Fiat Kobelco E200SR Evolution Hydraulic Excavator Workshop Manual – 604.13.255

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Fiat Kobelco E200SR Evolution Hydraulic Excavator Workshop Manual – 604.13.255

This complete service repair workshop manual PDF download for the Fiat Kobelco E200SR Evolution Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

“Excavator” and “Engine” Workshop Manuals contain the technical information necessary for machine/engine service and repair, service equipment, information on maintenance standards, remove and install procedures, disassembly and assembly procedures.

TABLE OF CONTENTS :

INDEX
SPECIFICATIONS
Section 1 – Outline
Section 2 – Specification
Section 3 – Attachment dimension
MAINTENANCE
Section 11 – Tools
Section 12 – Standard maintenance time schedule
Section 13 – Maintenance standard and test procedure
SYSTEM
Section 21 – Mechatro control system
Section 22 – Hydraulic system
Section 23 – Electric system
Section 24 – Components system
Section 25 – Air-conditioner system
DISASSEMBLING
Section 31 – Disassembling and assembling
Section 32 – Attachment
Section 33 – Upper structure
Section 34 – Travel system
TROUBLESHOOTING
Section 41 – Troubleshooting (mechatro control)
Section 42 – Troubleshooting (Hydraulic)
Section 43 – Troubleshooting (Electric)
Section 44 – Troubleshooting (Engine)
ENGINE
Section 51 – Engine
OPT
Section 63 – Mounting the breaker and nibbler & breaker

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : 604.13.255
Total Pages : 915

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

INDEX

SECTION 1 – OUTLINE
1. GENERAL PRECAUTIONS FOR MAKING REPAIRS
2. INTERNATIONAL UNIT CONVERSION SYSTEM

SECTION 2 – SPECIFICATION
1. NAME OF COMPONENTS
2. GENERAL DIMENSION
3. WEIGHT OF COMPONENTS
4. TRANSPORTATION DIMENSION AND WEIGHT
5. SPECIFICATIONS AND PERFORMANCE
6. TYPE OF CRAWLER
7. TYPE OF BUCKET
8. COMBINATIONS OF ATTACHMENT
9. ENGINE SPECIFICATION

SECTION 3 – ATTACHMENT DIMENSION
1. BOOM
1.1 BOOM DIMENSIONAL DRAWING
1.2 BOOM MAINTENANCE STANDARD
2. ARM
2.1 ARM DIMENSIONAL DRAWING
2.2 ARM MAINTENANCE STANDARD
3. BUCKET
3.1 BUCKET DIMENSIONAL DRAWING
3.2 BUCKET DIMENSIONAL TABLE
3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION
3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION

SECTION 11 – TOOLS
1. TIGHTENING TORQUES FOR CAPSCREWS AND NUTS
2. SCREW SIZE
3. TIGHTENING TORQUES FOR NUTS AND SLEEVES
4. PLUG
5. SPECIAL SPANNER FOR TUBE
6. SPECIAL TOOLS
7. APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND
8. SUCTION STOPPER
9. COUNTER WEIGHT LIFTING JIG
10. UPPER FRAME LIFTING JIG
11. ENGINE MOUNTING PEDESTAL
12. TRACK SPRING SET JIG

SECTION 12 – STANDARD MAINTENANCE TIME SCHEDULE
1. STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR
01. ATTACHMENT
02. CAB & GUARD
03. SWING FRAME
04. TRAVEL SYSTEM
06. ELECTRIC EQUIPMENT
2. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE

SECTION 13 – MAINTENANCE STANDARD AND TEST PROCEDURE
1. HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED
2. PERFORMANCE INSPECTION STANDARD TABLE
3. MEASUREMENT OF ENGINE SPEED
4. MEASUREMENT OF HYDRAULIC PRESSURE
5. MEASURING TRAVEL PERFORMANCES
6. MEASURING SWING PERFORMANCES
7. MEASURING ATTACHMENT OPERATING
8. MEASURING PERFORMANCES OF SWING BEARING
9. MECHATRO CONTROLLER“A”ADJUSTMENT

SECTION 21 – MECHATRO CONTROL SYSTEM
1. SUMMARY OF MECHATRO CONTROL SYSTEM
1.1 MECHATRO CONTROL SYSTEM IN GENERAL
1.2 BOOM RAISE CONFLUX
1.3 SWING CUT VALVE CONTROL
1.4 ARM IN RECIRCULATION & SEQUENCE CONFLUX
1.5 ARM IN ANTI- CAVITATION CONTROL
1.6 ARM OUT CONFLUX
1.7 TRAVEL STRAIGHT
1.8 SWING PRIORITY CONTROL
1.9 PRESSURE DRAINING (RELEASING) CONTROL
1.10 PUMP CONTROL (POSITIVE CONTROL & P_Q CO NTRO L )
1.11 STANDBY FLOW CONSTANT CONTROL
1.12 FC MODE CONTROL
2. MECHATRO CONTROLLER
2.1 SUMMARY OF MECHATRO CONTROLLER
2.2 SELF DIAGNOSIS DISPLAY FUNCTION
2.3 SERVICE DIAGNOSIS
2.4 TROUBLE HISTORY DIAGNOSIS
2.5 HOW TO CORRECT THE E/G OIL SUPPLY CUMULATIVE TIME
2.6 MECHATRO CONTROL EQUIPMENT

