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Fiat Hitachi Excavator EX165 Workshop Manual – PDF DOWNLOAD
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Description
Fiat Hitachi Excavator EX165 Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
Fiat Hitachi Excavator EX165 Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 515
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Fiat Hitachi Excavator EX165 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
RECOGNISE SAFETY INFORMATION
• This is your SAFETY ALERT SYMBOL
• 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
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 FIATHITACHI 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.
• Keep the machine in proper working conditions.
– Unauthorised changes to the machine may
impair function and/or safety and affect machine
life.
– 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
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Fiat Hitachi Excavator EX165 Workshop Manual – PDF DOWNLOAD
WORKSHOP MANUAL............................................................................................. 1 INTRODUCTION................................................................................................ 2 SAFETY PRECAUTIONS.......................................................................................... 4 SECTION AND GROUP CONTENTS.................................................................................. 28 SECTION 1- GENERAL INFORMATION.......................................................................... 30 GROUP 1 - PRECAUTIONS FOR DISASSEMBLING............................................................. 30 PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING.................................................... 31 GROUP 2 - TIGHTENING TORQUE......................................................................... 30 TIGHTENING TORQUE SPECIFICATIONS................................................................ 35 TORQUE CHART.................................................................................... 36 PIPING JOINT.................................................................................... 39 SECTION 2 - UPPERSTRUCTURE.............................................................................. 43 GROUP 1 - CAB....................................................................................... 43 REMOVE AND INSTALL CAB.......................................................................... 44 GROUP 2 - COUNTERWEIGHT............................................................................. 43 REMOVE AND INSTALL COUNTERWEIGHT................................................................ 50 GROUP 3 - MAIN FRAME................................................................................ 43 REMOVE AND INSTALL MAIN FRAME................................................................... 52 GROUP 4 - PUMP DEVICE............................................................................... 43 REMOVE AND INSTALL PUMP DEVICE.................................................................. 60 DISASSEMBLE PUMP DEVICE......................................................................... 61 ASSEMBLE PUMP DEVICE............................................................................ 65 DISASSEMBLE REGULATOR COVER..................................................................... 69 ASSEMBLE REGULATOR COVER........................................................................ 71 DISASSEMBLE AND ASSEMBLE PILOT PUMP............................................................. 73 GROUP 5 - CONTROL VALVE............................................................................. 43 REMOVE AND INSTALL CONTROL VALVE................................................................ 76 DISASSEMBLE CONTROL VALVE 1..................................................................... 77 ASSEMBLE CONTROL VALVE 1........................................................................ 79 DISASSEMBLE CONTROL VALVE 2..................................................................... 83 ASSEMBLE CONTROL VALVE 2-1...................................................................... 87 ASSEMBLE CONTROL VALVE 2-2...................................................................... 89 DISASSEMBLE CONTROL VALVE 3..................................................................... 93 ASSEMBLE CONTROL VALVE 3........................................................................ 95 DISASSEMBLE CONTROL VALVE 4..................................................................... 99 ASSEMBLE CONTROL VALVE 4-1......................................................................103 ASSEMBLE CONTROL VALVE 4-2......................................................................107 GROUP 6 - SWING DEVICE.............................................................................. 43 REMOVE AND INSTALL SWING DEVICE.................................................................110 DISASSEMBLE SWING DEVICE........................................................................111 ASSEMBLE SWING DEVICE...........................................................................115 DISASSEMBLE SWING MOTOR.........................................................................121 ASSEMBLE SWING MOTOR............................................................................125 MAINTENANCE STANDARD............................................................................129 GROUP 7 - PILOT VALVE............................................................................... 43 REMOVE AND INSTALL RIGHT PILOT VALVE............................................................132 REMOVE AND INSTALL LEFT PILOT VALVE.............................................................135 REMOVE AND INSTALL TRAVEL PILOT VALVE...........................................................138 DISASSEMBLE RIGHT AND LEFT PILOT VALVE..........................................................139 ASSEMBLE RIGHT AND LEFT PILOT VALVE.............................................................141 DISASSEMBLE TRAVEL PILOT VALVE..................................................................145 ASSEMBLE TRAVEL PILOT VALVE.....................................................................147 REMOVE AND INSTALL POSITIONING PILOT VALVE......................................................151 DISASSEMBLE POSITIONING PILOT VALVE.............................................................152 GROUP 8 - PILOT SHUT-OFF VALVE...................................................................... 43 REMOVE AND INSTALL PILOT SHUT-OFF VALVE.........................................................164 DISASSEMBLE PILOT SHUT-OFF VALVE................................................................165 ASSEMBLE PILOT SHUT-OFF VALVE...................................................................167 GROUP 9 - SHOCKLESS VALVE........................................................................... 43 REMOVE AND INSTALL SHOCKLESS VALVE..............................................................170 DISASSEMBLE AND ASSEMBLE SHOCKLESS VALVE........................................................171 GROUP 10 - SOLENOID VALVE........................................................................... 