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Fiat Hitachi Excavator EX135 EX215 Engine Workshop Manual – PDF DOWNLOAD
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Fiat Hitachi Excavator EX135 EX215 Engine Workshop Manual – PDF DOWNLOAD
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Description
Fiat Hitachi Excavator EX135 EX215 Engine Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
Fiat Hitachi Excavator EX135 EX215 Engine Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 205
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Fiat Hitachi Excavator EX135 EX215 Engine Workshop Manual – PDF DOWNLOAD
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
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Fiat Hitachi Excavator EX135 EX215 Engine Workshop Manual – PDF DOWNLOAD
ENGINE.............................................................................................................. 1 Introduction........................................................................................................ 2 List of Sections.................................................................................................... 4 Section1 - Diagnostics.......................................................................................... 5 Diagnostics ................................................................................................ 6 Section2 - Removal & Installation Ex 135 Engine................................................................. 17 Engine/Pumps Assembly Removal............................................................................... 18 Air Conditioner......................................................................................... 21 Electrical Connections.................................................................................. 21 Hydraulic Pumps......................................................................................... 22 Engine/Pumps Assembly Lifting........................................................................... 22 Engine/Pumps Assembly Installation.......................................................................... 23 Tightening Torques...................................................................................... 23 Filling..................................................................................................... 24 Fuel System Air Bleeding................................................................................ 25 Filling The Cooling Sistem.............................................................................. 26 Hydraulic System Oil Refilling.......................................................................... 27 Section3 - Engine Ex 135 Overhaul............................................................................... 28 Specifications and data..................................................................................... 30 Mounting clearances - Data.................................................................................. 33 Graphic Representation and Symbols.......................................................................... 40 Tightening torques.......................................................................................... 41 Special tools............................................................................................... 42 Stripping down the engine in the Workshop................................................................... 44 Repairs - Cylinder block - Checks and measurements.......................................................... 50 Replacement of cylinder liners.......................................................................... 51 Camshaft - Bushes - Valve Lifters........................................................................... 52 Cam pitch and bearing journal alignment check............................................................... 53 Driven toothed wheel replacement............................................................................ 53 Bush replacement............................................................................................ 53 Valve lifters............................................................................................... 54 Replacement of valve lifters............................................................................ 54 Mounting of valve lifters - camshaft.................................................................... 55 Crankshaft.................................................................................................. 56 Main and connecting rod bearing journals.................................................................... 56 Check of main bearing journal alignment..................................................................... 57 Replacement of driving toothed wheel steering and oil pump.................................................. 58 Mounting of main bearings................................................................................... 58 Checking of main bearing journal mounting clearance......................................................... 58 Crankshaft end play check............................................................................... 59 Rear flywheel cover......................................................................................... 60 Engine flywhee.............................................................................................. 60 Replacement of engine flywheel toothed wheel................................................................ 60 Connecting rod ± piston assembly............................................................................ 61 Piston...................................................................................................... 61 Piston diameter measurement............................................................................. 61 Piston pins................................................................................................. 62 Piston rings................................................................................................ 63 Connecting rods............................................................................................. 63 Check of rectangularity of connecting rod............................................................... 64 Bushes...................................................................................................... 64 Mounting of connecting rod - piston assembly................................................................ 65 Connecting rod - piston mating.......................................................................... 65 Connecting rod - piston rectangularity check............................................................ 65 Mounting of piston rings................................................................................ 65 Adjustment of the mounting clearance of the connecting rod journals......................................... 66 Mounting of connecting rod covers....................................................................... 67 Steering.................................................................................................... 67 Check and replacement of the transmission gear wheel........................................................ 67 Replacement of bush for transmission gear wheel............................................................. 67 Mounting of the transmission gear wheel and adjustment of the steering.................................. 68 Cylinder head............................................................................................... 68 Tightness check......................................................................................... 68 Dismounting of valves....................................................................................... 69 Check of cylinder head bearing surface on cylinder block................................................ 69 Valves...................................................................................................... 69 Removal of incrustration and valve check.................................................................... 69 Valve grinding.......................................................................................... 70 Boring of inner surfaces of valve stem guides........................................................... 70 Check of clearance between valve spindle and valve stem guide........................................... 70 Refinishing of valve seats.................................................................................. 71 Valve sealing test...................................................................................... 71 Remounting of valves.................................................................................... 