with the
timing pointer.
2. Check to see if there is play in the No. 1
intake and exhaust valve rocker arms.
If the No. 1 cylinder intake and exhaust
valve rocker arms have play, the No. 1
piston is at TDC on the compression
stroke.
If the No. 1 cylinder intake and exhaust
valve rocker arms are depressed, the No.
6 piston is at TDC on the compression
stroke.
SM7439
SM7440
Adjust the No. 1 or the No. 6 cylinder valve

clearances while their respective cylinders
are at TDC on the compression stroke.
mm (in)
Intake and Exhaust
Valve Clearance (cold)
0.40 (0.016)
3. Loosen each valve clearance adjusting

screw as shown in the illustration.
4. Insert a 0.40 mm (0.016 in) feeler gauge
between the rocker arm and the valve
stem end.
5. Turn the valve clearance adjusting screw
until a slight drag can be felt on the feeler
gauge.
6. Tighten the lock nut securely.
7. Rotate the crankshaft 360.
Realign the crankshaft pulley TDC
notched line with the timing pointer.
8. Adjust the clearances for the remaining
valves as shown in the illustration.
Nm (kgfm/ft.lb)
Rocker Arm Screw
Lock Nut Torque
SM7439
Front
When No. 1 cylinder at TDC

in compression stroke
SM7441
Front
21-30 (2.1-3.1/15-22)
When No. 6 cylinder at TDC

in compression stroke
SM7442
W5-2-8
EX255-EX285
MAINTENANCE
INJECTION TIMING
NOTE: Take care to avoid entry of dust or
foreign particles into the pump interior when
the timing adjustment is made.
The flange mounted injection pump is installed
behind the timing gear case.
Checking Procedure
1. Align the crankshaft pulley TDC mark with
the pointer.
Remove the inspection hole cover at the
front of the injection pump on the timing
gear case cover.
Check the alignment between the pointer
(4) on the injection pump gear nut lock plate
and the projection area mark (3) on the
injection pump gear case.
If it is in misalignment, recheck with turning the crankshaft pulley one more turn to
repeat the aforegoing procedure to mark
sure that it is in alignment.
Check the alignment of the notched lines
(1) and (2) .
(These notched lines were aligned at the
factory to set the injection pump body and
the mounting flange.)
Next, inspect the crankangle position of
the injection starting.
2. Reversely turn the crankshaft pulley
counterclockwise about 30 crankangle.
3. Disconnect the injection pipe from the No.
1 plunger.
This will allow you to visually check the full
injection starting flow at No. 1 plunger.
4. Remove the delivery valve holder (1) , the

valve seat (2) , valve spring (3) the delivery
valve (4) from the No. 1 plunger.
5. Reinstall the delivery holder (1) and tighten
it to the specified torque.
Do not reinstall the delivery valve spring,
the valve seat and the delivery valve.
These parts will be reinstalled later.
SM7440
SM7443
SM7444
SM7445
SM7446
EX255-EX285
W5-2-9
MAINTENANCE
6. Hold the fuel control lever at the fully open
position.
SM7447
7. Slowly turn the crankshaft pulley clockwise, at the same time, continue to feed
the fuel with pumping the priming
pump.
When the fuel stop to flow out from the No.
1 delivery valve holder, stop the pump
instantaneously.
This crankangle position is the injection
starting of the engine.
SM7448
8. Observe and make sure that mark (injection starting angle line ) on the crankshaft pulley is aligning with the pointer.
The timing line shows the injection starting
angle of the engine.
Blow out the remaining fuel from the delivery valve holder.
Make sure that there is no fuel being
delivered from the priming pump.
NOTE: This engine has eight timing notch lines

punched on the crankshaft damper pulley.
These notched lines must be aligned for correct engine timing.
Refer to the illustration.
Degree
Injection Timing B.T.D.C.
Damper
pulley
SM7449
W5-2-10
EX255-EX285
MAINTENANCE
NOTE: Injection pump injection timing will vary
among identical engines, contact your FIAT
KOBELCO Dealer.
9. Remove the delivery valve holder from the
No. 1 plunger.
10. Reinstall the delivery valve internal parts
(seat, spring, and valve) to the delivery
valve holder.
11. Reinstall the delivery valve holder assembly to the No. 1 plunger and tighten it to the
specified torque.
Holder
Nm (kgfm/ft.lb)
Delivery Valve Holder
39-44 (4-4.5/29-33)
Torque
12. Install the No. 1 cylinder injection pipe and
tighten it to the specified torque.
Nm (kgfm/ft.lb)
Injection Pipe Nut
Torque
28-32 (2.9-3.3/21-24)
NOTE: DO NOT OVERTIGHTEN THE INJECTION PUMP BODY.

THE INJECTION PUMP BODY IS MADE OF
ALUMINUM. OVERTIGHTENING WILL DISTORT THE INJECTION PUMP BODY SHAPE
AND ADVERSELY AFFECT CONTROL
RACK OPERATION.
Seat
Spring
Derivery Valve
SM7450
EX255-EX285
W5-2-11
MAINTENANCE
Adjusting Procedure
1. Align the pointer and the specified timing
mark on the crank pulley.
2. Perform the operations described on page
W5-2-8 and W5-2-9, steps 3, 4, 5, 6.
3. Loosen the four injection pump fixing nut.
4. To advance the timing
Pivot the injection pump at the pump
driveshaft toward out.
To retard the timing.
Pivot the injection pump at the pump
driveshaft toward in (toward the cylinder
block).
Reference; the 1 mm misalignment between the two setting mark lines corresponds to about 2 in crankangle.
5. Do a fine injection pump position adjustment, while continue the pumping operation to feed the fuel, and stop to pivot the
injection pump when the fuel stop to flow
out from the No. 1 delivery valve holder.
6. Tighten the four injection pump fixing nuts.
7. Once remove the No. 1 delivery valve
holder, and reinstall the delivery valve,
spring and the valve holder with the specified torque.
8. Install the No. 1 injection pipe and tighten
it to the specified torque.
Loosen
(Back side nuts also)
SM7451
W5-2-12
EX255-EX285
MAINTENANCE
COMPRESSION PRESSURE MEASUREMENT
1. Operate the engine to warm-up until the
coolant temperature reaches to 75 C
(167 F).
2. Remove all of the glow plugs and the
injection pipes.
3. Attach a compression gauge to the No. 1
cylinder glow plug installation threads.
Compression gauge adaptor
NOTE: Compression pressure may be measured starting at any cylinder and in no particular
cylinder order. However, it is very important
that the compression pressure be measured in
each cylinder.
Therefore, start at the No.1 cylinder and work
back. In this way, you will be sure to measure
the compression pressure in each cylinder.
SM7458
Compression Gauge:
Compression Gauge Adapter: 5-85317-001-0
(JKM-1015)
4. Crank the engine with the starter motor and

take the compression gauge reading.
MPa (kgf/cm2/psi) at 200 min-1 at sea level
Standard
Limit
3.0 (31/440)
2.5 (26/370)
5. Repeat the procedure (Steps 2 and 3) for

the remaining cylinders.
Compression pressure should be approximately the same for each cylinder. A variation exceeding 200 kPa (2 kgf/cm2/28 psi)
is unacceptable.
If the measured value exceeds the specified limit, the related parts must be
checked.
SM7459
EX255-EX285
W5-2-13
MAINTENANCE
TURBOCHARGER INSPECTION
1. Check the air intake duct connections for
air leakage.
SM7460
2. Check the air duct connections for air

leakage.
SM7461
3. Check the exhaust duct connections for

smoke leakage.
4. Check the turbocharger mounting nuts for
looseness.
SM7462
5. Check the oil feed pipe for oil leakage.
SM7463
6. Check the oil return pipe joints for oil

leakage.
SM7464
W5-2-14
EX255-EX285
MAINTENANCE
ENGINE REPAIR KIT
VIEW (A)
SM7465
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Cylinder head gasket

Cylinder head cover gasket
Cylinder head cover nut gasket
Chamber cover fixing bolt gasket
Oil pump hole cover gasket
Oil relief valve gasket
Water drain valve gasket
Gear case to cylinder block gasket
Crank pulley to gear case oil seal
Gear case cover gasket
Crankshaft rear end oil seal
Valve guide oil seal
Drain plug gasket
Oil pan gasket
Oil pipe gasket
Oil filter gasket
Oil filter fixing bolt gasket
Oil cooler gasket
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Oil pipe joint gasket

Joint bolt gasket
Oil pipe gasket
Injection pump oil pipe gasket
Injection pump oil pipe gasket
Water pump gasket
Thermostat housing gasket
Intake manifold gasket
Inlet pipe manifold gasket
Exhaust manifold gasket
Exhaust manifold to turbocharger gasket
Oil feed pipe gasket
Oil drain pipe gasket
Oil drain pipe gasket
Overflow fuel pipe gasket
Injection nozzle gasket
Injection nozzle leak off pipe gasket
Thermostat gasket
EX255-EX285
W5-2-15
MAINTENANCE
RECOMMENDED LUBRICANTS
ENGINE TYPE
TYPE OF LUBRICANT (API)
With turbocharger
Diesel engine oil

CD grade
ENGINE OIL VISCOSITY CHART
ENGINE OIL VISCOSITY GRADE-AMBIENT TEMPERATURE

[Single grade]
Ambient
temperature
(5F)
(59F)
(77F)
(86F)
[Multi-grade]
SM7033
W5-2-16
EX255-EX285
MAINTENANCE
NOTE
EX255-EX285
W5-3-1
ENGINE DISASSEMBLY
EXTERNAL PARTS
SM7466
Right-hand Side Disassembly Steps

1. Cooling fan
2. Not installed
3. Not installed
4. Intake pipe
5. Fuel return pipe
6. Fuel pipe; fuel filter to injection pump
7. Fuel pipe; feed pump to filter
8. Injection pipe and leak off pipe
9.
10.
11.
12.
13.
14.
15.
16.
Injection nozzle
Oil pipe; injection pump to cylinder body
Not installed
Oil pipe; filter to oil cooler
Injection pump with injection pump gear
Fuel filter
Oil filters
Glow plug
W5-3-2
EX255-EX285
ENGINE DISASSEMBLY
Important Operations
13. Injection Pump with Injection Pump
Gear
Use the shipping plugs (or something similar) to seal the injection pump delivery
valve ports. This will prevent the entry of
foreign material.
1) Remove the injection pump flange
bolts.
2) Pull the injection pump with the injection
pump drive gear free.
SM7467
EX255-EX285
W5-3-3
ENGINE DISASSEMBLY
SM7469
Left-hand Side Disassembly Steps

1. Dipstick and guide tube
2. Air breather
3. Oil feed pipe
4. Oil drain pipe
5. Turbocharger
6. Gasket
7.
8.
9.
10.
11.
Starter
Fan belt
Alternator
Fan pulley
Cylinder head cover
W5-3-4
EX255-EX285
ENGINE DISASSEMBLY
5. Turbocharger
Plug oil ports in turbocharger body immediately after removal of the turbocharger.
SM7470
EX255-EX285
W5-3-5
ENGINE DISASSEMBLY
MAJOR COMPONENTS
* : Repair kit
SM7471
Disassembly Steps - I
1. Rubber hose; water by-pass
2. Rocker arm shaft assembly
3. Push rod
4. Cylinder head bolt
5. Cylinder head assembly
6. Cylinder head gasket
7. Water pump assembly
8.
9.
10.
11.
12.
13.
14.
15.
16.
Tappet chamber cover

Oil pump driving pinion
Starting handle nut
Taper bushing
Crankshaft pulley and dust thrower
Timing gear cover
Oil thrower
Flywheel
Rear oil seal
W5-3-6
EX255-EX285
ENGINE DISASSEMBLY
2. Rocker Arm Shaft
Loosen the rocker arm shaft fixing bolts a
little at a time in numerical sequence as
specified.
SM7472
4. Cylinder Head Bolts

Loosen the cylinder head bolts a little at a
time in the numerical order shown in the
illustration.
Cylinder head bolt wrench: 1-85111-003-0
Front
SM7473
10. Crankshaft Pulley Nut

Wrench: 54 mm (2.13 in)
Use an appropriate wrench to remove the
crankshaft pulley nut.
Crankshaft pulley
Wrench
SM7474
EX255-EX285
W5-3-7
ENGINE DISASSEMBLY
11. Taper Bushing
Remover: 9-8521-0122-0 Use the taper
bushing remover to remove the crankshaft
end taper bushing.
Taper bushing
Crankshaft
Pulley
Taper bushing
remover
SM7475
15. Flywheel
Loosen the flywheel bolt a little at a time in
the numerical order as specified.
SM7476
16. Crankshaft Rear Oil Seal (Axial Type)

With the oil seal pushed in deep, install the
special tool as shown in the illustration and
remove the oil seal.
Oil Seal Remover: 5-8840-2360-0
SM7477
W5-3-8
EX255-EX285
ENGINE DISASSEMBLY
* : Repair kit
SM7471
Disassembly Steps - II
1. Oil cooler
2. Oil pan
3. Oil pump and coupling
4. Flywheel housing
5. Piston and connecting rod
6. Idler gear
7. Camshaft
8. Tappet
9.
10.
11.
12.
13.
14.
15.
16.
Timing gear case

Idler gear shaft
Crankshaft bearing cap
Crankshaft bearing (lower half)
Thrust bearing
Crankshaft
Crankshaft bearing (upper half)
Oiling jet
EX255-EX285
W5-3-9
ENGINE DISASSEMBLY
6. Idler Gear
Measure the following points before disassembly.
mm (in)
Idler Gear End
Play
Standard
Limit
0.128-0.185
(0.005-0.0070)
0.2
(0.008)
Feeler gauge
mm (in)
Timing Gears
Backlash
Standard
Limit
0.10-0.17
(0.004-0.007)
0.3
(0.012)
SM7479
Includes the crankshaft gear, the camshaft gear, and the idler gear.
Dial indicator
SM7480
7. Camshaft
Measure the following points before disassembly.
Crankshaft gear
mm (in)
Cam Gear End
Play
Standard
Limit
0.050-0.114
(0.002-0.005)
0.2
(0.008)
Thrust plate
Feeler gauge
Camshaft
SM7481
11. Crankshaft Bearing Cap

Measure the crankshaft end play at the
thrust bearing (center main bearing) before disassembly.
Feeler gauge
mm (in)
Crankshaft End
Play
Standard
Limit
0.15-0.33
(0.006-0.013)
0.4
(0.016)
Crankshaft
SM7482
W5-3-10
EX255-EX285
ENGINE DISASSEMBLY
ROCKER ARM AND ROCKER ARM SHAFT
SM7483
Disassembly Steps
1. Bracket
2. Rocker arm
3.
4.
Spring
Rocker arm shaft
EX255-EX285
W5-3-11
ENGINE DISASSEMBLY
CYLINDER HEAD
* : Repair kit
SM7484
Disassembly Steps
1. Exhaust manifold and gasket
2. Intake manifold and gasket
3. Water outlet pipe
4. Thermostat
5. Thermostat housing and gasket
6. Split collar
7.
8.
9.
10.
11.
Spring seat (upper)

Valve spring
Spring seat (lower)
Valve
Valve stem oil seal
Important Operation
6. Split collar
Use the valve spring compressor to remove the split collar.
Valve Spring Compressor: 1-85235-006-0
Valve spring compressor

SM7485
W5-3-12
EX255-EX285
ENGINE DISASSEMBLY
PISTON AND CONNECTING ROD
SM7486
Disassembly Steps
1. Piston rings
2. Snap ring
3. Piston pin and connecting rod
4.
5.
Piston
Connecting rod bearing
EX255-EX285
W5-3-13
ENGINE DISASSEMBLY
Important Operation
NOTE: Remove any carbon deposits from the
upper part of the cylinder bore. This will prevent
damage to the piston and the piston rings when
they are removed from the cylinder bore.
Carbon deposits
SM7487
1.
Piston Rings
Use a piston ring remover to remove the
piston rings. Do not attempt to use some
other tool. Piston ring stretching will result
in reduced piston ring tension.
Piston ring remover:
Piston ring remover
SM7488
2, 3.Snap Ring and Piston Pin

(1) Use a pair of snap ring pliers to remove
the snap ring.
SM7489
(2) Tap the piston pin out with a hammer

and brass bar.
Piston pin
SM7490
W5-3-14
EX255-EX285
ENGINE DISASSEMBLY
NOTE
EX255-EX285
W5-4-1
ENGINE INSPECTION AND REPAIR

