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Fiat Hitachi EX135 Excavator (3 Manual Set) Shop Manual + Technical Manual +Troubleshooting Manual – PDF DOWNLOAD
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Fiat Hitachi EX135 Excavator (3 Manual Set) Shop Manual + Technical Manual +Troubleshooting Manual
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Description
Fiat Hitachi EX135 Excavator (3 Manual Set) Shop Manual + Technical Manual +Troubleshooting Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:600+
DOWNLOADABLE:YES
FILE TYPE:PDF
FIAT HITACHI EX135 EXCAVATOR (3 MANUAL SET) SHOP MANUAL + TECHNICAL MANUAL +TROUBLESHOOTING MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Fiat Hitachi EX135 Excavator (3 Manual Set) Shop Manual + Technical Manual +Troubleshooting Manual
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.
ADDITIONAL REFERENCES:
Please refer to the materials listed below in addition to this service manual:
- The Operator’s Manual
- The Spare Parts Catalog
SERVICE MANUAL COMPOSITION
The complete service manual consists of four books:
- Technical Manual – Operational Principle
- Technical Manual – Troubleshooting
- Excavator Workshop Manual
- Engine Workshop Manual
– The Technical Manual (Operational Principle) includes the technical information concerning the operation of main devices and systems.
– The Technical Manual (Troubleshooting) includes the technical information needed for operational performance tests, and troubleshooting procedures.
– The Excavator and the Engine Workshop Manuals include 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.
TABLE OF CONTENTS:
Fiat Hitachi EX135 Excavator (3 Manual Set) Shop Manual + Technical Manual +Troubleshooting Manual
TECHNICAL MANUAL:
TECHNICAL MANUAL........................................... 1 INTRODUCTION............................................... 2 SECTION AND GROUP CONTENTS................................. 4 Section 1 - GENERAL.................................... 5 Group 1 - Specification............................ 6 Excavator Dimensions........................... 6 Excavator performance.......................... 7 Engine......................................... 7 Engine accessory............................... 7 Hydraulic Device............................... 8 Electrical Equipment........................... 9 Group 2 - Components layout........................ 10 Section 2 - SYSTEM..................................... 18 Group 1 - Control system........................... 19 Outline........................................ 19 Engine control................................. 20 Valve control.................................. 26 Other control function......................... 29 Group 2 - Hydraulic system......................... 31 Main circuit................................... 31 Pilot circuit.................................. 32 Neutral circuit................................ 33 Single actuator operation...................... 33 Combined operation............................. 34 Group 3 - Electrical system........................ 37 Outline........................................ 37 Electric power circuit......................... 38 Bulb check circuit............................. 39 Intake air heater circuit...................... 40 Starting circuit............................... 42 Charging circuit............................... 44 Surge voltage prevention circuit............... 45 Accessory circuit.............................. 46 Engine stop circuit............................ 47 Engine emergency stop.......................... 48 Section 3 - COMPONENT OPERATION........................ 49 Group 1 - Pump device.............................. 50 Outline........................................ 50 Main pump...................................... 51 Regulator...................................... 54 Pilot pump..................................... 61 Pump delivery pressure sensor.................. 61 Group 2 - Swing device............................. 62 Outline........................................ 62 Swing motor.................................... 63 Brake valve.................................... 65 Swing parking brake............................ 67 Swing reduction gear........................... 68 Group 3 - Control valve............................ 70 Outline........................................ 70 Hydraulic circuit.............................. 75 Flow combiner valve............................ 77 Pump control valve............................. 78 Main relief valve.............................. 80 Overload relief valve.......................... 80 Arm regenerative valve......................... 81 Boom anti-drift valve, arm anti-drift valve.... 83 Bucket flow control valve...................... 83 Travel flow control valve...................... 85 Travel/boom lower selector valve............... 85 Boom regenerative valve........................ 87 Group 4 - Pilot valve.............................. 88 Outline........................................ 88 Operation...................................... 90 Group 5 - Travel device............................ 98 Outline........................................ 98 Travel reduction gear.......................... 99 Travel motor...................................100 Travel brake valve.............................104 Parking brake..................................106 Group 6 - Others components (Upperstructure).......107 Pilot shut-off valve...........................107 Shockless valve................................108 Solenoid valve unit............................110 Pilot relief valve.............................112 EC motor.......................................112 Group 7 - Others components (Undercarriage)........113 Swing bearing..................................113 Center joint...................................114 Track adjuster.................................115 Troubleshooting Manual
TROUBLESHOOTING................................................................... 1 INTRODUCTION...................................................................... 2 SECTION AND GROUP CONTENTS........................................................ 28 Section 4 - Operational Performance Test...................................... 29 Group 1 Introduction...................................................... 30 Operational performance test.......................................... 30 Preparation for performance tests..................................... 31 Group 2 Standard.......................................................... 32 Operational Performance standard tables............................... 32 Main pump P-Q diagram................................................. 36 Group 3 Engine test....................................................... 38 Engine speed.......................................................... 38 Group 4 Excavator test.................................................... 40 Travel speed.......................................................... 40 Track revolution speed................................................ 41 Mistrack check........................................................ 42 Travel parking function check......................................... 43 Swing speed........................................................... 44 Swing function drift check............................................ 45 Swing motor leakage................................................... 46 Swing bearing play.................................................... 47 Maximum swingable slant angle......................................... 