71 Mounting of cylinder head............................................................................... 72 Rods........................................................................................................ 73 Mounting of valve lifter shaft and adjustment of working clearance between valves and valve liftersi.... 74 Lubrication................................................................................................. 74 Oil pump.................................................................................................... 74 Oil filter.................................................................................................. 76 Oil pump assembly....................................................................................... 76 Cooling system.............................................................................................. 76 Water pump.................................................................................................. 76 Thermostat.................................................................................................. 76 Carrying out engine assembly at work bench.............................................................. 77 Injection pump installation and timing...................................................................... 77 Adjustment of the driving belt tension: water pump ± generator and fan...................................... 79 Turbocharger................................................................................................ 82 Description............................................................................................. 82 Necessary checks before dismounting the turbocharger from the engine.................................... 83 Dismounting................................................................................................. 83 Checks.................................................................................................. 85 Mounting................................................................................................ 86 Fuel feed................................................................................................... 88 Dismounting............................................................................................. 88 Calibration................................................................................................. 88 Injection pump.............................................................................................. 89 Marking..................................................................................................... 89 BOSCH stock number.......................................................................................... 89 Mode of operation........................................................................................... 90 Feed step............................................................................................... 90 Delivery................................................................................................ 90 Automatic injection adjustment.......................................................................... 91 Starting device disconnected............................................................................ 92 Load±dependent feed start (L.F.B.)...................................................................... 93 Description............................................................................................. 93 Position of the governor collar in the LFB.............................................................. 94 L.D.A. device (load±dependent feed adjustment).......................................................... 95 Mode of operation....................................................................................... 94 Dismounting of the injection pump....................................................................... 95 Checks .....................................................................................................101 Check of pressure increasing control valve..............................................................108 Pre±adjustment of the adjustment screw for the L.D.A. device............................................109 Lift adjustment of the L.D.A. device....................................................................110 Adjustment of the starting dimension "MS" (only engine 8040.45).........................................112 Calibration tables......................................................................................114 Section4 - Removal & Installation Ex215 Engine..................................................................118 Engine/Pumps Assembly Removal...............................................................................119 Air Conditioner.........................................................................................122 Electrical Connections..................................................................................122 Hydraulic Pumps.........................................................................................123 Engine/Pumps Assembly Lifting...........................................................................123 Engine/Pumps Assembly Installation..........................................................................124 Tightening Torques......................................................................................124 Filling.....................................................................................................125 Fuel System Air Bleeding................................................................................126 Filling The Cooling Sistem..............................................................................127 Hydraulic System Oil Refilling..........................................................................128 Section5 - Engine Ex215 Overhaul................................................................................129 Specifications and data.....................................................................................131 Fitting data................................................................................................134 Graphic Representations and Symbols.........................................................................141 Tightening torques..........................................................................................142 Tools.......................................................................................................143 Stripping down the engine in the workshop...................................................................145 Repeirs Cylinder block Checks and measurements..............................................................150 Replacement of cylinder liners..............................................................................151 Camshaft....................................................................................................152 Bushes - valve lifters......................................................................................152 Cam pitch and bearing journal alignment check...............................................................152 Driven toothed wheel replacement............................................................................152 Bushes......................................................................................................153 Bush replacement............................................................................................153 Valve lifters...............................................................................................154 Replacement of valve lifters................................................................................154 Mounting of valve lifters - Camshaft....................................................................154 Crankshaft..................................................................................................155 Main and connecting rod bearing journals....................................................................156 Check of main bearing journal alignment.....................................................................157 Replacement of driving toothed wheel steering and oil pump..................................................157 Mounting of main bearings...................................................................................158 Crankshaft end play check...............................................................................158 Rear flywheel cover.........................................................................................160 Engine flywheel.............................................................................................160 Replacement of engine flywheel toothed wheel................................................................160 Mounting of engine flywheel.............................................................................160 Connecting rod -piston assembly.............................................................................160 Piston......................................................................................................161 