NOTE: Make the necessary adjustments, repairs, and part replacements if excessive wear
or damage is discovered during inspection.
CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to
measure the four sides and the two diagonals of the cylinder head lower face.
2. Regrind the cylinder head lower face if the
measured values are greater than the
specified limit but less than the maximum
grinding allowance.
SM7491
If the measured values exceed the maximum

grinding allowance, the cylinder head must be
replaced.
Cylinder Head Lower Face Warpage mm (in)
Standard
Limit
Maximum Grinding
Allowance
0.075
0.2
(0.003) or less (0.0079)
0.3
(0.012)
SM7492
Cylinder Head Height (Reference)
mm (in)
Standard
Limit
89.95 (3.541)-90.05 (3.545)
89.65 (3.530)
NOTE: If the cylinder head lower face is

reground, valve depression must be checked.
SM7493
Water Jacket Water Pressure Test

Use the hydraulic gauge to check the water
jacket water pressure.
Apply water pressure to the water jacket at
490 kPa (5 kgf/cm2/71.1 psi) for three minutes.
Check the entire cylinder head for water leakage.
SM7494
W5-4-2
EX255-EX285

VALVE GUIDE
Valve Stem and Valve Guide Clearance
MEASURING METHOD - I
1. With the valve stem inserted in the valve
guide, set the dial indicator needle to 0.
2. Move the valve head from side to side.
Note the total dial indicator reading (TIR).
This value is the clearance between the
valve stem and the valve guide.
If the measured values exceed the specified limit, the valve and the valve guide
must be replaced as a set.
SM7495
Valve Stem Clearance
mm (in)
Standard
Limit
Intake Side TIR
0.039-0.071
0.20
(0.0015-0.0028) (0.008)
Exhaust Side TIR
0.064-0.096
0.25
(0.0025-0.0038) (0.0098)
MEASURING METHOD - II
1. Measure the valve stem outside diameter.
2. Use a caliper calibrator or a telescoping
gauge to measure the valve guide inside
diameter.
The difference between the valve stem
outside diameter and the valve guide inside diameter is equal to the valve stem
clearance.
SM7496
Valve Guide Replacement

REMOVAL
Use a hammer and the valve guide remover to
drive out the valve guide from the cylinder head
lower face.
Valve Guide Remover: 9-85220-035-0
INSTALLATION
1. Apply clean engine oil the outer periphery
of the valve guide.
2. Attach the installer to the valve guide.
3. Use a hammer to drive in the valve guide
from the upper face of the head until the
installers lower edge meets the head surface.
Valve guide installer: 1-85232-001-0
4. After installation, measure the distance
(height) from the cylinder heads upper
surface to the upper edge of the valve
guide.
Height to valve guide upper edge
SM7497
mm (in)
14.1 (0.555)
SM7498
EX255-EX285
W5-4-3

VALVE
Valve Depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with
steel rule to measure the valve depression
from the cylinder head lower surface. If the
measured value exceeds the specified
limit, the valve seat insert and/or valve
must be replaced. If the valve is replaced,
the valve guide must be also replaced.
mm (in)
Standard
Limit
SM7499
Intake and Exhaust

1.0 (0.039) 2.5 (0.098)
Valve Depression
Valve Contact Width

1. Inspect the valve contact faces for roughness and unevenness. Make smooth the
valve contact surfaces.
2. Measure the valve contact width. If the
measured value exceeds the specified
limit, the valve seat insert must be replaced.
mm (in)
Standard
Valve Contact
Width
Limit
SM7500
1.5 (0.059) 2.0 (0.079)
W5-4-4
EX255-EX285

VALVE SEAT INSERT
Removal
1. Arc weld the entire inside circumference
(1) of the valve seat insert (2).
2. Allow the valve seat insert to cool for a few
minutes. This will invite contraction and
make removal of the valve seat insert
easier.
3. Use a screwdriver (3) to pry the valve seat
insert free.
Take care not to damage the cylinder head
(4).
4. Carefully remove carbon and other foreign
material from the cylinder head insert bore.
SM7501
Installation
1. Carefully place the attachment (1) (having
the smaller outside diameter than the valve
seat insert) on the valve seat insert (2).
NOTE: The smooth side of the attachment
must contact the valve seat insert.
2. Use a bench press (3) to slowly apply
pressure to the attachment and press the
valve seat insert into place. Amount of
pressure needed is more than 25 kN (2,500
kgf/5,512 lb).
SM7502
NOTE: Do not apply an excessive amount of

pressure with the bench press. Damage to the
valve seat insert will result.
Correction
1. Remove the carbon deposits from the
valve seat insert surface.
2. Use valve cutters (15, 30, or 75 blades)
to remove scratches and other rough areas.
This will bring the contact width back to the
standard value of 90 (A).
Remove only the scratches and rough
areas. Do not cut away too much. Take
care not to cut away unblemished areas of
the valve seat surfaces.
SM7503
EX255-EX285
W5-4-5

Angle Location
Standard
Intake Valve Seat Angle (B)
45
Exhaust Valve Seat Angle (B)
45
NOTE: Use an adjustable valve cutter pilot.

Do not allow the cutter pilot to wobble inside the
valve guide.
3. Apply abrasive compound to the valve
seat insert surface.
4. Insert the valve into the valve guide.
5. Hand lap the valve and the valve seat with
a lapping cup. This will provide optimum
valve and valve seat contact for effective
gas sealing.
6. Check that the valve contact width is
correct.
7. Check that the valve seat insert surface is
in contact with the entire circumference of
the valve.
SM7504
SM7505
SM7506
W5-4-6
EX255-EX285

VALVE SPRING
Valve Spring Free Length
Use a vernier caliper to measure the valve
spring free length.
If the measured value is less than the specified
limit, the valve spring must be replaced.
mm (in)
Exhaust and
Intake Valve
Spring Free
Length
Color
Standard
Limit
blue
60.6
(2.39)
58.0
(2.28)
SM7507
Painted portion
SM7508
Valve Spring Inclination

Use a surface plate and a square to measure
the valve spring inclination.
If the measured value exceeds the specified
mm (in)
Valve Spring
Inclination
Standard
Limit
less than
1.9 (0.075)
2.7
(0.106)
SM7509
Valve Spring Tension

Use a spring tester to measure the valve spring
tension.
N (kg/Ib)
Set Length
Standard
Limit
44.5 mm
(1.75 in)
142
(14.5/30.9)
127
(13.0/28.7)
SM7510
EX255-EX285
W5-4-7

TAPPET
Inspect the tappets for excessive wear, damage and any abnormalities.
Pitted
Crack
Normal contact
Irregular contact
SM7511
Use a micrometer to measure the tappet diameter.

mm (in)
Tappet
Diameter
Standard
Limit
27.97-27.98
(1.1020-1.1024)
27.92
(1.1000)
SM7512
Use a dial indicator to measure the clearance

between the tappet and cylinder body tappet
travelling bore.
mm (in)
Standard
Tappet and Tappet
Travelling Bore
Clearance
Limit
0.020-0.054
0.1
(0.001-0.002) (0.004)
SM7513
W5-4-8
EX255-EX285

ROCKER ARM SHAFT AND ROCKER
ARM
Inspect all disassembled parts for wear, damage and any abnormalities.
SM7516
Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm
outside diameter.
limit, the shaft must be replaced.
mm (in)
Standard
Rocker Arm Shaft
Diameter
Limit
18.98-19.00
18.85
(0.747-0.748) (0.742)
SM7517
Rocker Arm Shaft and Rocker Arm Clearance

1. Use a vernier caliper to measure the rocker
arm bushing inside diameter.
mm (in)
Rocker Arm
Bushing
Inside Diameter
Standard
Limit
19.01-19.03
(0.749-0.750)
19.05
(0.751)
2. Measure the rocker arm shaft outside diameter. Replace either the rocker arm or
the rocker arm shaft if the clearance exceeds the specified limit.
SM7518
mm (in)
Standard
Limit
Rocker Arm
Bushing and
0.01-0.05
0.2
Rocker Arm
(0.0004-0.0020) (0.0079)
Shaft Clearance
3. Check that the rocker arm oil port is free of
obstructions. If necessary, use compressed air to clean the rocker arm oil port.
SM7519
EX255-EX285
W5-4-9

Rocker Arm Correction
Inspect the rocker arm valve stem contact
surfaces for ridge (1) and scoring (2).
If the surfaces have light ridge or scoring, they
may be honed with an oil stone. If the ridge or
scoring is severe, the rocker arm must be
replaced.
SM7515
PUSH ROD
Use a filler gauge to measure the valve push
rod run out. Roll the push rod along a smooth
flat surface (illustration).
mm (in)
Limit
Push Rod Run-Out
0.3 (0.012)
SM7514
IDLER GEAR AND IDLER GEAR

SHAFT
1. Use a micrometer to measure the idler gear
shaft outside diameter. If measured diameter exceeds specified limit, replace the
idler gear shaft.
mm (in)
Standard
Idler Gear Shaft 44.945-44.975
Outside Diameter (1.769-1.771)
Limit
44.9
(1.768)
SM7520
2. Use a dial indicator to measure the idler

gear inside diameter.
mm (in)
Idler Gear
and Idler
Gear Shaft
Clearance
Standard
Limit
0.025-0.085
(0.001-0.003)
0.2
(0.008)
SM7521
W5-4-10
EX255-EX285

CAMSHAFT
1. Use the camshaft bearing remover and
installer to remove camshaft bearing from
the cylinder body.
Camshaft Bearing Remover and Installer:
9-8523-1818-0
2. Measure the clearance between the cam
journal and the camshaft bearing.
mm (in)
Standard
Remover and installer

SM7522
Limit
Cam Journal
and Cam
0.03-0.09
Bearing Clearance (0.001-0.004)
0.15
(0.006)
Cam bearing
SM7523
3. Align the camshaft bearing oil holes with

the mating oil ports (machined on the
cylinder body camshaft bearing fitting
bore).
Align oil ports
SM7524
4. Use a micrometer to measure the cam lobe

height. If the cam lobe height is less than
the specified limit, the camshaft must be
replaced.
mm (in)
Standard
Limit
Cam Lobe
Height (C-D)
7.71 (0.304) 7.21 (0.284)
Cam Journal
Diameter
55.94-55.97
(2.202-2.204) 55.6 (2.189)
SM7525
5. Place the camshaft on a measuring stand.

Use a dial indicator to measure the camshaft runout. Note the total indicator reading (TIR). If the measured run-out exceeds
the specified limit, the camshaft must be
replaced.
mm (in)
Limit
Camshaft Run-Out TIR
0.12 (0.005)
SM7526
EX255-EX285
W5-4-11

CYLINDER BODY AND LINER
Cylinder Liner Bore Measurement
Use a cylinder indicator to measure the cylinder liner bore at measuring position (1) in line
with the crankshaft (2) and across the crankshaft (3).
Measuring Point (1) mm (in): 20.0 (0.79) (Maximum Wear Portion)
If the measured value exceeds the specified
limit, the cylinder liner must be replaced.
mm (in)
Standard
Cylinder Liner
Bore
Total Indicator
Reading
SM7527
Limit
105.021-105.060 105.20
(4.1347-4.1362) (4.1417)
NOTE: The inside of the dry type cylinder liner

is chrome plated. It cannot be rebored or
honed.
If the inside of the cylinder liner is scored or
scorched, the cylinder liner must be replaced.
Cylinder Liner Projection Inspection
1. Hold a straight edge (1) along the top edge
of the cylinder liner to be measured.
2. Use a feeler gauge (2) to measure each
cylinder liner projection.
SM7528
mm (in)
Standard
Cylinder Liner
Projection
0.03-0.10 (0.001-0.004)
The difference in the cylinder liner projection

height between any two adjacent cylinders
must not exceed 0.03 mm (0.001 in).
Cylinder Liner Replacement
REMOVAL
1. Set the cylinder liner remover to the cylinder liner.
2. Check that the remover shaft ankle is
firmly gripping the cylinder liner bottom
edge.
3. Slowly turn the remover shaft handle
counterclockwise to pull the cylinder liner
free.
Cylinder Liner Remover: 9-8523-1169-0
Cylinder Liner Remover Ankle:
5-8523-1004-0
NOTE: Take care not to damage the cylinder
body upper face during the cylinder liner removal procedure.
SM7529
Remover
SM7530
W5-4-12
EX255-EX285

CYLINDER LINER GRADE SELECTION
The term grade refers to the cylinder body
inside diameter and the cylinder liner outside
diameter combination.
Measure the cylinder body inside diameter and
select the appropriate cylinder liner grade.
Loose fitting cylinder liners (the liner is too
small for the cylinder bore) will adversely affect
engine cooling efficiency and may lead to
serious engine damage.
Cylinder liners which are too large for the
cylinder bore will be difficult to install.
Cylinder Body Inside Diameter Measurement
1. Take measurements at measuring point
(1) across the positions W-W, X-X, Y-Y,
and Z-Z.
Measuring Point (1): 115 mm (4.531 in)
2. Calculate the average value of the four
measurements to determine the correct
cylinder liner grade.
Cylinder Bore and Cylinder Liner Outside Diameter Combinations

(Reference)
mm (in)
Grade
Cylinder Bore
SM7531
SM7532
Cylinder Liner
Outside Diameter
107.001-107.010 107.011-107.020
(4.2126-4.2130) (4.2130-4.2134)
107.011-107.020 107 .021-107.030

(4.2130-4.2134) (4.2134-4.2138)
107.021-107.030 107 .031-107.040

(4.2134-4.2138 ) (4.2138-4.2142 )
SM7533
Cylinder Liner Outside Diameter Measurement

1. Take measurements at measuring point
(1), (2), and (3).
Measuring Points mm (in):
(1) 20.0 (0.788)
(2) 105.0 (4.137)
(3) 195.0 (7.683)
2. Calculate the average value of the 6 measurements to determine the correct cylinder
liner grade.
mm (in)
Cylinder Liner Fitting
Clearance Standard
0.001-0.019
(0.00004-0.0007)
SM7534
EX255-EX285
W5-4-13

INSTALLATION
1. Carefully wipe away any foreign material
from the cylinder liner inside and outside
surfaces and the cylinder bore.
2. Use new kerosene or diesel oil to thoroughly clean the cylinder liner and bore
surfaces.
3. Use a clean rag to remove all traces of
kerosene or diesel oil from the cylinder liner
and bore surfaces.
4. Insert the cylinder liner (1) into the cylinder

body (2) from the top of the cylinder body.
5. Set the cylinder liner installer (3) to the top
of the cylinder liner.
Cylinder Liner Installer: 5-8522-1018-0
6. Position the cylinder body so that the
installer center (3) is directly beneath the
bench press shaft center (4).
7. Check that the cylinder liner is set perpendicular to the cylinder.
Check that the cylinder liner does not
wobble.
8. Use the bench press to apply an initial
seating force of 5 kN (500 kgf/1,102 lb) to
the cylinder liner.
9. Use the bench press to apply a final seating force of 25 kN (2,500 kgf/5,512 lb) to
fully seat the cylinder liner.
10. After installing the cylinder liner, measure
the cylinder liner projection.
Refer to Cylinder Liner Projection Inspection.
PISTON GRADE SELECTION

The term piston grade refers to the piston
diameter and cylinder liner bore combination.
Selection of the proper piston grade will ensure
efficient engine operation, free from cylinder
liner and piston problems.
SM7531
SM7532
W5-4-14
EX255-EX285

Cylinder Liner Bore Measurement
1. Locate the two measuring points.
Cylinder Liner Measuring Point (1): 20 mm
(0.788 in)
Cylinder Liner Measuring Point (2): 105
mm (4.173 in)
2. Measure the cylinder liner bore at measuring point (1) and (2) in four different directions (W-W, X-X, Y-Y, and Z-Z).
3. Calculate the average value of the eight
measurements.
mm (in)
Cylinder Liner Bore
Total Indicator Reading
105.021-105.060
(4.1347-4.1362)
SM7533
Relation between liner bore and piston grade

mm (in)
Liner Bore Diameter
Piston Grade
105.021-105.040
( 4.1347-4.1354)
AX
105.041-105.060
(4.1355-4.1362)
CX
NOTE: It is most important that the correct

piston grade be used. Failure to select the
correct piston grade will result in piston seizure.
Always measure the cylinder bore and select
the appropriate piston grade.
Piston Outside Diameter