48 Hydraulic cylinder cycle time......................................... 49 Dig function drift check.............................................. 51 Control lever operating force......................................... 52 Control lever stroke.................................................. 53 Combined boom raise/swing function check.............................. 54 Group 5 Component test.................................................... 56 Primary pilot pressure................................................ 56 Secondary pilot pressure.............................................. 58 Solenoid valve set pressure........................................... 59 Main pump delivery pressure........................................... 61 Main relief valve set pressure........................................ 62 Overload relief valve set pressure.................................... 66 Main pump flow test................................................... 69 Swing motor drainage.................................................. 73 Travel motor drain oil pressure....................................... 75 Section 5 - Troubleshooting................................................... 78 Group 1 Diagnosing Procedure.............................................. 80 Introduction.......................................................... 80 Diagnosing Procedure.................................................. 81 Dr.EX................................................................. 83 Dr.EX Start-Up Procedure.............................................. 83 Dr.EX Fault Code...................................................... 84 Dr.EX Monitoring Function............................................. 85 Dr.EX Special Function (Service Mode)................................. 86 Adjustable Data List.................................................. 93 Group 2 Component Layout.................................................. 94 Main Components....................................................... 94 Electrical System (Overall System).................................... 95 Electrical System (Relays)............................................ 96 Electrical System (Monitor and Switch Panels)......................... 97 Pump and Related Parts................................................ 98 Control Valve......................................................... 99 Others Components.....................................................103 Group 3 Troubleshooting A.................................................104 Troubleshooting A Procedure...........................................104 Fault Codes...........................................................105 Fault Code 01.........................................................107 Fault Code 02, 03.....................................................108 Fault Code 04, 05.....................................................109 Fault Code 06.........................................................110 Fault Code 07.........................................................111 Sensor Operating Range List...........................................112 Group 4 Troubleshooting B.................................................114 Troubleshooting B Procedure...........................................114 Relationship between Machine Trouble Symptoms and Parts in Trouble....115 Correlation between Trouble Symptoms and Part Failures................123 Engine Troubleshooting................................................129 Actuator Control System Troubleshooting...............................141 Front Attachment Control System Troubleshooting.......................147 Swing System Troubleshooting..........................................159 Travel System Troubleshooting.........................................162 Troubleshooting for Other Functions...................................167 Engine Speed Adjustment and Engine Learning...........................169 Exchange Inspection Method............................................170 Group 5 Troubleshooting C.................................................172 Troubleshooting C Procedure...........................................172 Malfunction of Coolant Temperature Gauge..............................173 Malfunction of Fuel Gauge.............................................175 Malfunction of Fuel Level Indicator...................................177 Malfunction of Indicator Light Check System...........................179 Malfunction of Level Check Switch.....................................179 Malfunction of Engine Oil Level Indicator.............................181 Malfunction of Coolant Level Indicator................................183 Malfunction of Hydraulic Oil Level Indicator..........................185 Malfunction of Alternator Indicator...................................187 Malfunction of Engine Oil Pressure Indicator..........................189 Malfunction of Overheat Indicator.....................................191 Malfunction of Air Filter Restriction Indicator.......................193 Malfunction of Buzzer.................................................195 Malfunction of Hour Meter.............................................197 Group 6 Electrical System Inspection......................................198 Precautions for Inspection and Maintenance............................198 Instructions for Disconnecting Connectors.............................200 Fuse Continuity Test..................................................201 Inspection and Replacement of Fusible Links...........................202 Battery Voltage Check.................................................203 How to Troubleshoot Alternator Malfunctions...........................204 Continuity Check......................................................205 Voltage and Current Check.............................................207 Replacement of Relay..................................................211 Group 7 Harness Check.....................................................212 Circuit Check.........................................................212 Shop Manual
EXCAVATOR............................................................................ 1 INTRODUCTION......................................................................... 2 SECTION AND GROUP CONTENTS........................................................... 28 Section 1 - GENERAL INFORMATION.................................................. 29 Group 1 - Precautions for Disassembling and Assembling....................... 30 Precautions for Disassembling and Assembling............................. 30 Group 2 - Tightening Torque.................................................. 34 Tightening Torque Specification.......................................... 34 Torque Chart............................................................. 35 Pipe Thread Connection / Union joint Tightening Torque Specifications.... 38 Section 2 - UPPERSTRUCTURE....................................................... 42 Group 1 - Cab................................................................ 43 Remove and Install Cab................................................... 43 Group 2 - Counterweight...................................................... 49 Remove and Install Counterweight......................................... 49 Group 3 - Main Frame......................................................... 51 Remove and Install Main Frame............................................ 51 Group 4 - Pump Device........................................................ 59 Remove and Install Pump Device........................................... 59 Disassemble Pump Device.................................................. 