SECTION 22 – HYDRAULIC SYSTEM
1. SUMMARY
2. HYDRAULIC CIRCUITS AND COMPONENTS
2.1 STD Model
2.2 Boom & Arm safety
2.3 EXTRA
3. OPERATON EXPLANATION OF HYDRAULIC CIRCUITS
3.1 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS
3.2 NEUTRAL CIRCUIT
3.3 TRAVEL CIRCUIT
3.4 BUCKET CIRCUIT
3.5 BOOM CIRCUIT
3.6 SWING CIRCUIT
3.7 ARM CIRCUIT
3.8 COMBINED CIRCUIT
3.9 PRESSURE DRAINING (RELEASING) CIRCUIT
4. PILOT PIPING
5. MAIN PIPING

SECTION 23 – ELECTRIC SYSTEM
1. ELECTRIC CIRCUIT DIAGRAM
2._ELECTRICAL EQUIPMENT LIST
2.1 SPECIFICATION
3. HARNESS
3.1 HARNESS LIST
3.2 HARNESS CONNECTION DRAWING
3.3 CONTROLLER ASSY
3.4 INSTRUMENT PANEL ASSY
3.5 UPPER ELECTRIC ASSY
3.6 UPPER HARNESS ASSY
3.7 ENGINE HARNESS ASSY
3.8 UPPER HARNESS ASSY (FLOOR PLATE)
3.9 CAB HARNESS ASSY
3.10 BOOM HARNESS ASSY
3.11 INSTALLING LIGHT
3.12 FUEL PUMP ASSY INSTALL

SECTION 24 – COMPONENTS SYSTEM
I. HYDRAULIC COMPONENTS
1. HYDRAULIC PUMP ・REGULATOR
2. PILOT VALVE (ATT)
3. PILOT VALVE (TRAVEL)
4. CONTROL VALVE
5. SWING MOTOR UNIT
6. TRAVEL MOTOR
7. SWIVEL JOINT
8. CYLINDER
II. ELECTRICAL EQUIPMENT
1. LIST OF ELECTRICAL EQUIPMENTS
2. SPECIFICATION OF ELECTRIC EQIUPMENTS

SECTION 25 – AIR-CONDITIONER SYSTEM
1. CONSTRUCTION AND PIPING
1.1 CONSTRUCTION
1.2 PIPING
2. CONSTRUCTION OF MAIN COMPONENTS
2.1 INTAKE UNIT
2.2 AIR-CONDITIONER UNIT
2.3 RECEIVER DRYER
3. FUNCTION
3.1 MECHANISM OF COOLING CIRCUIT
3.2 COOLING CIRCUIT
3.3 COMPONENT PARTS
4. DISASSEMBLY AND ASSEMBLY
4.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
4.2 REMOVAL AND INSTALLATION OF THE UNIT
5. CHARGING REFRIGERANT
5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
5.2 OPERATING PROCEDURE
5.3 CHARGING PROCEDURE
6. ELECTRIC CIRCUIT
6.1 WIRING DIAGRAM AND CONNECTORS
6.2 INSPECTING FUNCTIONAL PARTS
7. TROUBLESHOOTING

SECTION 31 – DISASSEMBLING AND ASSEMBLING
1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY

SECTION 32 – ATTACHMENT
1. ATTACHMENT ASSY AND NAME
2. BUCKET
3. ARM
4. BOOM
1. CYLINDER

SECTION 33 – UPPER STRUCTURE
1. CAB
2. OPERATOR SEAT
3. BATTERY
4. GUARD
5. UNDER COVER
6. FUEL TANK
7. HYDRAULIC TANK
8. HYDRAULIC PUMP
9. AIR CLEANER
10. MUFFLER
11. COUNTERWEIGHT
12. RADIATOR & OIL COOLER
13. ENGINE
14. INSTRUMENT PANEL
15. MULTI CONTROL VALVE (OPT)
16. CONTROL VALVE
17. PILOT VALVE (FOR ATT)
18. PILOT VALVE (FOR TRAVEL)
19. SWING MOTOR UNIT
20. SWIVEL JOINT
21. UPPER FRAME
1. HYDRAULIC PUMP REGULATOR
2. CONTROL VALVE
3. PILOT VALVE (FOR ATT)
4. PILOT VALVE (FOR TRAVEL)
5. SWING MOTOR UNIT
6. SWIVEL JOINT