Measure the piston outside diameter at the
measuring piston shown in the illustration.
Piston Grade (For service parts)
mm (in)
AX
CX
104.959-104.974
(4.1322-4.1328)
104.975-104.990
(4.1329-4.1335)
SM7533
Cylinder Liner Bore and Piston Clearance

mm (in)
Cylinder Liner Bore and
Piston Clearance
0.051-0.085
(0.002-0.0033)
Piston Selection
Select the same grade number as the one for
the cylinder liner inside diameter.
NOTE: Cylinder liner piston kit clearances are
preset. However, the cylinder liner installation
procedure may result in slight decreases in
cylinder liner bore clearances.
Grade of
cylinder inside
diameter
Grade of
piston
Combination
AX
CX
AX
CX
AX
CX
CX
AX
OK
OK
NG
NG
EX255-EX285
W5-4-15

PISTON AND PISTON RING
Piston Ring and Piston Ring Groove Clearance
Use a feeler gauge to measure the clearance
between the piston ring and the piston ring
groove. Do this at several points around the
piston. If the clearance between the piston ring
and the piston ring groove exceeds the specified limit, the piston ring must be replaced.
mm (in)
Standard
Limit
SM7539
st
1 Compression
Ring
2nd Compression
0.070-0.110
0.15
Ring
(0.0028-0.0043) (0.0059)
3rd Compression
0.050-0.090
0.15
Ring
(0.0020-0.0035) (0.0059)
Oil Ring
0.030-0.070
(0.12-0.28)
0.15
(0.0059)
Piston Ring Gap

1. Insert the piston ring horizontally (in the
position it would assume if it were installed
to the piston) into the cylinder liner.
2. Use an inverted piston to push the piston
ring into the cylinder liner until it reaches
either measuring point (1) or measuring
point (2). Cylinder liner diameter is the
smallest at these two points.
Do not allow the piston ring to slant to one
side or the other. It must be perfectly
horizontal.
Cylinder Liner Measuring Point (1):
10 mm (0.39 in)
Cylinder Liner Measuring Point (2):
130 mm (5.12 in)
3. Use a feeler gauge to measure the piston
ring gap. If the measured value exceeds
the specified limit, the piston ring must be
replaced.
SM7540
SM7541
mm (in)
Standard
st
Limit
1 Compression
Ring
0.35-0.50
(0.014-0.020)
2nd Compression
Ring
0.60-0.75
(0.0236-0.0295)
3rd Compression
Ring
0.60-0.75
(0.059)
(0.0236-0.0295)
Oil Ring
0.30-0.50
(0.014-0.020)
1.5
W5-4-16
EX255-EX285

PISTON PIN
Piston Pin Outside Diameter
Use a micrometer to measure the piston pin
outside diameter at several points. If the measured piston pin outside diameter exceeds the
specified limit, the piston pin must be replace.
mm (in)
Piston Pin
Outside
Diameter
Standard
Limit
35.000-35.005
(1.3780-1.3781)
34.95
(1.3760)
SM7542
Piston Pin and Piston Clearance

Use an inside dial indicator to measure the
piston pin hole.
mm (in)
Standard
Piston Pin Hole
Diameter
35.015-35.023
(1.3785-1.3789)
SM7543
Determine the clearance between the piston

pin and the piston pin hole by calculating the
difference between the piston pin hole diameter and the piston pin outside diameter.
mm (in)
Standard
Piston Pin
and Piston
Pin Hole
Clearance
Limit
0.010-0.023
0.050
(0.00039-0.0009) (0.00197)
SM7544
If an inside dial indicator is not available, use

the following procedure to check the piston pin
fit.
1. Use a piston heater to heat the piston to
approximately 60 C (140 F).
2. Push strongly against the piston pin with
your thumbs. The piston pin fitting should
feel tight.
SM7545
EX255-EX285
W5-4-17

CONNECTING ROD
Connecting Rod Alignment
Use a connecting rod aligner to measure the
connecting rods twist distortion and
parralelism between the rods large and small
ends.
If the measured value exceeds the limit, replace the connecting rod.
Connecting Rod Alignment
(Per Length of 100 mm (3.94 in))
Standard
Twist, Parallelism 0.05 (0.002)
or less
mm (in)
Limit
0.20
(0.0079)
SM7546
Piston Pin and Connecting Rod Small End

Bushing Clearance
Use a caliper calibrator and a micrometer to
measure the piston pin and connecting rod
small end bushing clearance.
If the clearance between the piston pin and the
connecting rod small end bushing exceeds the
specified limit, replace either the piston pin or
the connecting rod bushing.
mm (in)
Standard
Limit
Piston Pin and

Connecting
0.012-0.025
0.05
Rod Small End
(0.00047-0.00098)
(0.00197)
Bushing
Clearance
Connecting Rod Bushing Replacement

REMOVAL
1. Clamp the connecting rod in a vise.
2. Use a brass bar and a bench press or
hammer to remove the connecting rod
bushing.
SM7547
W5-4-18
EX255-EX285

INSTALLATION
Use the connecting rod bushing installer to
install the connecting rod bushing.
Connecting Rod Bushing Installer:
9-8523-1369-0 (J-29765)
NOTE: The connecting rod bushing oil port
must be aligned with the connecting rod oil
port.
3. Use a piston pin hole grinder (1) fitted with
a reamer (2) or an adjustable pilot reamer to
ream the piston pin hole.
SM7548
mm (in)
Standard
Connecting Rod Bushing
Inside Diameter
35.017-35.025
(1.3786-1.3789)
SM7549
Connecting Rod Bearing Inspection

1. Fit the connecting rod bearing lower half
into the connecting rod bearing cap.
2. Check the connecting rod bearing lower
half tension. If the tension is insufficient,
the bearing must be replaced.
3. Tighten the connecting rod and the bearing
cap to the specified torque.
Nm (kgfm/ft.lb)
st
Connecting Rod and

Bearing Cap Bolt
Tightening Torque
1 step
2nd step
39
(4/29)
60-90
SM7550
4. Use an inside dial indicator to measure the

connecting rod inside diameter.
mm (in)
Standard
Connecting Rod Bearing
Nominal Diameter
64 (2.520)
SM7551
EX255-EX285
W5-4-19

CRANKSHAFT
Crankshaft and Bearing Inspection
1. Inspect the crankshaft journal surfaces
and the crank pin surfaces for excessive
wear and damage.
2. Inspect the oil seal fitting surfaces of the
crankshaft front and rear ends for excessive wear and damage.
3. Replace or repair the crankshaft if any
excessive wear or damage is discovered.
4. Inspect the crankshaft oil ports for obstructions.
5. Use high pressure air to clean the oil ports
if necessary.
Crankshaft Journal and Crankpin Outside
Diameter
1. Use a micrometer to measure the crankshaft journal outside diameter across
points (1) - (1) and (2) - (2).
2. Use the micrometer to measure the crankshaft journal outside diameter at the two
points (3) and (4).
3. Repeat steps 1. and 2. to measure the
crankpin outside diameter.
mm (in)
Position at
Center
Crankshaft Bearing Only
Journal
Other
Diameter
Bearings
Standard
79.905-79.925
(3.1459-3.1467)
79.919-79.939
(3.1464-3.1472)
mm (in)
Standard
Crankpin Diameter
63.924-63.944
(2.5167-2. 517 5)
4. Measure the crankshaft journal outside

diameter (and/or the crankpin outside diameter) and the bearing inside diameters
to determine the bearing clearance.
Crankshaft Journal and Bearing Clearances
If the bearing clearance exceeds the specified
limit, the bearing must be replaced.
mm (in)
Position at
Crankshaft
Journal
and Main
Bearing
Clearance
Center
Bearing
Only
Other
Bearings
Standard
Limit
0,039-0.098
(0.0015-0.0039)
0.025-0.084
(0.0010-0.0033)
0.11
(0.0043)
Crankpin and Bearing Clearance

mm (in)
Standard
Limit
Crankpin and
0.03-0.073
0.10
Connecting Rod
(0.0012-0.0029)
(0.0039)
Bearing Clearance
SM7552
W5-4-20
EX255-EX285

Crankshaft Journal Bearing Inside Diameter
1. Install the main bearing cap with bearings
to the cylinder body with the specified
torque and facing the arrow mark on the
bearing cap toward front. Place them in
order of punched cylinder numbers.
2. Use an inside dial indicator to measure the
main bearing diameters.
Nm (kgfm/ft.lb)
Main Bearing Cap
Torque
226 - 245
(23 - 25/160 - 181)
SM7553
mm (in)
Main Bearing Nominal
Diameter
80
(3.149)
Crankshaft Run-Out
1. Mount the crankshaft on a set of V-blocks.
2. Set a dial indicator to the center of the
crankshaft journal.
3. Gently turn the crankshaft in the normal
direction of engine rotation.
Read the dial indicator (TIR) as you turn the
crankshaft.
If the measured value exceeds the specified limit, the crankshaft must be replaced.
mm (in)
Crankshaft
Run-Out
Standard
Limit
0.05 (0.002)
or less
0.40 (0.016)
SM7554
If the crankshaft generated a crack after repair,

replace the crankshaft.
Crankshaft can not be bench pressed, because it is finished with tufftride method.
Main Bearing and Connecting Rod Bearing

Tension
Check to see if the bearing has enough tension, so that good finger pressure is needed to
fit the bearing into position.
SM7550
EX255-EX285
W5-4-21

Plastigage Clearance Measurements
This is another method to measure the crank
journal bearing clearance.
CRANKSHAFT JOURNAL BEARING CLEARANCE

1. Clean the cylinder body, the journal bearing
fitting portions, the bearing cap, and the
inside the outside surfaces of the bearing.
2. Install the new journal bearing to the cylinder body.
3. Carefully place the crankshaft on the bearing.
4. Rotate the crankshaft approximately 30 to
seat the bearing.
5. Place the Plastigage (arrow) over the
crankshaft journal across the full width of
the bearing.
Apply engine oil to the Plastigage to keep
it from falling.
6. Install the bearing cap with the bearing.
7. Tighten the bearing cap to the specified
torque.
Do not allow the crankshaft to turn during
bearing cap installation and tightening.
8. Remove the bearing cap.
9. Compare the width of the plastigage attached to either the crankshaft or the bearing against the scale printed on the
plastigage container.
If the measured value exceeds the limit,
perform the following additional steps.
1) Use a micrometer to measure the crankshaft outside diameter.
2) Use an inside dial indicator to measure
the bearing inside diameter.
3) Replace the crankshaft and/or the bearing if the measured values) exceed the
limit.
SM7555
SM7556
SM7557
W5-4-22
EX255-EX285

CRANKPIN BEARING CLEARANCE
1. Clean the crankshaft, the connecting rod,
the bearing cap, and the bearings.
2. Install the bearing to the connecting rod.
Do not allow the crankshaft to move when
installing the bearing cap.
3. Hold the connecting rod (with the bearing
installed) against the crankpin.
4. Attach the plastigage to the crankpin.
Apply engine oil to the plastigage to keep
it from falling.
5. Install the connecting rod bearing cap and
tighten it to the specified torque.
Do not allow the connecting rod to move
when installing and tightening the bearing
cap.
6. Remove the bearing cap.
7. Compare the width of the plastigage attached to either the crankshaft or the bearing against the scale printed on the
plastigage container.
If the measured value exceeds the limit,
perform the following additional steps.
1) Use a micrometer to measure the crankpin outside diameter.
2) Use an inside dial indicator to measure
the bearing inside diameter.
3) Replace the crankshaft and/or the bearing if the measured values) exceed the
limit.
EX255-EX285
W5-4-23

Crankshaft Regrinding
NOTE: Crankshaft can not be reground because it is finished with TUFFTRIDE method.
For the crankshaft on this engine no attempt
should be made to grind finish the faces of the
journals and crankpins as they are
TUFFTRIDED (Special hardening treatment).
Therefore, the undersize bearings are not prepared.
Crankshaft Tufftriding
INSPECTION
1. Use an organic cleaner to thoroughly clean
the crankshaft. There must be no traces of
oil on the surfaces to be inspected.
2. Prepare a 10% solution of ammonium
cuprous chloride (dissolved in distilled
water).
3. Use a spot glass rod to apply the solution
to the surface to be inspected.
Hold the surface to be inspected perfectly
horizontal to prevent the solution from
running.
NOTE: Do not allow the solution to come in
contact with the oil ports and their surrounding
area.
JUDGEMENT
1. Wait for thirty to forty seconds.
If there is no discoloration after thirty or
forty seconds, the crankshaft is usable.
If discoloration appears (the surface being
tested will become the color of copper), the
crankshaft must be replaced.
2. Clean the surface being tested with clean
water of steam immediately after completing the test.
NOTE: The ammonium cuprous chloride solution is highly corrosive. Because of this, it is
imperative that the surfaces being tested be
cleaned immediately after completing the test.
Ammonium cuprous
chloride
Test liquid should

not be applied to
area around oil port
Face in contact with

crank pin or journal
SM7558
W5-4-24
EX255-EX285

Crankshaft Gear
INSPECTION
Visually inspect the crankshaft gear.
Replace the crankshaft gear if excessive wear
or damage is discovered.
REMOVAL
Use the crankshaft gear remover to remove the
crankshaft gear.
Crankshaft Gear Remover: 9-8521-0141-0
Remover
SM7559
INSTALLATION
Use the crankshaft gear installer to install the
crankshaft gear.
Crankshaft Gear Installer: 9-8522-0033-0
Installer
SM7560
EX255-EX285
W5-4-25

FLYWHEEL AND FLYWHEEL HOUSING
Ring Gear Inspection
Inspect the ring gear.
If the ring gear teeth are broken or excessively
worn, the ring gear must be replaced.
Ring Gear Replacement
REMOVAL
Strike around the edges of the ring gear with a
hammer and chisel to remove it.
INSTALLATION
1. Heat the ring gear evenly with a gas-burner
to invite thermal expansion. Do not allow
the temperature of the ring gear to exceed
200 C (390 F).
2. Use a hammer to install the ring gear when
it is sufficiently heated.
SM7561
SM7562
TIMING GEAR CASE COVER

Crankshaft Front Oil Seal Replacement
REMOVAL
Use an adapter and a hammer to remove the
crankshaft front end oil seal.
INSTALLATION
Use the crankshaft front oil seal installer to
install the crankshaft front oil seal.
Crankshaft Front Oil Seal Installer:
9-8522-0034-0
SM7563
W5-4-26
EX255-EX285

NOTE
EX255-EX285
W5-5-1
ENGINE REASSEMBLY
PISTON AND CONNECTING ROD
SM7564
Reassembly Steps
1. Piston
2. Connecting-rod
3. Piston pin, Snap ring
4.
5.
Piston ring
W5-5-2
EX255-EX285
ENGINE REASSEMBLY
1. Piston
Use a piston heater to heat the pistons to
approximately 60 C (140 F).
Conventional
piston heater
2. Connecting Rod
1) Install the connecting rod to the piston
with setting the marks as illustrated.
2) Install the piston pin into the piston and
the connecting rod bushing.
Refer the description of piston pin in
page W5-4-16.
3. Piston Pin, Snap Ring

1) Use a pair of snap ring pliers to install
the piston pin snap ring.
2) Check that the piston moves smoothly
on the piston pin.
4. Piston Ring
1) Use a piston ring installer to install the
three piston rings.
Piston Ring Installer
Install the piston rings in the following
order.
(1) Oil ring
(2) 3rd compression ring
(3) 2nd compression ring
(4) 1st compression ring
The marked side of the three compression rings must be facing up.
rd
The undercut side of the 3 compression ring will be facing down.
As the oil ring has no any facing mark,
it may face in either direction.
2) Lubricate the piston ring surfaces with
engine oil.
3) Check that the piston rings rotate
smoothly in the piston ring grooves.
SM7565
Piston head
Front mark
()
Put cylinder
number
marked side in
this position
SM7566
SM7489
5. Connecting Rod Bearing

1) Install the connecting rod bearings to
the connecting rod large-end and the
connecting rod cap.
2) Install the bearing cap to the connecting
rod with semi-tightening the cap bolts.
3) Lubricate the bearing with engine oil.
Marked side up
1st comp
2nd comp
3rd comp
Oil
SM7567
EX255-EX285
W5-5-3
ENGINE REASSEMBLY
CYLINDER HEAD
* : Repair kit
SM7568
Reassembly Steps
1. Valve stem oil seal
2. Intake and exhaust valves
3. Spring seat (Lower)
4. Intake and exhaust valve springs
5. Spring seat (Upper) or valve rotator
6. Spring seat split collar
7.
8.
9.
10.
11.
Thermostat housing and gasket

Thermostat
Water outlet pipe
Intake manifold and gasket
Exhaust manifold and gasket
W5-5-4
EX255-EX285
ENGINE REASSEMBLY
Installer
1. Valve Stem Oil Seal