60 Assemble Pump Device..................................................... 68 Disassemble Regulator.................................................... 80 Assemble Regulator....................................................... 82 Disassemble and Assemble Pilot Pump...................................... 84 Maintenance Standard..................................................... 86 Group 5 - Control Valve...................................................... 89 Remove and Install Control Valve......................................... 89 Disassemble Control Valve 1.............................................. 90 Assemble Control Valve 1................................................. 92 Disassemble Control Valve 2.............................................. 96 Assemble Control Valve 2-1...............................................100 Assemble Control Valve 2-2...............................................102 Disassemble Control Valve 3..............................................106 Assemble Control Valve 3.................................................108 Disassemble Control Valve 4..............................................112 Assemble Control Valve 4-1...............................................116 Assemble Control Valve 4-2...............................................120 Group 6 - Swing Device.......................................................123 Remove and Install Swing Device..........................................123 Disassemble Swing Device.................................................124 Assemble Swing Device....................................................128 Disassemble Swing Motor..................................................132 Assemble Swing Motor.....................................................136 Maintenance Standard.....................................................140 Disassemble Brake Valve..................................................142 Assemble Brake Valve.....................................................144 Group 7 - Pilot Valve........................................................147 Remove and Install Right Pilot Valve.....................................147 Remove and Install Left Pilot Valve......................................150 Remove and Install Travel Pilot Valve....................................153 Disassemble Right and Left Pilot Valve...................................154 Assemble Right and Left Pilot Valve......................................156 Disassemble Travel Pilot Valve...........................................160 Assemble Travel Pilot Valve..............................................162 Group 8 - Pilot Shut-Off Valve...............................................167 Remove and Install Pilot Shut-off Valve..................................167 Disassemble Pilot Shut-off Valve.........................................168 Assemble Pilot Shut-off Valve............................................170 Group 9 - Shockless Valve....................................................173 Remove and Install Shockless Valve.......................................173 Disassemble and Assemble Shockless Valve.................................174 Group 10 - Solenoid Valve....................................................177 Remove and Install Solenoid Valve Unit...................................177 Disassemble Propotional Solenoid Valve...................................178 Assemble Propotional Solenoid Valve......................................180 Group 11- Pilot Relief Valve Unit............................................183 Remove and Install Pilot Relief Valve Unit...............................183 Disassemble Pilot Relief Valve...........................................184 Assemble Pilot Relief Valve..............................................186 Section 3 - UNDERCARRIAGE........................................................189 Group 1 - Swing Bearing......................................................190 Remove and Install Swing Bearing.........................................190 Group 2 - Travel Device......................................................192 Remove and Install Travel Device.........................................192 Disassemble Travel Device................................................193 Assemble Travel Device...................................................199 Disassemble Travel Motor.................................................207 Assemble Travel Motor....................................................209 Disassemble Base Plate...................................................211 Assemble Base Plate......................................................213 Maintenance Standard.....................................................215 Group 3 - Center Joint.......................................................218 Remove and Install Center Joint..........................................218 Disassemble Center Joint.................................................219 Assemble Center Joint....................................................221 Maintenance Standard.....................................................224 Group 4 - Track Adjuster.....................................................226 Remove and Install Track Adjuster........................................226 Disassemble Track Adjuster...............................................227 Assemble Track Adjuster..................................................235 Group 5 - Front Idler........................................................242 Remove and Install Front Idler...........................................242 Disassemble Front Idler..................................................243 Assemble Front Idler.....................................................247 Maintenance Standard.....................................................249 Group 6 - Upper and Lower Roller.............................................250 Remove and Install Upper Roller..........................................250 Remove and Install Lower Roller..........................................253 Disassemble Upper Roller.................................................256 Disassemble Lower Roller.................................................257 Assemble Lower Roller....................................................259 Maintenance Standard.....................................................261 Group 07 - Tracks............................................................264 Remove and Install Tracks................................................264 Maintenance Standard.....................................................268 Section 4 - FRONT ATTACHMENT.....................................................270 Group 1 - Front attachment...................................................271 Remove and install front attachment......................................271 Maintenance Standard.....................................................276 Bucket teeth.............................................................278 Standard dimensions for arm and bucket connection........................279 Group 2 - Cylinders..........................................................281 Remove and install cylinders.............................................281 Hydraulic circuit pressure release procedure.............................289 Disassemble cylinders....................................................290 Assemble cylinders.......................................................294 Maintenance Standard.....................................................298 Special Tools............................................................
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