43 REMOVE AND INSTALL SOLENOID VALVE UNIT..........................................................174 DISASSEMBLE PROPORTIONAL SOLENOID VALVE.........................................................175 ASSEMBLE PROPORTIONAL SOLENOID VALVE............................................................177 GROUP 11- PILOT RELIEF VALVE UNIT................................................................... 43 REMOVE AND INSTALL PILOT RELIEF VALVE UNIT......................................................180 DISASSEMBLE PILOT RELIEF VALVE..................................................................181 ASSEMBLE PILOT RELIEF VALVE.....................................................................183 SECTION 3 - UNDERCARRIAGE...............................................................................186 GROUP 1 - SWING BEARING.............................................................................186 REMOVE AND INSTALL SWING BEARING................................................................187 GROUP 2 - TRAVEL DEVICE.............................................................................186 REMOVE AND INSTALL TRAVEL DEVICE................................................................189 DISASSEMBLE TRAVEL DEVICE.......................................................................190 DISASSEMBLE TRAVEL REDUCTION GEAR...............................................................191 REASSEMBLY......................................................................................196 ASSEMBLE TRAVEL REDUCTION GEAR..................................................................198 DISASSEMBLE TRAVEL MOTOR........................................................................204 ASSEMBLE TRAVEL MOTOR...........................................................................206 DISASSEMBLE BASE PLATE..........................................................................208 ASSEMBLE BASE PLATE.............................................................................210 MAINTENANCE STANDARD............................................................................212 GROUP 3 - CENTER JOINT..............................................................................186 REMOVE AND INSTALL CENTER JOINT.................................................................215 DISASSEMBLE CENTER JOINT........................................................................216 ASSEMBLE CENTER JOINT...........................................................................218 MAINTENANCE STANDARD............................................................................221 GROUP 4 - TRACK ADJUSTER............................................................................186 REMOVE AND INSTALL TRACK ADJUSTER...............................................................223 DISASSEMBLE TRACK ADJUSTER......................................................................224 ASSEMBLE TRACK ADJUSTER.........................................................................232 GROUP 5 - FRONT IDLER...............................................................................186 REMOVE AND INSTALL FRONT IDLER..................................................................239 DISASSEMBLE FRONT IDLER.........................................................................240 ASSEMBLE FRONT IDLER............................................................................244 MAINTENANCE STANDARD............................................................................246 GROUP 6 - UPPER AND LOWER ROLLER....................................................................186 REMOVE AND INSTALL UPPER ROLLER.................................................................247 REMOVE AND INSTALL LOWER ROLLER.................................................................250 DISASSEMBLE UPPER ROLLER........................................................................253 DISASSEMBLE LOWER ROLLER........................................................................254 ASSEMBLE LOWER ROLLER...........................................................................256 MAINTENANCE STANDARD............................................................................258 GROUP 07 - TRACKS...................................................................................186 REMOVE AND INSTALL TRACKS.......................................................................261 MAINTENANCE STANDARD............................................................................265 SECTION 4 - FRONT ATTACHMENT............................................................................267 GROUP 1 - FRONT ATTACHMENT..........................................................................267 REMOVE AND INSTALL FRONT ATTACHMENT (Monobloc Version)..........................................268 MAINTENANCE STANDARD (Monobloc Version).........................................................273 BUCKET TEETH....................................................................................275 STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION...............................................276 REMOVE AND INSTALL FRONT ATTACHMENT (Triple Articulation Version)...............................278 MAINTENANCE STANDARD (Triple Articulation Version)..............................................283 GROUP 2 - CYLINDERS.................................................................................267 REMOVE AND INSTALL CYLINDERS....................................................................286 HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE....................................................297 DISASSEMBLE CYLINDERS...........................................................................299 ASSEMBLE CYLINDER...............................................................................305 MAINTENANCE STANDARD............................................................................311 SPECIAL TOOLS...................................................................................312 SECTION 5 - ENGINE......................................................................................313 GROUP 1- GENERAL INFORMATION........................................................................313 GENERAL REPAIR INSTRUCTIONS.....................................................................314 NOTES ON THE FORMAT OF THIS MANUAL..............................................................314 MAIN DATA AND SPECIFICATIONS....................................................................318 PERFORMANCE CURVE...............................................................................321 EXTERNAL VIEW...................................................................................327 TIGHTENING TORQUE SPECIFICATIONS................................................................330 ANGULAR NUT AND BOLT TIGHTENING METHOD..........................................................332 MAJOR PART FIXING NUTS AND BOLTS................................................................334 IDENTIFICATIONS.................................................................................345 GROUP 2 - MAINTENANCE...............................................................................346 LUBRIFICATING SYSTEM............................................................................347 FUEL SYSTEM.....................................................................................347 COOLING SYSTEM..................................................................................351 VALVE CLEARANCE AND ADJUSTEMENT.................................................................351 INJECTION TIMING................................................................................353 COMPRESSION PRESSURE MEASUREMENT................................................................357 TURBOCHARGER INSPECTION.........................................................................358 ENGINE REPAIR KIT (FOR NATURALLY ASPIRATED ENGINES).............................................359 ENGINE REPAIR KIT (FOR TURBOCHARGED ENGINES)....................................................360 RECOMMENDED LUBRICANTS..........................................................................361 GROUP 3 - ENGINE ASSEMBLY I (DISASSEMBLY)...........................................................362 EXTERNAL PARTS DISASSEMBLY STEPS (Right-Hand side)..............................................363 EXTERNAL PARTS DISASSEMBLY STEPS (Left-Hand side)...............................................366 MAJOR