SECTION 34 – TRAVEL SYSTEM
1. TRAVEL SYSTEM
2. CRAWLER
2.1 REMOVING CRAWLER
2.2 INSTALLING
2.3 CONSTRUCTION
2.4 MAINTENANCE STANDARD
2.5 TOOLS AND JIGS
3. UPPER ROLLER
3.1 UPPER ROLLER ASSY
3.2 REMOVING
3.3 INSTALLING
3.4 CONSTRUCTION
3.5 DISASSEMBLY AND ASSEMBLY
3.6 MAINTENANCE STANDARD
3.7 TOOLS AND JIGS
4. LOWER ROLLER (TRACK ROLLER)
4.1 LOWER ROLLER ASSY
4.2 REMOVAL
4.3 INSTALLATION
4.4 CONSTRUCTION
4.5 DISASSEMBLY AND ASSEMBLY
4.6 MAINTENANCE STANDARD
4.7 TOOLS AND JIGS
5. FRONT IDLER (IDLER ADJUSTER ASSY)
5.1 FRONT IDLER ASSY
5.2 REMOVING
5.3 IDLER ASSY
5.4 IDLER ADJUSTER ASSY
6. SPROCKET
6.1 REMOVING
6.2 INSTALLING
6.3 MAINTENANCE STANDARD
6.4 TOOLS AND JIGS
7. TRAVEL MOTOR
7.1 TRAVEL MOTOR
7.2 REMOVING
7.3 INSTALLING
8. SWING BEARING
8.1 SWING BEARING ASSY
8.2 REMOVING
8.3 INSTALLING
8.4 CONSTRUCTION
8.5 DISASSEMBLY AND ASSEMBLY
8.6 MAINTENANCE STANDARD
1. REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT

SECTION 41 – TROUBLESHOOTING (MECHATRO CONTROL)
1. OUTLINE
2. TABLE OF ACTUATOR FOR TROUBLESHOOTING ; MECHATRO CONTROL
3. TROUBLESHOOTING OUTLINE ; MECHATRO CONTROL
4. CHECK POINTS FOR MECHATRO SYSTEM

SECTION 42 – TROUBLESHOOTING (HYDRAULIC)
1. TROUBLE DIAGNOSIS
2. TROUBLESHOOTING

SECTION 43 – TROUBLESHOOTING (ELECTRIC)
1. TROUBLE DIAGNOSIS TABLE; ELECTRIC
2. SELF DIAGNOSIS TABLE
3. SERVICE DIAGNOSIS TABLE
4. TROUBLESHOOTING