Piston diameter measurement.............................................................................161 Piston pin..................................................................................................161 Check of correct fit between piston pin and piston......................................................161 Piston rings................................................................................................162 Connecting rods.............................................................................................163 Check of rectangularity of connecting rod...............................................................164 Bushes......................................................................................................164 Mounting of connecting rod - piston assembly................................................................164 Connecting rod -piston mating...........................................................................164 Mounting of piston rings................................................................................165 Adjustment of the mounting clearance of the connecting rod journals.........................................166 Mounting of connecting rod covers.......................................................................166 Steering....................................................................................................166 Check and replacement of the transmission gear wheel........................................................166 Replacement of bush for transmission gear wheel.............................................................167 Mounting of the transmission gear wheel and adjustment of the steering..................................167 Cylinder head...............................................................................................168 Tightness check.........................................................................................168 Dismounting of valves.......................................................................................168 Check of cylinder head bearing surface on cylinder block................................................168 Valves......................................................................................................169 Removal of incrustration and valve check....................................................................169 Valve grinding..........................................................................................169 Check of clearance between valve spindle and valve stem guide...........................................169 Valve stem guide............................................................................................169 Boring of inner surfaces of valve stem guides...........................................................170 Remounting of valves....................................................................................171 Mounting of cylinder head...............................................................................171 Mounting of valve lifter shaft and adjustment of working clearance between valves and valve lifters.....173 Lubrification...............................................................................................174 Oil pump....................................................................................................174 Oil filter..................................................................................................176 Oil pump assembly.......................................................................................176 Cooling system..............................................................................................176 Water pump..................................................................................................176 Thermostat..................................................................................................177 Carrying out engine assembly at work bench..............................................................177 Injection pump installation and timing......................................................................177 Adjustment of the tension of control belts: water pump - generator and fan..................................178 Turbocharger................................................................................................181 Description.............................................................................................181 Necessary checks before dismounting the turbocharger from the engine....................................181 Dismounting.................................................................................................182 Checks..................................................................................................183 Mounting................................................................................................185 Fuel system.................................................................................................187 Injectors...................................................................................................187 Calibration.............................................................................................187 Dismantling.............................................................................................187 Injection pump with RSV speed governor......................................................................188 L.D.A. device (delivery adjustment as a function of load)...............................................188 Pump marking............................................................................................188 Speed governor marking..................................................................................188 Speed governor..........................................................................................188 High -pressure pumping elements.........................................................................188 Delivery valves.........................................................................................189 Pressure control valve assembly.........................................................................189 Fuel injector units.....................................................................................189 Calibration tables......................................................................................191 Section6 - Recharge and Start - Up .............................................................................194 Starter Motor...............................................................................................195 Quick diagnosis.........................................................................................195 Magneti Marelli MT 67CB - 4kW...........................................................................196 Test and checks on the vehicle Current absorption test..................................................197 Voltage drop test on the circuit........................................................................197 Excessive voltage drop test on the circuit..............................................................197 Starter motor earth test................................................................................198 Voltage drop test on the solenoid contacts..............................................................198 Disassembly.............................................................................................199 Assembly................................................................................................199 Bench test..............................................................................................200 Alternator..................................................................................................201 Quick diagnosis.........................................................................................201 Bosch NL1 28V 10/55A................................................................................202 Test and Checks the Vehicle.................................................................................203 Maximum output test.....................................................................................203 Pressure drop test on the circuit.......................................................................203 Voltage drop test on the earth circuit..................................................................204 Voltage regulator calibration test......................................................................204 Alternator belt tensioning..............................................................................204 Disassembly and bench test..............................................................................205 Assembly................................................................................................205
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