COMPONENTS - I............................................................................369 ROCKER ARM, AND ROCKER ARM SHAFT DISASSEMBLY STEPS..............................................374 CYLINDER HEAD DISASSEMBLY STEPS.................................................................375 PISTON AND CONNECTING ROD DISASSEMBLY STEPS.....................................................376 GROUP 4 - ENGINE ASSEMBLY II (INSPECTION & REPAIR)..................................................378 CYLINDER HEAD...................................................................................379 VALVE GUIDE.....................................................................................380 VALVE SPRING....................................................................................383 TAPPET..........................................................................................384 PUSH ROD........................................................................................385 ROCKER ARM SHAFT AND ROCKER ARM.................................................................385 IDLER GEAR AND IDLER GEAR SHAFT.................................................................386 CAMSHAFT........................................................................................387 CYLINDER BODY AND LINER.........................................................................388 PISTON AND PISTON RING..........................................................................393 PISTON PIN......................................................................................395 CONNECTING ROD..................................................................................396 CRANKSHAFT......................................................................................398 FLYWHEEL AND FLYWHEEL HOUSING...................................................................405 TIMING GEAR CASE COVER..........................................................................406 GROUP 5 - ENGINE ASSEMBLY III (REASSEMBLY)..........................................................408 PISTON AND CONNECTING ROD REASSEMBLY STEPS......................................................409 PISTON AND CONNECTING ROD.......................................................................410 CYLINDER HEAD REASSEMBLY STEPS..................................................................411 ROCKER ARM AND ROCKER ARM SHAFT REASSEMBLY STEPS................................................415 MAJOR COMPONENT REASSEMBLY STEPS I..............................................................416 MAJOR COMPONENT REASSEMBLY STEPS II.............................................................421 EXTERNAL PARTS REASSEMBLY STEPS (Left-hand side)................................................425 EXTERNAL PARTS REASSEMBLY STEPS (Right-hand side)...............................................429 ENGINE TUNING OPERATION.........................................................................432 ENGINE SECTIONAL VIEW...........................................................................434 GROUP 6 - LUBRICATING SYSTEM........................................................................436 GENERAL DESCRIPTION.............................................................................437 OIL PUMP........................................................................................438 OIL COOLER......................................................................................440 GROUP 7 - COOLING SYSTEM............................................................................442 GENERAL DESCRIPTION.............................................................................443 WATER PUMP......................................................................................444 THERMOSTAT......................................................................................449 GROUP 8 - FUEL SYSTEM...............................................................................450 GENERAL DESCRIPTION.............................................................................451 INJECTION NOZZLE................................................................................452 INJECTION PUMP CALIBRATION DATA.................................................................457 GROUP 9 - TURBOCHARGER..............................................................................466 GENERAL DESCRIPTION.............................................................................467 TURBOCHARGER IDENTIFICATION.....................................................................468 INSPECTION AND REPAIR...........................................................................469 GROUP 10 - AIR COMPRESSOR...........................................................................470 GENERAL DESCRIPTION.............................................................................471 DISASSEMBLY STEPS...............................................................................472 INSPECTION AND REPAIR...........................................................................473 REASSEMBLY STEPS................................................................................475 GROUP 11 - ENGINE ELECTRICALS.......................................................................478 STARTER MOTOR IDENTIFICATION ...................................................................479 STARTER.........................................................................................480 STARTER MOTOR SECTIONAL VIEW....................................................................481 STARTER MOTOR EXPLODED VIEW.....................................................................482 ALTERNATOR IDENTIFICATION.......................................................................483 MAIN DATA AND SPECIFICATIONS....................................................................484 ALTERNATOR SECTIONAL VIEW.......................................................................485 ALTERNATOR EXPLODED VIEW........................................................................486 GROUP 12 - TROUBLESHOOTING..........................................................................488 HARD STARTING...................................................................................489 1) STARTER INOPERATIVE .....................................................................489 2) STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER....................................490 3) ENGINE TURNS OVER BUT DOES NOT START FUEL I S BEING DELIVERED TO THE INJECTION PUMP ....491 4) ENGINE TURNS OVER BUT DOES NOT START.....................................................492 UNSTABLE LOW IDLING ............................................................................493 INSUFFICIENT POWER .............................................................................496 EXCESSIVE FUEL CONSUPTION.......................................................................499 EXCESSIVE OIL CONSUPTION........................................................................501 OVERHEATING.....................................................................................502 WHITE EXHAUST SMOKE.............................................................................504 DARK EXHAUST SMOKE..............................................................................505 OIL PRESSURE DOES NOT RISE......................................................................506 ABNORMAL ENGINE NOISE...........................................................................508 GROUP 13 - SPECIAL TOOL LIST........................................................................512 SPECIAL TOOL LIST...............................................................................513
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- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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