SECTION 44 – TROUBLESHOOTING (ENGINE)
1. TROUBLE DIAGNOSIS TABLE; ENGINE
2.TROUBLESHOOTING

SECTION 51 – ENGINE
GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS
NOTES ON THE FORMAT OF THIS MANUAL
MAIN DATA AND SPECIFICATIONS
TIGHTENING TORQUE SPECIFICATIONS
ANGULAR NUT AND BOLT TIGHTENING METHOD
MAJOR PART FIXING NUTS AND BOLTS
IDENTIFICATIONS
MAINTENANCE
LUBRICATING SYSTEM
FUEL SYSTEM
COOLING SYSTEM
VALVE CLEARANCE ADJUSTMENT
INJECTION TIMING
COMPRESSION PRESSURE MEASUREMENT
TURBOCHARGER INSPECTION
ENGINE REPAIR KIT
RECOMMENDED LUBRICANTS
ENGINE OIL VISCOSITY CHART
DISASSEMBLY
EXTERNAL PARTS DISASSEMBLY STEPS
MAJOR COMPONENTS
ROCKER ARM AND ROCKER ARM SHAFT DISASSEMBLY STEPS
CYLINDER HEAD DISASSEMBLY STEPS
PISTON AND CONNECTING ROD DISASSEMBLY STEPS
INSPECTION & REPAIR
CYLINDER HEAD
VALVE GUIDE
VALVE SPRING
TAPPET
PUSH ROD
ROCKER ARM SHAFT AND ROCKER ARM
IDLER GEAR AND IDLER GEAR SHAFT
CAMSHAFT
CYLINDER BODY AND LINER
PISTON AND PISTON RING
PISTON PIN
CONNECTING ROD
CRANKSHAFT
FLYWHEEL AND FLYWHEEL HOUSING
TIMING GEAR CASE COVER
REASSEMBLY
PISTON AND CONNECTING ROD REASSEMBLY STEPS
CYLINDER HEAD REASSEMBLY STEPS
ROCKER ARM AND ROCKER ARM SHAFT REASSEMBLY STEPS
MAJOR COMPONENT REASSEMBLY STEPS I
MAJOR COMPONENT REASSEMBLY STEPS II
EXTERNAL PARTS REASSEMBLY STEPS (LEFT-HAND SIDE)
EXTERNAL PARTS REASSEMBLY STEPS (RIGHT-HAND SIDE)
ENGINE TUNING OPERATION
ENGINE SECTIONAL VIEW
LUBRICATING SYSTEM
GENERAL DESCRIPTION
OIL PUMP
MAIN OIL FILTER
OIL COOLER
COOLING SYSTEM
GENERAL DESCRIPTION
WATER PUMP
THERMOSTAT
FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FILTER
INJECTION NOZZLE
INJECTION PUMP CALIBRATION DATA
TURBOCHARGER
CONSTRUCTION
CAUTIONS TO BE EXERCISED ON HANDLING
INSPECTION PROCEDURE
TROUBLESHOOTING
AIR COMPRESSOR
GENERAL DESCRIPTION
DISASSEMBLY STEPS
INSPECTION AND REPAIRS
REASSEMBLY STEPS
ENGINE ELECTRICALS
STARTER IDENTIFICATION
STARTER MAIN DATA AND SPECIFICATIONS
STARTER SECTIONAL VIEW
STARTER EXPLODED VIEW
ALTERNATOR IDENTIFICATION
MAIN DATA AND SPECIFICATIONS
ALTERNATOR SECTIONAL VIEW
ALTERNATOR EXPLODED VIEW
TROUBLESHOOTING
HARD STARTING
UNSTABLE LOW IDLING
INSUFFICIENT POWER
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
OVERHEATING
WHITY EXHAUST SMOKE
DARKISH EXHAUST SMOKE
OIL PRESSURE DOES NOT RISE
ABNORMAL ENGINE NOISE
SPECIAL TOOL LIST
SPECIAL TOOL LIST
CONVERSION TABLE
LENGTH
AREA
VOLUME
MASS
PRESSURE
TORQUE
TEMPERATURE

SECTION 63 – MOUNTING THE BREAKER AND NIBBLER & BREAKER
1. LIST OF ADDITIONAL PARTS
1.1 ADDITIONAL PARTS FOR THE MODIFICATION OF THE NIBBLER & BREAKER
1.2 ADDITIONAL PARTS FOR THE MODIFICATION OF THE BREAKER
2. SUMMARY
2.1 GENERAL PRECAUTIONS
2.2 BASIC METHOD TO BE TAKEN WHEN MOUNTING
2.3 OUTLINE OF MODIFICATION
3. HYDRAULIC CIRCUIT DIAGRAM
3.1 HYDRAULIC CIRCUIT DIAGRAM OF NIBBLER & BREAKER (2 WAY P/V)
3.2 HYDRAULIC CIRCUIT FOR BREAKER
3.3 HYDRAULIC COMPONENTS
4. ELECTRIC SYSTEM DIAGRAM FOR NIBBLER & BREAKER
5. MODIFICATION PROCEDURE FOR NIBBLER & BREAKER
5.1 MODIFICATION ITEM
5.2 FLOOR MAT (NIBBLER & BREAKER)
5.2a MODIFICATION OF THE CONTROL VALVE ( BREAKER, NIBBLER & BREAKER)
5.2b REPLACEMENT OF RETURN FILTER OF THE HYDRAULIC TANK
5.3 REMOTE CONTROL PIPING; P/V
5.4 CONTROL BLOCK PIPING
5.5 MAIN REMOTE CONTROL PIPING; C/V
5.6 UPPER HYDRAULIC PIPING (NIBBLER & BREAKER)
5.7 MODIFICATION OF THE INSTRUMENT PANEL
5.8 INSTALL OF THE NAME PLATE
6. MODIFICATION PROCEDURE FOR BREAKER
6.1 MODIFICATION ITEM
6.2 FLOOR MAT (NIBBLER)
6.2a MODIFICATION OF THE CONTROL VALVE (SAME AS N&B, SEE ITEM 5.2a)
6.2b MODIFICATION OF THE HYDRALUIC TANK (SAME AS N&B, SEE ITEM 5.2b)
6.3 REMOTE CONTROL PIPING
6.4 REMOTE CONTROL BLOCK (SAME AS N&B, SEE ITEM 5.4)
6.5 MAIN REMOTE CONTROL PIPING; C/V
6.6 UPPER HYDRAULIC PIPING (BREAKER)
6.7 INSTALL OF THE NAME PLATE
7. MODIFICATION PROCEDURE FOR ATTACHMENT
8. REMINDERS ON THE USE OF NIBBLER & BREAKERS
9. PRECAUTIONS TO BE EXERCISED ON BREAKERS OF DIFFERENT MANUFACTURERS
10. REFERENCE

 

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