1) Lubricate the oil seals and valve stem
sealing areas with engine oil.
2) Use a valve stem oil seal installer to
install the oil seal.
Valve Stem Oil Seal Installer:
1-85221-005-0
SM7569
2. Intake and Exhaust Valves

1) Place the cylinder head on a flat wooden
surface.
2) Lubricate valve stems with engine oil.
3) Install the valves to the intake or exhaust guides.
Install the valves to their original lapped
valve seats.
SM7570
4. Intake and Exhaust Valve Springs

Install the valve springs with their painted
end (the close pitched end) facing down.
Painted portion
SM7508
6. Spring Seat Split Collar

1) Use a spring compressor to push the
valve spring into position.
2) Install the spring seat split collar.
Set the spring seat split collar by tapping lightly around the head of the collar
with a rubber hammer.
Spring Compressor: 1-85235-006-0
Spring compressor
SM7485
SM7571
EX255-EX285
W5-5-5
ENGINE REASSEMBLY
10. Intake Manifold and Gasket
1) Install the intake manifold gasket.
The intake manifold gasket must be
installed with its unchamfered corner
facing up and to the front of the engine.
2) Install the intake manifold.
3) Tighten the intake manifold bolts to the
specified torque a little at a time in the
numerical order shown in the illustration.
Unchamfered corner
Rear
SM7572
Nm (kgfm/Ib.ft)
Intake Monifold
Bolt Torque
21-30 (2.1-3.1/15-22)
SM7573
11. Exhaust Manifold and Gasket

1) Install the exhaust manifold gasket.
The TOP mark must be facing up.
2) Install the exhaust manifold.
3) Tighten the exhaust manifold bolts to
the specified torque a little at a time in
the numerical order shown in the illustration.
TOP
SM7574
Nm (kgfm/Ib.ft)
Exhaust Manifold
Bolt Torque
25-31 (2.6-3.2/19-23)
SM7575
4) Install either end of the distance tube to

the spot facing.
Distance tube
Spot facing
SM7576
W5-5-6
EX255-EX285
ENGINE REASSEMBLY
ROCKER ARM AND ROCKER ARM SHAFT
SM7577
Reassembly Steps
1. Rocker arm shaft
2. Spring
3. Rocker arm
4. Bracket
Important Operation
1. Rocker Arm Shaft
The rocker arm shaft must be installed with the oil
ports facing up.
EX255-EX285
W5-5-7
ENGINE REASSEMBLY
MAJOR COMPONENT
* : Repair kit
SM7578
Reassembly Steps-I
1. Oil jet
2. Crankshaft bearing (upper half)
3. Crankshaft
4. Thrust bearing
5. Crankshaft bearing (lower half) and crankshaft
bearing cap
6. Timing gear case
* 7. Tappet
8. Camshaft
9.
10.
11.
12.
13.
14.
15.
16.
*
Idler gear shaft

Idler gear
Piston and connecting rod
Oil pump and coupling
Flywheel housing
Rear oil seal
Oil pan
Oil cooler
The tappet must be installed before the camshaft installation.
W5-5-8
EX255-EX285
ENGINE REASSEMBLY
1. Oil Jet
Install the oil jets taking care not to damage
the oil jet nozzles.
Nm (kgfm/lb.ft)
Oil Jet Torque
16-25 (1.6-2.6/12-19)
2. Crankshaft Bearing (Upper Half)

5. Crankshaft Bearing (Lower Half) and
Crankshaft Bearing Cap
The Crankshaft Bearing Configuration
With Oil
Groove
Without Oil
Groove
Bearing
Upper Half
All Upper
Halves
Bearing
Lower Half
SM7579
With oil hole and

groove (upper)
Fit correctly
All Lower
Halves
Take care not to misinstall the bearing halves.
No oil groove and

hole (lower)
SM7580
4. Thrust Bearing
Install the thrust bearings with the oil
groove side facing the crankshaft sliding
face.
Oil groove side

SM7581
5. Crankshaft Bearing Cap

1) Lubricate the bearing cap bolts with
engine oil.
2) Install the bearing caps to the crankshaft. The arrow mark must be pointing
to the front of the engine.
3) Tighten the bearing cap bolts to the
specified torque a little at a time in the
numerical order shown in the illustration.
Arrow mark (Position

No. punched)
Front
SM7582
EX255-EX285
W5-5-9
ENGINE REASSEMBLY
Nm (kgfm/Ib.ft)
Crankshaft Bearing
Cap Bolt Torque
226-245
(23.0-25.0/166-181)
4) Check that the crankshaft turns

smoothly by manually rotating it.
6. Timing Gear Case
1) Apply liquid gasket to the timing gear
case surfaces contacting the cylinder
body.
2) Tighten the timing gear case bolts to the
specified torque.
Lubricate with engine oil
SM7583
Nm (kgfm/Ib.ft)
Timing Gear Case
Bolt Torque
21-30
(2.1-3.1/15-22)
SM7584
8. Camshaft
Tighten the thrust plate bolts through the
camshaft gear hole.
Nm (kgfm/Ib.ft)
Thrust Plate Bolt
Torque
21-30
(2.1-3.1/15-22)
Nm (kgfm/Ib.ft)
Camshaft Gear Bolt

Torque
142-172
(14.5-17.5/105-127)
Camshaft gear
SM7585
Oil port
9. Idler Gear Shaft

Use the thrust collar fixing bolt as a guide
to install the idler gear shaft.
The oil port must be facing the camshaft.
10. Idler Gear

1) Install the idler gear.
Set the timing marks A and B as shown
in the illustration.
2) Tighten the idler gear bolts seating the
thrust collar to the specified torque.
The thrust collar must be installed with
the chamfered side facing the front of
the engine.
SM7586
Injection pump
gear
Idle gear
Nm (kgfm/Ib.ft)
Idle Gear Bolt
Torque
44-64
(4.5-6.5/33-47)
"C" mark
"B" mark
Camshaft gear
"A" mark
Crankshaft gear
SM7587
W5-5-10
EX255-EX285
ENGINE REASSEMBLY
11. Piston and Connecting Rod
1) Set the piston ring gaps as shown in the
illustration.
2) Lubricate the piston, the piston rings,
and the connecting rod bearings with
engine oil.
3) Position the piston front mark towards
the front of the engine.
4) Use the piston ring compressor to compress the piston rings.

Piston Ring Compressor:
9-8522-1251-0
5) Use a hammer grip to push the piston in
until it makes contact with the crankpin.
At the same time, rotate the crankshaft
until the crankpin reaches its highest
point.
SM7588
Piston ring compressor
Front mark
()
SM7589
6) Set the bearing cap cylinder number

marks and the connecting rod cylinder
number marks.
The marks must be facing the exhaust
manifold.
Cylinder
number
7) Lubricate the connecting rod cap bolt

threads and setting fases with Mos
grease.
8) Use the angular tightening method to
tighten the connecting rod cap bolts to
the specified torque.
SM7590
Nm (kgfm/lb.ft)
st
Connecting Rod
Bolt Torque
and Angle
1 step
2nd step
39
(4/29)
60-90
12. Oil Pump and Coupling

1) Lubricate the oil pump with the specified
grade of engine oil.
2) Install the oil pump with the coupling.
3) Tighten the oil pump bolts to the specified torque.
SM7591
Coupling
Nm (kgfm/Ib.ft)
Oil Pump Bolt
Torque
42-62 (4.3-6.4/31-46)
SM7592
EX255-EX285
W5-5-11
ENGINE REASSEMBLY
13. Flywheel Housing
1) Apply a sealant to the shaded area of the
illustration.
2) Install the flywheel housing.
Tighten the flywheel housing bolts to the
specified torque.
Nm (kgfm/Ib.ft)
147-167
Flywheel Housing Outer Bolt (15.0-17.0/108-123)
Bolt Torque
Inner Bolt
21-30
(2.1-3.1/15-22)
SM7593
14. Rear Oil Seal (Axial Type)

1) Tighten the adapter to the crankshaft
rear end section with 2 bolts.
2) Insert the oil seal into the peripheral
section of adapter.
3) Insert the sleeve into the adapter section, and tighten it with a bolt until the
adapter section hits the sleeve.
4) Remove the adapter and the sleeve.
5) With the seal pressed in, check the
dimension of the oil seal section.
Standard Dimension = 11.6 0.3 mm
(0.457 0.012 in)
Oil Seal Installer:
5-8840-9025-0
11.60.3mm (0.4570.012in)
SM7594
15. Oil Pan

1) Apply sealant to the area indicated by
the arrows in the illustration.
2) Install the oil pan gasket
3) Install the oil pan.
Tighten the oil pan bolts to the specified
torque.
Nm (kgfm/Ib.ft)
Oil Pan Bolt Torque
21-30 (2.1-3.1/15-22)
SM7595
16. Oil Cooler

1) Apply sealant to the oil cooler gasket.
2) Install the oil cooler gasket to the oil
cooler body case.
3) Install the oil cooler.
Tighten the oil cooler bolts to the specified torque.
Start from the middle and work out to
either side.
Refer to the illustration
Nm (kgfm/lb.ft)
Oil Cooler Torque
14-24 (1.4-2.4/10-17)
SM7596
W5-5-12
EX255-EX285
ENGINE REASSEMBLY
* : Repair kit
SM7597
Reassembly Steps-II
1. Flywheel
2. Injection pump and injection pump gear
3. Oil thrower
4. Timing gear cover
5. Crankshaft pulley and dust thrower
6. Taper bushing
7. Crankshaft pulley nut
8. Oil pump driving pinion
9.
10.
11.
12.
13.
14.
15.
16.
Tappet chamber cover

Water pump
Cylinder head
Cylinder head bolt
Push rod
Rocker arm and rocker arm shaft
Rubber hose (Water by-pass)
EX255-EX285
W5-5-13
ENGINE REASSEMBLY
1. Flywheel
1) Lubricate the flywheel bolt threads.
2) Install the flywheel.
The crankshaft rear end dowel pin and
the flywheel dowel hole must be aligned.
3) Tighten the flywheel bolts to the specified torque in the numerical order shown
in the illustration.
Lubricate with
engine oil
Nm (kgfm/lb.ft)
Flywheel
Bolt Torque
197-240(20.1-24.5/145-177)
SM7598
2. Injection Pump and Injection Pump

Gear Assembly
1) Install the injection pump bracket with
the injection pump to the timing gear
case.
Dowel the injection pump bracket with
the timing gear case.
2) Tighten the injection pump bolts to the
specified torque.
Nm (kgfm/Ib.ft)
Injection Pump
Bolt Torque
21 - 30
(2.1 - 3.1/15 - 22)
SM7468
3) Align the injection pump gear C timing

mark with the idler gear C timing mark.
Injection pump
gear
"C" mark
Idle gear
"B" mark
Camshaft gear
"A" mark
Crankshaft gear
SM7587
W5-5-14
EX255-EX285
ENGINE REASSEMBLY
7. Crankshaft Pulley Nut
1) Apply MoS2 to the crankshaft pulley nut
threads and fitting face.
2) Use the appropriate wrench to tighten
the crank shaft pulley nut to the specified torque.
Pulley
Nm (kgfm/Ib.ft)
Crankshaft Pulley
Nut Torque
Wrench
539-637
(55-65/378-470)
SM7474
9. Tappet Chamber Cover

1) Apply sealant (TB 1207B) to the tappet
chamber cover.
2) Install the tappet chamber cover and
tighten the bolts to the specified torque.
Nm (kgfm/lb.ft)
Tappet Chamber
Cover
Bolt Torque
21-30 (2.1 - 3.1/15 - 22)
SM7601
10. Water Pump

Apply sealant (Belco Bond No. 4) to the
water pump gasket before installing the
water pump.
Apply sealant to the

cylinder body side only
SM7602
11. Cylinder Head Gasket

12. Cylinder Head
13. Cylinder Head Bolt
1) Carefully place the cylinder head gasket
on the cylinder body upper surface.
The gasket TOP mark must be facing
up.
2) Align the cylinder body dowels and the
cylinder head dowel holes.
Front, Top mark
Front
SM7603
EX255-EX285
W5-5-15
ENGINE REASSEMBLY
3) Carefully place the cylinder head on the
cylinder body.
4) Apply molybdenum disulfide grease to
the cylinder head bolt threads and setting faces.
5) Use the Angular Tightening Method.
6) Tighten the cylinder head bolt as follows.
1) As cylinder head bolts have two
kinds of length, install them at
proper location.
The shorter ones (6 bolts) must be
used at the injection pump side.
2) Follow the numerical sequence
shown in the illustration.
Front
SM7604
Nm (kgfm/lb.ft)
Bolt
Torque
1st step
2nd step
3rd step
69
(7.0/51)
88
(9.0/65)
90-120
15. Rocker Arm and Rocker Arm Shaft

1) Check that the rocker arm shaft bracket
lower surface oil port is free from obstruction.
2) Install the rocker arm shaft with the
bracket to the cylinder head.
3) Tighten the rocker arm bracket bolts to
the numerical order shown in the illustration.
4) Lubricate the rocker arm and the rocker
arm shaft with engine oil.
Nm (kgfm/Ib.ft)
Rocker Arm Shaft
Bracket Bolt and
Nut Torque
25-35 (2.6-3.6/19-26)
5) Adjust the valve clearance.

Refer to MAINTENANCE for the valve
clearance adjustment procedure.
SM7605
W5-5-16
EX255-EX285
ENGINE REASSEMBLY
EXTERNAL PARTS
SM7606
Left-hand Side Reassembly Steps

1. Cylinder head cover
2. Fan pulley
3. Alternator
4. Fan belt
5. Starter
6. Turbocharger mounting flange gasket.
7. Turbocharger
8. Oil drain pipe
9. Oil feed pipe
10. Air breather
11. Dipstick and guide tube
EX255-EX285
W5-5-17
ENGINE REASSEMBLY
1. Cylinder Head Cover
1) Check that the rocker arms, the rocker
arm shafts, and the valve springs are
thoroughly lubricated with engine oil.
If required, relubricate these parts.
2) Place the cylinder head cover gasket on
the cylinder head cover.
Check the head cover gasket for looseness.
3) Tighten the cylinder head cover bolts to
the sequence shown in the illustration.
SM7607
Nm (kgfm/lb.ft)
Cylinder Head
Cover
Bolt Torque
7.8 - 9.8
(0.8 - 1.0/5.8 - 7.2)
4. Fan Belt
Adjust the fan belt tension.
Refer to MAINTENANCE for the fan belt
tension adjustment.
5. Starter
Install the starter to the flywheel housing
and tighten the bolts to the specified
torque.
Nm (kgfm/lb.ft)
Starter Fixing
Bolts
Torque
75 - 91
(7.6 - 9.3/55 - 67)
SM7608
6. Turbocharger Mounting Flange Gasket

Carefully position the gasket with the
edged side facing up.
SM7609
W5-5-18
EX255-EX285
ENGINE REASSEMBLY
7. Turbocharger
Semitighten the turbocharger mounting
nuts.
The nuts will be fully tightened after installation of the oil pipes.
Nm (kgfm/lb.ft)
Turbocharger Mounting
Nut Torque
42-62
(4.3-6.3/31-46)
SM7610
8. Oil Drain Pipe

1) Remove the exhaust manifold distance
tube immediately beneath the turbocharger.
This will make it easier to install the oil
drain pipe.
2) Install the oil drain pipe and tighten the
oil drain pipe flange nuts to the specified
torque.
Distance tube
Nm (kgfm/lb.ft)
Oil Drain Pipe
Torque
28 - 46
(2.9 - 4.7/21 - 34)
SM7611
3) Reinstall the exhaust manifold distance

tube and tighten it to the specified
torque.
Exhaust manifold nut torque is shown in
the page W5-5-5.
9. Oil Feed Pipe

1) Pre-lubricate the turbocharger with CD
grade oil through the oil port shown by
the arrow in the illustration.
2) Install the oil feed pipe and tighten the
pipe flange bolts to the specified torque.
Nm (kgfm/lb.ft)
Oil Feed Pipe Flange
Bolt Torque
16 - 25
(1.6 - 2.6/12 - 19)
SM7612
EX255-EX285
W5-5-19
ENGINE REASSEMBLY
SM7613
Right-hand Side Reassembly Steps

1. Glow plug
2. Injection nozzle
3. Injection pipe and fuel leak off pipe
4. Oil filter
5. Oil pipe; filter to cooler
6. Not installed
7. Oil pipe; injection pump to engine body
8. Fuel filter
9.
10.
11.
12.
13.
14.
Fuel pipe; feed pump to fuel filter

Fuel pipe; fuel filter to injection pump
Fuel return pipe
Air duct
Not installed
Cooling fan
W5-5-20
EX255-EX285
ENGINE REASSEMBLY
Important Operation
2. Injection Nozzle
Install the injection nozzles with the injection nozzle gaskets.
Be careful not to damage the nozzle tips.
Dust cover
Nm (kgfm/lb.ft)
Injection Nozzle
Bolt Torque
17 - 21
(1.7 - 2.1/12 - 15)
Nozzle gasket
SM7614
3. Injection Pipe and Fuel Leak Off Pipe

1) Install the fuel injection pipes (1) and
tighten the bolts to the specified torque.
Nm (kgfm/lb.ft)
Injection Pipe
Torque
28 - 32
(2.9 - 3.3/21 - 24)
2) Carefully position and set the clips (2).

It is very important that each clip be
positioned correctly.
An improperly positioned clip will result
in objectionable fuel pulsing noise and
injection pipe breakage.
3) Install the fuel leak off pipes (3) .
4. Oil filter
(When the oil filter is being removed in
an oil filter assembly with the filter
cover.)
1) Before the installation, set the special
gaskets which are included within the
repair kit with the oil filter mounting
bolts.
2) Apply a coat of LOCTITE 271 on the bolt
threads to seal the oil leak from the
crankcase.
3) Install the oil filter assembly with tightening the bolts securely.
Nm (kgfm/lb.ft)
Oil Filter Assembly
Mounting Bolt Torque
42-62
(4.3-6.3/31-46)
SM7615
SM7424
EX255-EX285
W5-5-21
ENGINE REASSEMBLY
9. Fuel Pipe (Feed Pump to Fuel Filter)
10. Fuel Pipe (Fuel Filter to Injection Pump)
11. Fuel Return Pipe
Install the fuel pipes and tighten the fuel
pipe joint bolts to the specified torque.
Take care not to interchange the check
valves and joint bolts.
Nm (kgfm/lb.ft)
Fuel Pipe Joint
Bolt Torque
16 - 18
(1.6 - 1.8/12 - 13)
SM7617
12. Air Duct

Install the air duct and tighten the air duct
flange bolts to the specified torque.
Nm (kgfm/lb.ft)
Intake Pipe
Flange Bolt
Torque
21 - 30 (2.1 - 3.1/15 - 22)
SM7618
W5-5-22
EX255-EX285
ENGINE REASSEMBLY
ENGINE TUNING OPERATION
After reassembly, the engine must be tuned.
This will ensure that the engine operates at its
maximum efficiency.
1. Mount the engine on a test bench.
2. Fill the engine with the specified oil.
3. Connect the cooling pipes and the fuel
pipes.
Reference
Starter switch
PREHEAT
OFF
ON
Glow plug
START
Control resistor
0.85 mm2
0.5
Charge
lamp
1.25
Fuse box
Warning lamp
0.85
Ammeter
0.85
Fusible link
1.25
0.5
Relay
Oil pressure
switch
0.85
Starter
Battery
Regulator
Alternator
Condenser
SM7619
4. Connect the electrical wiring. Refer to the

wiring diagram.
5. Connect the air intake line to the air
cleaner.
6. Connect the exhaust pipe.
7. Manually operate the fuel feed pump to
feed fuel to the engine.
8. Bleed the fuel lines of air. Refer to Page
W5-2-5 of Section 2 MAINTENANCE for
the air bleeding procedure.
EX255-EX285
W5-5-23
ENGINE REASSEMBLY
9. Crank the engine with the starter
(non-ignition operation) for about twenty
seconds.
This will prelubricate the engine internal
components.
10. Start the engine and allow it to run at 750 to
800 rpm for five minutes.
11. Remove the cylinder head cover while the
engine is running.
12. Check that the engine oil is continuously
circulating from the oil pump to the valve
rockers through the cylinder head.
If there is no oil circulation or if the oil
circulation is sluggish, stop the engine and
make the appropriate repairs or adjustments.
Reinstall the cylinder head cover.
13. Increase the engine speed to 1,500 rpm to
do the engine warming-up operation.
14. Check the engine for oil, fuel, coolant, and
air intake leakage.
15. Check for abnormal noise and odor.
16. Check for abnormal electrical charging.
17. Check the engine fastening parts for looseness.
18. When the engine coolant temperature
reached to 75 C (167 F) or more, increase
the engine speed to 2,000 rpm and allow it
to run for twenty minutes.
This will give the engine the essential
run-in operating time.
19. Adjust the engine operation speed to the
specified value.
20. Stop the engine to complete the tuning
procedure.
W5-5-24
EX255-EX285
ENGINE REASSEMBLY
NOTE
EX255-EX285
W5-6-1
LUBRICATING SYSTEM
GENERAL DESCRIPTION
Valve opening
pressure 780 kPa
Full flow filter
Oil pressure
and oil filter
warning light
By-pass
valve
Valve opening
pressure 98 kPa
Oil pressure switch

Cylinder body oil gallery
Partial
filter
Valve opening
pressure 440 kPa
Turbocharger
Oiling
jet
Piston
Oil pump
Oil relief
valve
Oil relief
valve
Timing
idle
gear
Cyl. head
valve sys.
Crank Camshaft shaft

brgs. brgs.
Valve opening pressure

196 kPa
Inj.
pump
Oil
cooler
conn. rod
brgs.
Paper
filter
By-pass
valve
Starter
switch Battery
Oil
strainer
Oil pan
SM7620
This family of engines uses a normal forced circulation lubricating system.

The gear type oil pump is driven by the camshaft oil pump drive.
The cartridge (spin-on) type oil filter is used.
W5-6-2
EX255-EX285
LUBRICATING SYSTEM
OIL PUMP
SM7621
Disassembly Steps
1. Strainer
2. Suction pipe
3. Cover and dowel
4. Driven gear
5. Drive shaft and gear
6. Driven gear shaft
EX255-EX285
W5-6-3
LUBRICATING SYSTEM
Inspection and Repair
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Visually inspect the disassembled parts for

excessive wear and damage
OIL PUMP DRIVE GEAR
between the oil pump cover (oil pump case)
inside surface and the drive gear.
If the clearance exceeds the specified limit,
the drive gear and/or the oil pump cover must
be replaced.
mm (in)
Limit
Oil Pump Cover and
Oil Pump
Drive Gear Clearance
SM7622
0.20 (0.0079)
SM7623
OIL PUMP DRIVEN GEAR

between the oil pump case cover inside surface and the driven gear.
If the clearance exceeds the specified limit,
the driven gear or the oil pump cover must be
replaced.
mm (in)
Limit
Oil Pump Body
and Driven
Gear Clearance
0.15 (0.0059)
Reassembly
To assemble, follow the disassembly procedures in reverse order.
SM7624
W5-6-4
EX255-EX285
LUBRICATING SYSTEM
OIL COOLER
SM7625
Disassembly Steps
1. Oil cooler element
2. Element gasket
3. By-pass valve plug
4.
5.
6.
O-ring; plug
By-pass valve spring
By-pass valve

inspection.
EX255-EX285
W5-6-5
LUBRICATING SYSTEM
SM7626
Reassembly Steps
1. By-pass valve
2. By-pass valve spring
3. O-ring; plug
4. By-pass valve plug

5. Element gasket
6. Oil cooler element
Important Operation
6. Oil Cooler Element
Install the oil cooler element to the oil
cooler, and tighten the cooler element fixing nuts to the specified torque.
Nm (kgfm/lb.ft)
Oil Cooler Element
Fixing Nut Torque
14-24 (1.4-2.4/10-17)
SM7627
W5-6-6
EX255-EX285
LUBRICATING SYSTEM
NOTE
EX255-EX285
W5-7-1
COOLING SYSTEM
GENERAL DESCRIPTION
Water outlet pipe

Thermostat
Reserve tank
Radiator
Cylinder head
Cylinder body
Water pump
SM7628
This family of engines uses a pressurized, forced circulation cooling system with a V-belt driven centrifugal water
pump and a wax pellet thermostat with jiggle valve.
W5-7-2
EX255-EX285
COOLING SYSTEM
THERMOSTAT
inspection.
Visually inspect the thermostat function referring Section 2 MAINTENANCE in page W5-2-6.
Thermometer
Agitating rod
Wood piece
SM7438
EX255-EX285
W5-8-1
FUEL SYSTEM
GENERAL DESCRIPTION
Nozzle holder
Fuel filter
Feed pump
Fuel tank
Water sedimentor
Injection pump
SM7629
The fuel system consists of the fuel tank, the water sedimentor, the fuel filter, the injection pump, and the injection
nozzle.
The fuel from the fuel tank passes through the water sedimentor and the fuel filter where water particles and other
foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum
timing for efficient engine operation.
W5-8-2
EX255-EX285
FUEL SYSTEM
INJECTION NOZZLE
SM7630
Disassembly Steps
1. Nozzle holder cap nut
2. Cap nut gasket
3. Nozzle adjusting screw
4. Push rod spring
5. Nozzle holder push rod
6.
7.
8.
9.
10.
Retaining nut
Injection nozzle
Injection pipe connector
Connector gasket
Nozzle holder body
Important Operation
7. Nozzle
Remove the nozzle assembly from the
nozzle body.
Keep the parts separately to maintain the
proper needle valve to body combination.
SM7631
EX255-EX285
W5-8-3
FUEL SYSTEM
inspection.
PUSH ROD SPRING

Check the push rod spring for wear, weakness,
and corrosion.
SM7632
NOZZLE HOLDER PUSH ROD

1. Check the nozzle holder push rod curvature.
2. Check the nozzle holder push rod and
needle valve contact surfaces for excessive wear and poor contact.
SM7633
INJECTION NOZZLE
1. Check the injection nozzle needle valve,
the valve seat, and the injection nozzle
hole for carbon deposits.
If carbon deposits are present, the injection nozzle and the needle valve must be
replaced.
2. Hold the nozzle body vertically.
Pull the needle valve about one-third of the
way out of the nozzle body.
Release the needle valve.
Check that the needle valve falls back into
the nozzle body as far as the valve seat.
If the needle valve does not fall back into
the nozzle body as far as the valve seat,
the injection nozzle and the needle valve
must be replaced.
SM7634
W5-8-4
EX255-EX285
FUEL SYSTEM
SM7635
Reassembly Steps
1. Nozzle holder body
2. Connector gasket
3. Injection pipe connector
4. Injection nozzle
5. Retaining nut
6.
7.
8.
9.
10.
Nozzle holder push rod

Push rod spring
Nozzle adjusting screw
Cap nut gasket
Nozzle holder cap nut
EX255-EX285
W5-8-5
FUEL SYSTEM
Important Operation
1. Injection Pipe Connector
Nm (kgfm/lb.ft)
Nozzle Connector
Torque
49 - 59
(5.0 - 6.0/36 - 43)
SM7636
4. Injection Nozzle
There must be no oil on the contact surfaces of the injection nozzle and the injection nozzle holder.
Clean these contact surfaces with diesel
fuel before installation.
The nozzle dowel pin must be aligned with
the dowel hole in the nozzle holder body.
SM7637
5. Retaining Nut
Nm (kgfm/lb.ft)
Nozzle Retaining
Nut Torque
59 - 78
(6 .0 - 8.0/43 - 58)
SM7638
Injection Starting Pressure Adjustment

The injection nozzle injection starting pressure can be adjusted after the adjusting
screw is installed.
Refer to FUEL SYSTEM on Page W5-2-3
of the MAINTENANCE Section of this
Workshop Manual.
MPa (kgf/cm2/psi)
Injection Starting
Pressure
18.1 (185/2630)
SM7639
10. Nozzle Holder Cap Nut

Nm (kgfm/lb.ft)
Cap Nut Torque
29 - 39
(3.0 - 4.0/22 - 29)
SM7427
W5-8-6
EX255-EX285
FUEL SYSTEM
INJECTION PUMP CALIBRATION DATA
Identification Plate and Product serial number
1. Injection pump adjustment and repair should be
made by the nearest ZEXEL CORPORATION or
ROBERT BOSCH Authorized Service Outlet.
2. When you ask such authorized service outlet the
adjustment or repair, the identification Plate and
Product Serial Number will give them a necessary
clue to get technical data distributed by the manufacturers previously.
Without this data, the Service Outlet will be unable
to effectively service your injection pump.
If you are unable to locate the data applicable to
your injection pump, please contact FIAT
KOBELCO Dealer.
3. Do not remove the Identification Plate and Product
Serial Number from the injection pump.
Keep the Identification Plate and Product Serial
Number clean at all times. Do not allow it to rust or
become illegible.
Pump No.
NP-PE
(LICENCE BOSCH)
Identification Number
SM7423
NOTE: Examples of test conditions and calibration

data are as follows.
Test conditions required for the fuel injection amount adjustment

Injection Nozzle
Injection Nozzle Holder
Injection Starting Pressure
Injection Line Dimensions
Inside Diameter
Outside Diameter
Length
Transfer Pump Pressure
Testing Diesel Fuel
Operating Temperature
Pump Rotation Direction
MPa (kgf/cm2/psi)
mm (in.)
*ZEXEL No.: 105160-5130

Bosch Type No.: NP-DLLA149SM304
ZEXEL No.: 105030-4750
18.1 (185/2630)
LE
P
M
EXA
kPa (kgf/cm2/psi)
C (F)
1.8 (0.071)
6.0 (0.236)
600.0 (23.6)
157 (1.6/23)
ISO4113 or SAE Standard Test Oil (SAEJ967D)
40 - 45 (104 - 113)
Clockwise (Viewed from the drive side)
EX255-EX285
W5-8-7
FUEL SYSTEM
INJ. PUMP CALIBRATION DATA
MOTORE MODELLO 6BG1-T
Injection pump :
PES6AD
000000-0000
Assy No.
Date :
000000-0000
Company :
No.
ISUZU
0-00000-0000
Governor : EP/RSV
000000-0000
Timing device :
1. Test Conditions:
Pump rotation:
clockwise (viewed from drive side)
Nozzle & Nozzle Holder Assy : 000000-0000 (BOSCH Type No. EF8511/9A)
Nozzle: 000000-0000
(BOSCH Type N. DN12SD12T)
Nozzle Holder: 000000-0000

(BOSCH Type N. EF8511/9)
Nozzle opening pressure: 17.2 MPa (175 kgf/cm2)
Pump pressure: 157 kPa (1.6 kgf/cm2)
E
L
P
M
A
X
E
Injection pipe: Outer Dia. 6 mm x Int. Dia. 2 mm - Length 600 mm
Oil Temp. : 40+5 C
Test Oil: ISO4113 or SAE Standard Oil (SAE J967d)
Overflow valve opening pressure: 127 kPa (1.3 kgf/cm2)

2. Injection Timing:
Pre-stroke: No. 1 Plunger 3.6 0.05 mm Note: Adjust with rack position of
Injection order: 1 ____ 5, 1 ____ 3, 1 ____ 6, 1 ____ 2, 1 ____ 4
6030'
12030'
18030'
24030
mm
30030''
(interval:
30')
Plungers are numbered from the Driver side.

Tappet clearance: Bolt adjustment type : More than 0.3 mm for all cylinders.
Shim adjustment type : Manually rotate the camshaft 2 ~ 3 times and confirm that
it rotates smoothly.
4. Injection Quantity :
Adjusting point
Rack
Position
(mm)
Pump
Speed
(min-1)
Injection qty
(cm3/1000 strokes)
Max. var
bet. cyl
(%)
Fixed
10.3
1,075
89.5 1.5
Lever
Approx.
7.4
450
9.5 1.3
14
Rack
100
85 5
Lever
Remarks
Basic
Rack limit
E
L
P
M
A
EX
5. Timing advance specification:
Pump speed
(min-1)
Advance
angle ()
ZEXEL CORPORATION
Service Department 1
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352

Japan
W5-8-8
EX255-EX285
FUEL SYSTEM
3. Governor adjustment
Recommended speed droop adjustment screw position: 12
(notches from fully tightened position)
Above 14.0
13.0
Rack limit
Governor spring setting
9.5
9.10.1
8.5
8.00.1
6.5
6.0
6.030
0
300
14530
475
350
1100
(430)
1130
1210
(1120)
Pump speed (r/min)

SM7640
Speed control lever angle
Stop lever angle
op
St
Norma
l
St
op
Full-speed
Rack position (mm)
Idle-sub spring setting
Idling
Dead point
SM7641
EX255-EX285
W5-9-1
TURBOCHARGER
GENERAL DESCRIPTION
RHG6
SM7642
W5-9-2
EX255-EX285
TURBOCHARGER
TURBOCHARGER IDENTIFICATION
The IHI Turbocharger nameplate gives the date of
manufacture and other important information required
to identify the unit when service inquiries or part orders
are made.
The arrow in the illustration indicates the location of the
Turbocharger nameplate.
SM7643
The turbocharger nameplate has the following information stamped on it. Refer to the illustration at the left.
(1) Turbo Specification Number, Production Year and
Month
(2) Production Date, Daily Serial Number
(3) ISUZU Parts Number
Turbo Spec.
Serial No. RHG6
Parts No.
SM7644
EX255-EX285
W5-9-3
TURBOCHARGER
INSPECTION
AND
REPAIR
If excessive wear or damage is discovered

during inspection, the appropriate parts must
be adjusted, repaired, or replaced. Damage or
improper adjustment of the turbocharger will
inhibit sufficient air flow to the engine, preventing it from delivering full performance.
If the engine demonstrates a significant drop in
performance, check for engine damage or
wear. If no significant engine damage or wear
can be found, it is likely that the turbocharger
is at fault.
When reduced performance is the result of a
faulty turbocharger, contact your nearest FIAT
KOBELCO Dealer for the proper repairs.
The following is primarily a description of the
particularly important rotor shaft end play, and
bearing clearance standard and limit values.
Rotor Shaft Axial Play Measurement

1) Install a dial indicator on the turbine housing as illustrated.
2) Use the dial indicator to measure the rotor
shaft axial play with moving the shaft push
and pull. Read the total indicator reading
(TIR).
Magnet base
Turbine
housing
mm (in)
IHI RHG6
Rotor Shaft Axial
Play TIR
Limit
Push and pull

Dial indicator
0.11 (0.0043)
SM7645
3) If the measured value exceeds the specified limit the shaft must be replaced.
Rotor Shaft Radial Play Measurement

1) Turn over the turbocharger with the turbine
exhaust inlet flange facing up.
2) Install a dial indicator to measure the rotor
shaft radial play.
3) Use the dial indicator to measure the play.
Read the TIR.
Dial indicator
Magnet base
mm (in)
IHI RHG6
Rotor Shaft Radial
Play TIR
Limit
0.205 (0.0081)
Push and
pull
Push and
pull
Oil inlet
SM7646
4) If the measured value exceeds the specified limit replace the shaft.
W5-9-4
EX255-EX285
TURBOCHARGER
NOTE
EX255-EX285
W5-10-1
STARTING AND CHARGING

STARTER MOTOR
Starter identification
The starter identification plate is attached to the starter motor outside yoke. The ISUZU part number, the
manufacturers code number, and other important information are stamped on the plate.
Refer to the identification plate together with the Main Data and Specifications Tables and accompanying charts
in this Manual when requesting service assistance from a qualified electrical repair shop.
If you are unable to locate the data applicable to your starter motor, please contact your FIAT KOBELCO Dealer.
Identification Plate
STARTING MOTOR
SM7647
A:
B:
C:
D:
Isuzu part number

Manufacturers code number
Rated output
Manufacturers production mark
W5-10-2
EX255-EX285

Main Data and Specifications
Isuzu Part No.
897225-1990
1-81100-3420
S25-177
S25-172
(V)
24
24
(kW)
4.5
4.5
(s)
30
30
Clockwise
Clockwise
Roller
Roller
Manufacturers code No. (HITACHI)

Rated voltage
Rated output
Rating
Direction of rotation
(Viewed from the pinion side)
Clutch type
Terminal voltage (No load)
(V)
24
24
Minimum current (No load)
(A)
Less than 100
100
(min-1)
More than 3500
More than 3500
Modules
Number of teeth
11
11
Starter motor minimum operating speed

(No load)
Pinion gear
Outside diameter
mm (in.)
40.64 (1.60)
40.64 (1.60)
Travel distance
mm (in.)
1.5 (0.032)
1.5 (0.032)
Yoke outside diameter
mm (in.)
90 (3.54)
90 (3.54)
Number of poles
Magnetic switch (at 20 C [68 F])
Series coil resistance
()
0.187
0.187
Shunt coil resistance
()
1.31
1.31
Brush length
Standard
mm (in.)
22 (0.866)
22 (0.866)
Limit
mm (in.)
14 (0.551)
14 (0.551)
38 (3.85/8.49)
38 (3.85/8.49)
Brush spring standard fitting load
N (kgf/lb.)
Commutator
Outside diameter
Standard
mm (in.)
37.0 (1.457)
37.0 (1.457)
Limit
mm (in.)
36.5 (1.437)
36.5 (1.437)
mm (in.)
0.1 (0.004)
0.1 (0.004)
mm (in.)
0.5-0.8
0.5-0.8
(0.020-0.031)
(0.020-0.031)
0.2 (0.008)
0.2 (0.008)
Difference between the largest and

smallest diameters (Run-out)
Limit
Depth of undercut mica
Standard
Limit
mm (in.)
EX255-EX285
W5-10-3

Starter motor sectional view
Magnetic switch
Gear shaft (Internal gear)
Shift lever
Yoke
Gear case
Armature
Brush
Pinion
Brush holder
Pinion gap
(0.3-1.5mm/0.012-0.059in.)
Baffer spring
Center bracket (2)
Rear cover
Ball bearing
Through bolt
Center bracket (1)
SM7648
Performance
Volt
age
Output
To
rqu
Speed
SM7649
W5-10-4
EX255-EX285

ALTERNATOR
Alternator Identification
The alternator identification plate is attached to the alternator rear bracket. The ISUZU part number, the
manufacturers code number, and other important information are stamped on the plate.
Refer to the identification plate together with the Main Data and Specifications Tables and accompanying charts
in this Manual when requesting service assistance from a qualified electrical repair shop.
If you are unable to locate the data applicable to your alternator, please contact ISUZU MOTORS LIMITED through
your machine supplier.
Identification Plate
SM7650
A:
B:
C:
D:
E:
Isuzu part number

Manufacturers short type name
System voltage output
Manufacturers lot no.
Bar code
EX255-EX285
W5-10-5

Main Data and Specifications
Isuzu Part No.
1-81200-5301
Manufacturers code No. (MITSUBISHI)
A004T05486
Rated voltage
(V)
24
Rated output
(A)
50
Rated speed
-1
5000
Rated output at r.p.m

No-load output at 0 Amp.
(min )
(A/V/min-1)
-1
(V/min )
Direction of rotation as viewed
50/27/5000
24/900
Clockwise
from pulley side

Polarity grounded
Pulley diameter
()
mm (in.)
80 (3.15)
Coil resistance at 20C

Field coil
()
4.4-5.2
Regulators applicable
Isuzu part No.
1-81260-0170
Manufacturers code No.
A866X38282
W5-10-6
EX255-EX285

Alternator Sectional Wiew
STARTER
RECTIFIER
ROTOR
BEARING
PULLEY
BEARING
IC REGULATOR
REAR
BRACKET
FRONT BRACKET
COIL ASSEMBLY
(FIELD COIL)
SM7651
Charging Circuit
ADDITIONAL
DIODES
STARTER COIL
INDICATOR LAMP
DIODE TRIO
KEY
SWITCH
BATTERY (24V)
FIELD
COIL
IC REGULATOR
ALTERNATOR
SM7652
EX255-EX285
W5-11-1
TROUBLESHOOTING
HARD STARTING
1) STARTER INOPERATIVE
Checkpoint
Neutral switch
(If so equipped)
Battery
Trouble Cause
NG
NG
NG
NG
Defective neutral switch
Loose battery cable terminals

Poor connections due to rusting
Battery discharged or weak
Fan belt loose or broken
Remedy
NG
Replace the neutral switch
NG
Clean and/or retighten the

battery cable terminals
NG
Recharge or replace the battery
NG
Adjust or replace the fan belt
OK
Fusible link
NG
Fusible link shorted
NG
Replace the fusible link
OK
Starter switch
NG
Defective starter switch or

starter relay
NG
Replace the starter switch or

the starter relay
NG
Defective magnetic switch or

starter relay
NG
Repair or replace the magnetic switch
NG
Repair or replace the starter

motor
OK
Starter
OK
NG
Starter
Defective starter motor
W5-11-2
EX255-EX285
TROUBLESHOOTING
HARD STARTING
2) STARTER OPERATES BUT ENGINE DOES NOT TURN OVER
Checkpoint
Battery
Trouble Cause
NG
NG
NG
Loose battery cable terminals

Poor connections due to rusting
Battery discharged or weak
Fan belt loose or broken
Remedy
NG
Clean and/or retighten the

battery cable terminals
NG
Recharge or replace the battery
NG
Adjust or replace the fan belt
OK
Starter
NG
NG
Defective pinion gear
Defective magnetic switch
NG
Replace the pinion gear
NG
Repair or replace the magnetic switch
NG
Brush wear
Weak brush spring
NG
Replace the brush and/or the

brush spring
NG
Piston, crank bearing seizure, or other damage
NG
Repair or replace the related

parts
OK
Engine
EX255-EX285
W5-11-3
TROUBLESHOOTING
HARD STARTING
3) ENGINE TURNS OVER BUT DOES NOT START
FUEL IS BEING DELIVERED TO THE INJECTION PUMP
Checkpoint
Injection nozzle
Trouble Cause
NG
Injection nozzle injection

starting pressure too low Improper spray condition
Remedy
NG
Adjust or replace the injection

nozzle
OK
Injection pump
NG
Defective fuel injection nozzle resulting in fuel drippage

after fuel injection
NG
NG
Defective injection pump

control rack operation
NG
Repair or replace the injection pump control rack
NG
Injection pump plunger worn

or stuck
NG
Replace the injection pump

plunger assembly
Replace the delivery valve
W5-11-4
EX255-EX285
TROUBLESHOOTING
HARD STARTING
4) ENGINE TURNS OVER BUT DOES NOT START
Checkpoint
Trouble Cause
Engine stop mechanism
NG
Defective engine stop

mechanism control wire improperly adjusted
Remedy
NG
Replace the engine stop

mechanism
Adjust the control wire
FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP
Fuel
NG
Fuel tank is empty
NG
Fill the fuel tank
OK
Fuel piping
Repair or replace the fuel

lines Retighten the fuel line
connections
NG
Clogged or damaged fuel

lines Loose fuel line connections
NG
NG
Fuel filter overflow valve does

not close
NG
Repair or replace the fuel filter overflow valve
NG
Clogged fuel filter element
NG
Replace the fuel filter element or the fuel filter cartridge
NG
Bleed the air from the fuel

system
OK
Fuel filter
OK
NG
Fuel system
Air in the fuel system
EX255-EX285
W5-11-5
TROUBLESHOOTING
UNSTABLE LOW IDLING
Checkpoint
Low idling system
Trouble Cause
Remedy
NG
Low idling improperly adjusted
NG
NG
Defective low idling speed

control device
NG
Repair or replace the low

idling speed control device
NG
Throttle control system improperly adjusted
NG
Adjust the throttle control system
NG
Fuel system leakage or blockage
NG
Repair or replace the fuel system
NG
Bleed the air from the fuel

system
Adjust the low idling
OK
Low idling speed control device
OK
Throttle control system
OK
Fuel system
NG
NG
Air in the fuel system
Water particles in the fuel system
NG
Change the fuel
OK
Fuel filter
Continued on the next page
NG
NG
W5-11-6
EX255-EX285
TROUBLESHOOTING
UNSTABLE LOW IDLING
Checkpoint
Trouble Cause
Remedy
Continued from the previous page

OK
Injection pump
NG
NG
NG
NG
NG
Defective governor lever operation
Broken plunger spring
Worn plunger
Worn camshaft
Worn roller tappet
NG
NG
NG
NG
NG
Repair or replace the governor lever
Replace the plunger spring
Replace the plunger assembly
Replace the camshaft
Replace the roller tappet
OK
Valve clearance
NG
Valve clearance improperly

adjusted
NG
Adjust the valve clearance
OK
NG
Blown out cylinder head gasket

Worn cylinder liner
Piston ring sticking or broken
Improper seating between the
valve and the valve seat
NG
Replace the related parts
EX255-EX285
W5-11-7
TROUBLESHOOTING
INSUFFICIENT POWER
Checkpoint
Air cleaner
Trouble Cause
NG
Clogged air cleaner element
Remedy
NG
Clean or replace the air

cleaner element
OK
Fuel
NG
Water particles in the fuel
NG
Replace the fuel
OK
Fuel filter
NG
NG
NG
Repair or replace the fuel

feed pump
NG
Replace the injection nozzle
NG

nozzle
NG
Replace the fuel injection

pipes
OK
Fuel feed pump
NG
Defective fuel feed pump
OK
Injection nozzle
NG
NG
Injection nozzle sticking

OK
Fuel injection pipes
NG
Fuel injection pipes damaged or obstructed
W5-11-8
EX255-EX285
TROUBLESHOOTING
INSUFFICIENT POWER
Checkpoint
Trouble Cause
Remedy

OK
Injection pump
NG
NG
NG
NG
NG
NG
NG
Defective delivery valve
Defective timer
Improper control lever operation
Defective injection timing
Weak governor spring
Worn plunger
Worn camshaft
NG
NG
Repair or replace the timer
NG
Adjust or replace the control

lever
NG
Adjust the injection timing

Repair or replace the injection pump timer
NG
Replace the governor

spring
NG
Replace the plunger assembly
NG
Replace the camshaft
EX255-EX285
W5-11-9
TROUBLESHOOTING
INSUFFICIENT POWER
Checkpoint
Trouble Cause
Remedy

OK
Injection pump
NG
Worn roller tappet
NG
Replace the roller tappet
OK
Turbocharger
NG
Exhaust gas leakage from the

exhaust system Air leakage
from the intake system
NG
Repair or replace the related

parts
NG
Defective turbocharger assembly
NG
Replace the turbocharger

assembly
NG
Blown out cylinder head gasket Worn cylinder liner Piston

ring sticking or broken Improper seating between the
valve and the valve seat
NG
OK
Valve clearance
NG

adjusted
NG
OK
Valve spring
NG
Valve spring weak or broken
NG
Replace the valve spring
OK
Exhaust system
NG
Exhaust pipe clogged
NG
Clean the exhaust pipe
OK
NG
Full load adjusting screw seal
Open and improperly set adjusting screw seal
NG
Adjust and reseal the adjusting screw
W5-11-10
EX255-EX285
TROUBLESHOOTING
OVERHEATING
Checkpoint
Cooling water
Trouble Cause
NG
Insufficient cooling water
Remedy
NG
Replenish the cooling water
OK
Fan belt
NG
Fan belt loose or cracked

causing slippage
NG
NG
Defective radiator cap or

clogged radiator core
NG
Replace the radiator cap or

clean the radiator core
NG
Repair or replace the water

pump
Replace the fan belt
OK
Radiator
OK
Water pump
NG
Defective water pump
OK
Cylinder head and cylinder

body sealing cap
NG
Defective sealing cap resulting in water leakage
NG
Replace the sealing cap
OK
Thermostat
NG
Defective thermostat
NG
Replace the thermostat
OK
Cooling system
NG
Cooling system clogged by

foreign material
NG
Clean the foreign material

from the cooling system
EX255-EX285
W5-11-11
TROUBLESHOOTING
OVERHEATING
Checkpoint
Trouble Cause
Remedy

OK
Fuel injection timing
NG
Fuel injection timing improperly adjusted
NG
Adjust the fuel injection timing
W5-11-12
EX255-EX285
TROUBLESHOOTING
WHITE EXHAUST SMOKE
Checkpoint
Fuel
Trouble Cause
NG
Water particles in the fuel
Remedy
NG
Replace the fuel
OK
NG
Delayed fuel injection timing
NG
OK
NG
Blown out cylinder head gasket. Worn cylinder liner

Improper seating between
the valve and the valve seat
NG
OK
Turbocharger
NG
Defective turbocharger
NG
OK
Inlet and exhaust valves

Valve seals
NG
Defective valve seals Worn

valves stems and valve
guides
NG
NG
Piston rings worn, broken or

improperly installed
NG
Replace the valve seals,

the valves, and the valve
guides
OK
Piston rings
Replace the piston rings or

properly install
OK
Cylinder liners
NG
Cylinder lines scored or worn
NG
Replace the cylinder liners
EX255-EX285
W5-11-13
TROUBLESHOOTING
DARK EXHAUST SMOKE
Checkpoint
Air cleaner
Trouble Cause
NG
Remedy
NG

cleaner element

nozzle
OK
Injection nozzle
NG

starting pressure too low
Improper spray condition
NG
NG
NG
NG
Defective delivery valve resulting in fuel drippage after

fuel injection
NG
OK
OK
Injection pump
NG
Excessive injection volume
NG
Adjust the injection volume
W5-11-14
EX255-EX285
TROUBLESHOOTING
OIL PRESSURE DOES NOT RISE
Checkpoint
Engine oil
Trouble Cause
Remedy
NG
Improper viscosity engine, oil

Too much engine oil
NG
Replace the engine oil

Correct the engine oil volume
NG
Defective oil pressure gauge

or unit Defective indicator
light
NG
Repair or replace the oil pressure gauge or unit

Replace the indicator light
NG
Replace the oil filter element

or the oil filter cartridge
NG
Replace the relief valve and/

or the by-pass valve spring
NG
Clean the oil pump strainer
NG
Replace the oil pump related

parts
OK
Oil pressure gauge or unit
Oil pressure indicator light
OK
Oil filter
NG
Clogged oil filter element
OK
Relief valve and by-pass valve
NG
Relief valve sticking and/or

weak by-pass valve spring
OK
Oil pump
NG
NG
Clogged oil pump strainer
Worn oil pump related parts
OK
Rocker arm shaft
NG
Worn rocker arm bushing
NG
Replace the rocker arm bushing
EX255-EX285
W5-11-15
TROUBLESHOOTING
OIL PRESSURE DOES NOT RISE
Checkpoint
Trouble Cause
Remedy

OK
Camshaft
NG
Worn camshaft and camshaft

bearing
NG
Replace the camshaft and

the camshaft bearings
NG
Worn crankshaft and bearings
NG
Replace the crankshaft and/

or the bearings
OK
Crankshaft and bearings
W5-11-16
EX255-EX285
TROUBLESHOOTING
EXCESSIVE FUEL CONSUMPTION
Checkpoint
Fuel system
Trouble Cause
NG
Fuel leakage
Remedy
NG
Repair or replace the fuel system related parts
NG

cleaner element
OK
Air cleaner
NG
OK
Low idling speed
NG
Poorly adjusted low idle

speed
NG
NG

NG

nozzle
NG
NG
NG
Defective delivery valve resulting is fuel drippage after

fuel injection
NG
NG
Air leakage from the turbocharger intake side
NG
Adjust the low idle speed
OK
Injection nozzle
OK
OK
Injection pump
OK
Turbocharger
Repair the turbocharger intake side
EX255-EX285
W5-11-17
TROUBLESHOOTING
EXCESSIVE FUEL CONSUMPTION
Checkpoint
Trouble Cause
Remedy

OK
Turbocharger
NG
Defective turbocharger assembly
NG
NG

adjusted
NG

assembly
OK
Valve clearance
OK
NG
Blown out cylinder head gasket. Worn cylinder liner

Improper seating between
the valve and the valve seat
NG
OK
Valve spring
NG
Valve spring weak or broken
NG
Replace the valve spring
W5-11-18
EX255-EX285
TROUBLESHOOTING
EXCESSIVE OIL CONSUMPTION
Checkpoint
Engine oil
Trouble Cause
Remedy
NG
Engine oil unsuitable

Too much engine oil
NG
Replace the engine oil

Correct the engine oil volume
NG
Oil leakage from the oil seal

and/or the gasket
NG
Replace the oil seal and/or

the gasket
OK
Oil seal and gasket
OK
Air breather
NG
Clogged air breather
NG
Clean the air breather
OK
Inlet and exhaust valves

Valve seals
NG
Defective valve seals

Worn valve stems and valve
guides
NG
Replace the valve seals, the

valves, and the valve guides
NG
Piston rings worn, broken or

improperly installed
NG
Replace the piston rings or

porperly install
OK
Piston rings
OK
Cylinder liners
NG
Cylinder lines scored or worn
NG
Replace the cylinder liners
EX255-EX285
W5-11-19
TROUBLESHOOTING
ABNORMAL ENGINE NOISE
1) ENGINE KNOCKING
Checkpoint
Trouble Cause
Remedy
Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.
Fuel
NG
Fuel unsuitable
NG
Replace the fuel
OK
NG
NG
NG

nozzle
NG
Replace the head gasket or

the piston ring
OK
Injection nozzle
NG
Improper injection nozzle

starting pressure and spray
condition
OK
NG
Blown out head gasket Broken piston ring
W5-11-20
EX255-EX285
TROUBLESHOOTING
2) GAS LEAKAGE NOISE
Checkpoint
Exhaust pipes
Trouble Cause
Remedy
NG
Loosely connected exhaust

pipes Broken exhaust pipes
NG
Tighten the exhaust pipe connections

Replace the exhaust pipes
NG
Loose injection nozzles and/

or glow plugs
NG
Replace the washers Tighten

the injection nozzles and/or
the glow plugs
NG
Loosely connected exhaust

manifold and/or glow plugs
NG
Tighten the exhaust manifold

connections
NG
Damaged cylinder head gasket
NG
Replace the cylinder head

gasket
OK
Injection nozzles and/or glow

plugs
OK
Exhaust manifold
OK
EX255-EX285
W5-11-21
TROUBLESHOOTING
3) CONTINUOUS NOISE
Checkpoint
Fan belt
Trouble Cause
NG
Remedy
NG
Loose fan belt
Readjust the fan belt tension
OK
Cooling fan
NG
Loose cooling fan
NG
Retighten the cooling fan
OK
Water pump bearing
NG
Worn or damaged water

pump bearing
NG
Replace the water pump

bearing
NG
Defective alternator
vacuum pump
or
NG
Repair or replace the alternator or the vacuum pump
NG

adjusted
NG
OK
Alternator or vacuum pump
OK
Valve clearance
W5-11-22
EX255-EX285
TROUBLESHOOTING
4) SLAPPING NOISE
Checkpoint
Valve clearance
Trouble Cause
NG

adjusted
Remedy
NG
OK
Rocker arm
NG
Damaged rocker arm
NG
Replace the rocker arm
OK
Flywheel
NG
Loose flywheel bolts
NG
Retighten the flywheel bolts
OK
Crankshaft and thrust bearings
NG
Worn or damaged crankshaft

and/or thrust bearings
NG
NG
Worn or damaged crankshaft

and/or connecting rod bearings
NG
NG
Worn or damaged connecting rod bushing and piston

pin
NG
Replace the connecting rod

bushing and/or the piston pin
NG
Worn or damaged piston and

cylinder liner Foreign material in the cylinder
NG
Replace the piston and the

cylinder liner
Replace the crankshaft and/

or the thrust bearings
OK
Crankshaft and connecting

rod bearings
Replace the crankshaft

and/or the connecting rod
bearings
OK
Connecting rod bushing and

piston pin
OK
Piston and cylinder liner
EX255-EX285
W5-12-1
REPAIR STANDARDS
GENERAL RULES
1. These tables provide standards relating the repair.
2. These Repair Standards are based on inspection items, together with dimensions, assembly standards, limit
values, and repair procedures.
(1) Nominal dimensions are the standard production values.
(2) Assembly standards considered to be the values used as objectives during the assembly procedures which
follow repairs; as a result, they may be somewhat at variance with the assembly dimensions of a new engine.
(3) Limit values refer to the measured values resulting from wear, etc., beyond which a part must not be used.
If a measured value falls beyond the limit value, the part involved must be repaired or replaced.
(4) "Repair Procedures" indicates normal repair methods.
(5) Unless otherwise stated, the unit of numerical values in tables should be taken to refer to millimeters mm
(in).
3. Explanation of Terms Used in Tables
(1) The dimension of "wear" refers to the difference between the dimensions of a part which is not worn (or the
"nominal dimension" of a part without wear) and the dimension of the part suffering from the most wear (the
dimension of the worn part).
(2) Uneven wear means the difference between the maximum and minimum wear values.
4. When repairs are requested on the overall engine, first perform bench tests to determine what parts require
repairs, then perform the minimum disassembly and repairs required to correct the problems.
When repairs on a specific engine part are requested, repairs to be made in reference to the relevant items in
accordance with the repair standards listed in this manual.
Name
of Part
Time for engine

disassembly
and repair
Nominal
Dimension
Inspection Item
Cylinder compression pressure

MPa (kgf/cm2/psi)
Assembly
Standard Value
3.0 (31/440)
Limit
Repair Procedure
2.5 (26/370)
Disassemble and
repair engine
Fuel consumption
L/h
100%
140%
Lubricating oil consumption
L/h
100%
200%
Comments
Water temperature
70 - 85C,
(158-185F) engine
speed 200 min-1
(varies depending on
altitude)
New engine performance is assumed
100%
Dia 105
(4.1339)
Dia 105.2
(4.1417)
Upper step wear must

be repaired, or replace
with standard dimension liner
(Ref)
Cylinder & liner
interference
Cylinder Block
Engine Body
0.001- 0.019
(0.00004 - 0.0007)
REPAIR STANDARDS
Wear on liner bore

Measured at A-A
24.120
W5-12-2
Major
Category
Liner projection
0.03 - 0.10
(0.001- 0.004)
0.05 or less
(0.002)
Pressure test: 3 minutes

kPa (kgf/cm2/psi)
490 (5/71.1)
0.2
(0.0079)
Must be repairable
0.3 (0.0118)
Leaks require repair or

replacement
EX255-EX285
Cylinder block upper face warpage
Some projection must

be present
Difference in liner
projection between
neighboring cylinders
not to exceed
0.03 (0.001)
Assembly
Standard Value
Limit
1.0
(0.039)
2.5
(0.098)
Replace insert
Valve seat angle:

45
1.5
(0.059)
2.0
(0.079)
Repair with valve seat

cutter
After repair, be sure

to lap contact surfaces
0.075 or less
(0.003)
0.2
0.079
Cannot be repaired:
must replace cylinder
head
Warpage of manifold mounting

surface
0.05 or less
(0.002)
0.4
(0.016)
repair
Water-pressure test, 3 minutes

kPa (kgf/cm2/psi)
490 (5/71.1)
Name
of Part
Inspection Item
Nominal
Dimension
Repair Procedure
EX255-EX285
Major
Category
Comments
Valve seat depression: B

(both inlet and exhaust)
(Insert)
(Cylinder
head)
Bottom
surface
to cylinder
Valve
Same for
inlet & exhaust
Must not protrude from
lower surface of cylinder head
Cylinder Head
Engine Body
Warpage and flatness of cylinder

head lower face (mounting
surface)
Cylinder head bolts tightening

torque (angular tightening method)
Nm (kgf-m/lbft)
Clean bolt mounting

surfaces and
threads, and apply
molybdenum disulfide grease.
Never tighten again
after using angular
tightening method.
Reuse bolts max. 2
times
W5-12-3
69
(7.0/51)
88
(9.0/65)
90 - 120
Leaks require repair or

replacement
REPAIR STANDARDS
Contact width with valve seat: A
Inspection Item
Nominal
Dimension
Assembly
Standard Value
Limit
Repair Procedure
Comments
Clearance with
major axis
0.051 - 0.085
(0.002 - 0.0033)
Piston pin and piston pin hole

clearance
0.010 - 0.023
(0.00039-0.0009)
0.05
(0.00197)
Replace piston or
piston pin
Pin wear
35.000 - 35.005
(1.3780 -1.3781)
34.95
(1.3760)
Replace piston pin
1.5
(0.059)
Replace rings when

performing engine
disassembly and
repair
Gauge inner
standard diameter
105 (4.134)
Replace
Measure with ring

compressed to
standard ring gap
Replace
Measure with
expander attached
Piston Ring
Piston Ring Gap
No. 1
compression ring
0.35 - 0.50
(0.014 - 0.020)
No. 2
compression ring
0.60 - 0.75
(0.0236-0.0295)
No. 3
compression ring
0.60 - 0.75
(0.0236 - 0.0295)
Oil ring
0.30 - 0.50
(0.014 - 0.020)
No. 1
compression ring
20.4 - 30.6
(2.08 - 3.12/
4.59 - 6.88)
9.8
(1.0/2.2)
No. 2
compression ring
14.1- 21.2
(1.44 - 2.16/
3.17 - 4.76)
4.9
(0.5/1.1)
No. 3
compression ring
14.1- 21.2
(1.44 - 2.16/
3.17 - 4.76)
4.9
(0.5/1.1)
Oil ring
36.3 - 55.9
(3.7 - 5.7/
8.16 -12.6
31
(3.2/7.05)
Tension N (kgf/lb)
EX255-EX285
Clearance with cylinder:

grade position from upper face
82 mm (3.228 in)
REPAIR STANDARDS
Main Operating Parts
Pistons
Name
of Part
W5-12-4
Major
Category
Piston Ring
Name
of Part
Assembly
Standard Value
Limit
No. 1
compression ring
No. 2
compression ring
0.070 - 0.110
(0.0028 - 0.0043)
0.15
(0.0059)
No. 3
compression ring
0.050 - 0.090
(0.0020 - 0.0035)
0.15
(0.0059)
Oil ring
0.030 - 0.070
(0.0012 - 0.0028)
0.15
(0.0059)
Inspection Item
Clearance
between piston
ring and ring
groove
Repair Procedure
Replace rings or
piston
At 90 intervals
Comments
When assembling
compression rings on
piston, be sure rings
marked surface is up
Backwards installation
will result in excessive
oil consumption
No top/bottom to oil
ring
REPAIR STANDARDS
Ring gap orientation
Nominal
Dimension
EX255-EX285
Major
Category
W5-12-5
Name
of Part
Inspection Item
Uneven wear on journal
and pins
Journal Diameter
Nominal
Dimension
Dia. 80
(3.1496)
Dia. 64
(2.5197)
79.905-79.925
(3.1459 - 3.1467)
Other
Bearing
79.919 - 79.939
(3.1464 - 3.1472)
Use those with projection

and proper arc; take care
with back side fit
Center
Bearing only
0.039 - 0.098
(0.0015 - 0.0039)
Other
Bearing
0.025 - 0.084
(0.0010 - 0.0033)
0.11
(0.0043)
Replace bearing
Undersize bearings cannot

be used
0.15 - 0.33
(0.006 - 0.013)
0.4
(0.016)
Replace thrust bearings
0.05 or less
(0.002)
0.4
(0.016)
Replace
Measure at crankshafts
No. 4 bearing thrust surface
36 or less
Check dynamic balance
(Ref. value)
At ends of journal
EX255-EX285
Perform lapping on gears

with burrs; in cases of
severe damage, replace.
Ring gear
Crankshaft balance
(g-cm)
Do not attempt to grind:

always replace with new
parts
REPAIR STANDARDS
Crankshaft runout
Replace
Ellipse and
taper 0.007
(0.0003)
Journal bearing
undersize
Crankshaft end play
Comments
Replace
Journal bearing arc

spread
Clearance
between journal
and bearing
Repair Procedure
Replace
63.924 - 63.944
(2.5167 - 2.5175)
Journal and pin finish

precision (taper and
ellipse)
Crankshaft
Limit
0.05
(0.002)
Center
Bearing only
Pin Diameter
Assembly
Standard Value
W5-12-6
Major
Category
Inspection Item
Nominal
Dimension
Assembly
Standard Value
Crankshaft bearing cap

bolt torque
Crankshaft
Name
of Part
226 - 245
(23-25/166-181)
Limit
Repair Procedure
EX255-EX285
Major
Category
Comments
Apply engine oil

to threads and
seating areas of bolts
before tightening
Do not catch foreign matter

in bolts
In case of oil leak, replace

oil seal
Check for oil seal collapse
Nm (kgf-m/Ib ft)
Crankshaft rear oil seal
wear
REPAIR STANDARDS
W5-12-7
Name
of Part
Inspection Item
Nominal
Dimension
Assembly
Standard Value
Limit
Clearance between
connecting rod
bearing and crankpin
0.030 - 0.073
(0.0012 - 0.0029)
0.10
(0.0039)
Contact between connecting rod bearing

and crankpin
0.012 - 0.025
(0.00047 - 0.00098)
0.05
(0.00197)
Replace bushing or pin
Sufficient gap to allow

smooth rotation when
holding big end
Crank must not be ground
(no undersizes available)

undersize
0.17 - 0.30
(0.0067 - 0.011)
Connecting rod and

crankpin end play
0.35
(0.014)
Replace connecting rod
192
(7.559)
Reference value
Big end to small end hole

twist
(per 100 mm)
0.05 or less
(0.002)
0.2
(0.0079)
Repair or replace
Big end to small end hole

parallelism
(per 100 mm)
0.05 or less
(0.002)
0.2
(0.0079)
Repair or replace
Piston weight difference

after assembly
g
20 or less
39
(4.0/29)
60 - 90
Repair or replace
Apply molybdenum disulfide grease to bolts before

tightening
EX255-EX285
Bearing cap bolt

tightening torque
(angular tightening
method)
Nm (kgf-m/lbft)
Take special care with

crankpin precision
REPAIR STANDARDS
Connecting Rod
Replace bearing or
crankshaft
Replace parts with poor
contact or abrasions
Clearance between
smallend bushing and
piston pin
Center distance
between big end and
small end
Comments
Use those with projection

and proper arc; take care with
back side fit

arc spread
Repair Procedure
W5-12-8
Major
Category
Name
of Part
Inspection Item
Journal uneven wear
Nominal
Dimension
Repair Procedure
Comments
Replace camshaft
0.03 - 0.09
(0.001- 0.004)
0.15
(0.006)
Replace camshaft or
bearing
Dia. 55.94 - 55.97

(2.202 - 2.204)
Dia. 56.6
(2.189)
Replace camshaft
7.21
(0.284)
Replace camshaft
Minor step wear on

cams can be repaired
Replace camshaft
Measure with dial

gauge at No. 3 or
No. 4 journal, runout
during one rotation.
Camshaft
Cam height:
A-B
7.71
(0.304)
0.12
(0.005)
Camshaft runout
Camshaft play (front-back

direction)
0.050 - 0.114
(0.002- 0.005)
0.2
(0.008)
REPAIR STANDARDS
Dia. 56
(2.205)
Limit
0.05
(0.002)
Dia. 56
(2.205)
Clearance between journal and

bearing
Journal wear
Assembly
Standard Value
EX255-EX285
Major
Category
W5-12-9
Name
of Part
Inspection Item
Inlet valve stem wear
Dia. 8.88
(0.3496)
Dia. 9
(0.3543)
Clearance between inlet valve

stem and valve guide
0.039 - 0.071
(0.0015-0.0028)
0.20
(0.008)
Clearance between exhaust valve

stem and guide
0.064 - 0.096
(0.0025-0.0038)
0.25
(0.0098)
Interference between valve guide

and cylinder head
0.024
(0.0009)
Valve
thickness
Thickness
14.1
(0.555)
Valve stem oil seal lip
Dia. 8.5
(0.335)
Tension N (kgf/Ib)
(When compressed to installed
length) 44.5mm(1.752in)
Free height
Repair Procedure
Replace valve and
valve guide together
Comments
Measure valve stem
at three positions
Replace valve and

Apply oil to valve
guide and press in
1.00
(0.039)
1.5
(0.059)
Height of valve
guide above
cylinder head
Valve spring
Valves
Limit
Replace valve and

Reference value
Dia. 8.8 (0.346)
142 (14.5/30.9)
127 (13.0/28.7)
60.6 (2.39)
58.0 (2.28)
less than
1.9 (0.075)
2.7 (0.106)
Replace oil seal
Don't damage lip
REPAIR STANDARDS
Valve System
Exhaust valve stem wear
Assembly
Nominal
Dimension Standard Value
W5-12-10
Major
Category
Replace valve spring
Inclination
EX255-EX285
Name
of Part
Inspection Item
Valve System
Valves
Air cleaner
Limit
0.4
(0.016)
Comments
Adjust
Clearance between rocker arm

shaft and rocker arm
0.01 - 0.05
(0.0004-0.002)
0.2
(0.0079)
Rocker arm shaft wear
18.98 - 19.00
(0.747- 0.748)
Dia. 18.85
(0.742)
Air cleaner element condition
Repair Procedure
Replace bushing or
shaft
Replace
Special order item

from manufacturer
REPAIR STANDARDS
Intake System
Valve clearance (inlet & exhaust)

(cold)
Assembly
Nominal
Dimension Standard Value
EX255-EX285
Major
Category
W5-12-11
Lubricating oil pressure

kPa (kgf/cm2/psi)
290 - 590
(3.0 - 6.0/43 - 85)
196
(2.0/28)
Clearance between pump body

inner wall and gear teeth
0.075 - 0.150
(0.003 - 0.0059)
0.2
(0.0079)
Replace bushing,
gear or body
Replace gear or
cover
Oil pump and Relief valve
Oil
pressure
Limit
Inspection Item
Nominal
Dimension
Pumping rate
1650 min-1, SAE #30,
pumping pressure 392 kPa
(4 kgf/cm2/57 psi)
oil temp. 80C (176F)
53.3
End gap between pump cover

and gear
0.040 - 0.094
(0.0016 - 0.0037)
0.15
(0.0059)
Clearance between drive shaft

and pump body
0.032 - 0.070
(0.0013 - 0.0028)
0.15
(0.0059)
Clearance between drive shaft

and bushing
0.045 - 0.078
(0.0018 - 0.0031)
0.15
(0.0059)
Replace bushing
Dia 15.9
(0.626)
Replace shaft
Initial operating
pressure of relief
valve kPa (kgf/cm2/psi)
Comments
L/min
Dia. 16
(0.6299)
Diameter of drive shaft

Oil gallery
441 (4.5/64)
Oil pump
785 (8/114)
Reference value
Clogging and damage to oil filter
Initial operating pressure of main oil

filter relief valve
kPa (kgf/cm2/psi)
Replace
196 (2.0/28)
Replace cartridge
every 500 hours of
operation
EX255-EX285
Oil filter
Repair Procedure
REPAIR STANDARDS
Lubricating System
Assembly
Standard Value
Name
of Part
W5-12-12
Major
Category
Name
of Part
Nominal
Dimension
Inspection Item
Water pump ball bearing chatter
(radial direction)
Pumping rate
Assembly
Standard Value
Limit
0.008 - 0.010
(0.0003-0.0004)
0.2
(0.0079)
Repair Procedure
Replace
Comments
#6305 (2)
#6205 (1)
L/min
pumping speed 3720 min-1,

water temp 30C (86F)
Total head 13.5m(531.5in) or more
Clearance between pump impeller

and pump body
300
Repair or replace if
impeller and pump
body are touching
Water pump
Fan belt
deflection
About 7 -10
(0.276 - 0.394)
Adjust
Initial thermostat operating

temperature (at sea level)
C
(F)
Thermostat full-open temperature C

(at sea level)
(F)
Fan center and bearing shaft

interference
Pulley and fan center clearance
Temperature at which
thermostat lift reaches
10mm(0.394in) or more.
0.07 - 0.11
(0.003 - 0.004)
Replace water
pump ASM
0.020 - 0.060
(0.0008 - 0.0024)
Replace water
pump ASM
0.14 or less
(0.006)
Replace water
pump ASM
W5-12-13
Bearing shaft and impeller

interference
Replace thermostat if
operation is incorrect.
82 2
(179.6 35.6)
95
(203)
(Reference)
98N (10kgf/22lb)
REPAIR STANDARDS
0.3 -1.0
(0.0118 - 0.039)
Press with finger
Cooling System
EX255-EX285
Major
Category
Nominal
Dimension
Assembly
Standard Value
Limit
Repair Procedure
Clogged, cracked, loose fuel pipes,

injection pipes, nozzle holders;
defective seals.
Repair or replace
Fuel filter element clogging or

damage
Replace
Delivery valve
Injection pump
Inspection Item
Delivery valve wear
Inspect for damage to

valve's piston and seat;
replace in case of severe
vertical cracks on piston
or impact scars on seat
with loss of finish gloss.
Immerse delivery valve in
clean diesel fuel, then
lightly press lower part of
valve seat with finger and
release; replace assembly
if valve does not return to
original state when finger
is released.
Comments
Cartridge type
REPAIR STANDARDS
Fuel System
Piping, etc.
Name
of Part
W5-12-14
Major
Category
EX255-EX285
Name
of Part
Nominal
Dimension
Inspection Item
Assembly
Standard Value
Limit
Repair Procedure
EX255-EX285
Major
Category
Comments
Pump Part No.

1-15603-328-0
Adjustment Item
Rotation Direction
Clockwise
(viewedloose
from fuel
drivepipes,
side)
Clogged,
cracked,
injection pipes, nozzle holders;
defective seals.
105780-0000
(BOSCH Type No. DN12SD12T)
Adjustment Conditions
Nozzle opening pressure

Fuel pumping pressure
MPa (kgf/cm2/psi)
17.2 (175/2490)
kPa (kgf/cm2/psi)
157 (1.6/23)
Pipe (o.d. x i.d. x lenght)
Dia. 6(0.236) x Dia. 2(0.079) x 600(23.62)
Test fuel
ISO4113 or SAE Standard Oil (SAE J967d)
Fuel temperature
C (F)
40 - 45 (104 -113)
Max. var
Injection qty
Pump speed
bet. cyl
-1
3
(mm /1000 strokes)
(min )
(%)
Adjustment
point
Rack position
mm
(in)
10.3
(0.4449)
1075
89 1.5
Lever
Approx 7.5
(0.295)
450
9 1.3
14
Rack
100
150 5
Lever
Fixed
Remarks
Basic
Rack limit
W5-12-15
Injiection adjustment
Injection pump
105780-2080
(BOSCH Type No. EF8511/9)
Nozzle holder assembly
REPAIR STANDARDS
Fuel System
Nozzle
Name
of Part
Nominal
Dimension
Inspection Item
Assembly
Standard Value
Limit
Repair Procedure
W5-12-16
Major
Category
Comments
Governor perfomance curve

Recommended speed droop adjustment screw position:9
(notched from fully tightened position)
Above 14.0
Stop lever angle
Idle-sub spring setting
10.2-0.5
7.30.3
op
7.5
Full-s
8.0
Nomin
al
9.80.1
peed
10.3
St
Rack position (mm)
Governor spring setting
op
Injection pump
Speed lever angle
10.90.1
St
Fuel System
11.0
REPAIR STANDARDS
Rack limit
Dead point
Idling
Pump speed (r/min)
EX255-EX285
Name
of Part
Nominal
Dimension
Inspection Item
Assembly
Standard
Value
Limit
Injection Nozzle
Fuel System
Technology Needle valve seat: 7.8MPa

(80 kgf/cm2/138psi)
Needle valve shaft seat: s
Impress fuel pressure of 29.4Mpa
(300kgf/cm2/4267psi) nozzle starting
pressure and measure time required for
pressure to drop from 24.5MPa (250kgf/cm2
/3556psi) to19.6MPa (200kgf/cm2/2845psi).
Repair or replace parts

with leaks from seat area
Replace
5.0 or more
(1) Visually inspect, no relatively

large drops scattered.
(2) No drops scattered to one side.
(3) No unevenness of spray from
jets.
Warning lamp indication

Check for looseness, cuts or damaged
insulation to wiring.
Repair
Rotor
Shaft runout
0.06 or less
(0.0024)
Bearing chatter
Rated output current
27 V (5000 min-1)
0.1
(0.0038)
Fuel used: diesel fuel;

37 - 40 s
120C (248F)
Replace faulty parts
If warning indicator lights

when engine is operating at
normal speeds, check and
repair electrical system.
Performance
Charge/
Wiring Discharge
(MITSUBISHI 1-81200-530-1)
indication
Alternator 24V, 50A
Electrical
Comments
REPAIR STANDARDS
Fuel spray and injection

Impress fuel pressure of 19.1Mpa
(195kgf/cm2/2770psi) (needle valve
opening pressure)
Repair Procedure
EX255-EX285
Major
Category
Replace rotor
Replace bearings
Rotate by hand and check

for smooth rotation; no
abnormal sound or resistance should be felt.
50A
W5-12-17
Name
of Part
Inspection Item
Nominal
Dimension
Assembly
Standard Value
Limit
22
(0.866)
Starter 24V, 7.4 kW (HITACHI 1-81100-342-0)
0.187
20 C (68 F)
Shant coil
resistance value ()
1.31
20 C (68 F)
O. D.
Commutator
Rear side
(armature)
Front (armature)
Pinion shaft (shaft)
Unloaded
characteristics
(24V, 100A or less)
Control register, glow plug
Battery terminals
0.5 - 0.8
(0.02 - 0.031)
Plates, separator plates, container,

etc.
Electrolyte turbidity
Dia. 28
(1.102)
Replace
If coil resistance value

is severely abnormal,
replace switch.
Dia. 36.5
(1.437)
0.2
(0.008)
Replace armature
Repair
6001 D
Dia. 16
(0.630)
Dia. 16
(0.630)
6905 D
Replace if rotation is
not smooth or if
abnormal sounds are
heard.
Smooth pinion
operation without
noise
3500 min-1
Replace if cut wiring

or shorts are found
Special order from

original manufacturer; manufacturer's
specs.
EX255-EX285
Battery
Dia. 37
(1.457)
Undercut depth
Performance
Preheater
Series coil
resistance value ()
14
(0.551)
REPAIR STANDARDS
Electrical
Brush height
Ball
bearings
Comments
Repair
Loose mount
Magnetic
switch
Repair Procedure
W5-12-18
Major
Category
Name
of Part
Inspection Item
Nominal
Dimension
Assembly
Standard Value
Limit
Repair Procedure
EX255-EX285
Major
Category
Comments
Battery
Electrical
Electrolyte specific gravity

(at recharging, 20C)
Capacity (20 hours)
Special order from

original manufacturer
Electrode voltage
Electrolye surface height
Engine run-in operation
Final Inspection
3.0 (31/441)
Difference in compression
between cylinders,
kPa (kgf/cm2/psi)
[water temp. 70 - 85 C, (158 -185 F)
about 200 min-1]
Lubricating oil pressure
kPa (kgf/cm2/psi)
290 - 590
(3.0 - 6.0/43 - 85)
Output check
85% or more
Fuel consumption check
110% or less
2.5 (26/370)
Inspect
Warm engine
290
(3 0/43)
Inspect
Warm engine
200 or less
(2.0/28)
Adjust
REPAIR STANDARDS
Cylinder compression pressure

MPa (kgf/cm2/psi)
[water temp. 70 - 85 C, (158 -185 F)
about 200 min-1]
30 minutes or more
When new engine

output is 100%
W5-12-19
W5-12-20
NOTE
REPAIR STANDARDS
EX255-EX285


Print No. 604.13.201 - VII - 2002


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EX255-EX285 Tier2

TECHNICAL MANUAL - OPERATIONAL PRINCIPLE

FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.

COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.

Reproduction of text or illustrations,

Print No. 604.13.191 - VII - 2002

- If you have any questions or comments, or if you

SERVICE MANUAL COMPOSITION

- The Workshop Manual includes information needed

- The Technical Manual -Troubleshooting includes

- Technical Manual - Operational Principle

- Technical Manual - Troubleshooting

This is the safety alert symbol.

SECTION AND GROUP CONTENTS

EX255 Excavator Dimensions ............. T1-1-1

Main Components ................................ T1-2-1

10 170 1) 3 206 2 815

EX255 EL (mm) 3 845

10 170 4) 3 204 2 815

(*) Rear swing radius

(**) Arm: 1) 2158 mm, 2) 2480 mm, 3) 2950 mm, 4) 3600 mm

M-Track shoe width

9 865 10 277 10 903

9 681 10 100 10 737

10 145 1) 3 083 2 815

EX255 EL (mm) 3 845

10 145 4) 3 290 2 815

(*) Rear swing radius

(**) Arm: 1) 2 158 mm, 2) 2 480 mm, 3) 2 950 mm, 4) 3 600 mm

11 099 11 237 11 379 12 128

EX285 LC (mm) 4 011

(*) Rear swing radius

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

(***) Arm: 2 120 mm

M-Track shoe width

9 834 10 062 10 705 11 299

9 864 10 519 11 124

EX285 LC (mm) 4 011

(*) Rear swing radius

(**) Arm: 1) 2100 mm, 2) 2400 mm, 3) 3100 mm, 4) 3750 mm

(***) Arm: 2 120 mm

M-Track shoe width

9 882 10 072 10 733 11 345

9 875 10 548 11 170

mm 11 285 11 370 11 924 12 413

EX255 ENGINE DATA

HYDRAULIC DEVICES EX255

Cylinder inner diameter

(*) Triple articulation version

FRONT ATTACHMENT PILOT VALVE

EX255 ELECTRICAL EQUIPMENT

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

EX285 ENGINE DATA

EX285 HYDRAULIC DEVICES

Cylinder inner diameter

(*) Triple articulation version

FRONT ATTACHMENT PILOT VALVE

EX285 ELECTRICAL EQUIPMENT

Engine Oil Pressure Switch

Breaker relay (R2) variant provision

Connectors for monitor and switch panels

- Connector not used

Fuel Level Indicator