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Fiat Hitachi Wheel Excavator EX135W EX165W Engine Workshop Manual – PDF DOWNLOAD
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Fiat Hitachi Wheel Excavator EX135W EX165W Engine Workshop Manual – PDF DOWNLOAD
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Description
Fiat Hitachi Wheel Excavator EX135W EX165W Engine Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
Fiat Hitachi Wheel Excavator EX135W EX165W Engine Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 461
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Fiat Hitachi Wheel Excavator EX135W EX165W Engine Workshop Manual – PDF DOWNLOAD
INTRODUCTION
About the Manual
The procedures in this manual were developed for a shop environment with engine disassembly and assembly being performed on a rollover stand. A Group System has been used to subdivide the instructions by major components and systems. Refer to the Table of Contents (page i-1) for the various groups. The information is presented in very basic terms to make sure the instructions are easily understood. Wrench sizes and shop tooling are identified in the procedure when needed.
Each group contains the following in sequence:
• An Alphabetical Table of Contents (Index).
• Exploded view(s) of all the components in the group.
• General Information Section(s) containing the basic service, maintenance, and design information necessary
to assist in the rebuild of the engine or a component.
• An Alphabetical Table of Contents (Index).
• Exploded view(s) of all the components in the group.
• General Information Section(s) containing the basic service, maintenance, and design information necessary
to assist in the rebuild of the engine or a component.
• Procedural instructions for the disassembly, inspection, repair, and assembly that can be required to rebuild an engine. Additional repairs that are not essential during every rebuild, but can be necessary, are included. These repairs depend on the length of time an engine has been in service and the condition of the parts
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Fiat Hitachi Wheel Excavator EX135W EX165W Engine Workshop Manual – PDF DOWNLOAD
WORKSHOP MANUAL ENGINE................................................ 1 GENERAL INFORMATION.................................................... 5 About the Manual................................................... 6 How To Use The Manual.............................................. 7 Generic Symbols.................................................... 8 lllustrations...................................................... 9 GENERAL SAFETY INSTRUCTIONS........................................ 10 General Repair Instructions........................................ 11 General Cleaning Instructions...................................... 12 Glossary of Terms.................................................. 13 Engine Identification.............................................. 15 Injection Pump Dataplate........................................... 17 General Engine Specifications...................................... 18 Engine Diagram - Components........................................ 21 GENERAL INFORMATION................................................ 25 FUEL SYSTEM........................................................ 26 LUBRICATING SYSTEM................................................. 27 LUBRICATION FOR THE TURBOCHARGER................................... 28 LUBRICATION FOR THE POWER COMPONENTS............................... 29 LUBRICATION FOR THE OVERHEAD....................................... 30 COOLANT SYSTEM..................................................... 31 INTAKE SYSTEM...................................................... 32 EXHAUST GAS SYSTEM................................................. 33 TROUBLESHOOTING PROCEDURES AND TECHNIQUES.......................... 35 TROUBLESHOOTING SYMPTOMS........................................... 35 DISASSEMBLY- ASSEMBLY.................................................. 71 REPAIR TOOLS REQUIRED.............................................. 77 COOLING SYSTEM REPAIR SUMMARY...................................... 78 COOLING SYSTEM REPAIR.............................................. 79 FUEL SYSTEM REPAIR - IN-LINE PUMP.................................. 87 INJECTION PUMP - IDLESPEED ADJUSTMENT..............................100 INTAKE SYSTEM REPAIR SUMMARY.......................................102 INTAKE SYSTEM REPAIR...............................................103 LUBRICATING SYSTEM REPAIR SUMMARY..................................113 LUBRICATING SYSTEM REPAIR..........................................114 ELECTRICAL SYSTEM REPAIR SUMMARY...................................118 ELECTRICAL SYSTEM REPAIR...........................................119 Engine Disassembly and Assembly....................................123 Engine Disassembly and Assembly - Service Tools....................124 Engine Disassembly Check List......................................126 Rollover Stand Engine Mounting (0-5)...............................127 Starter- Removal (0-3).............................................127 Steam Cleaning The Engine (0-2)....................................127 Engine Disassembly (0-1)...........................................127 Engine Weight (0-4)................................................127 Drive Belt - Removal (0-8).........................................128 Oil - Draining (0-6)...............................................128 Lifting Bracket Removal - Rear (0-7)...............................128 Fan Pulley - Removal (0-9).........................................129 Vibration Damper/Crankshaft Pulley Removal (0-10)..................129 Belt Tensioner - Removal (0-11)....................................129 Alternator - Removal (0-13)........................................130 Fan Hub - Removal (0-12)...........................................130 Turbocharger- Removal (0-15).......................................131 Thermostat - Removal (0-14)........................................131 Exhaust Manifold - Removal (0-16)..................................133 Fuel Filter - Removal (0-17).......................................133 Fuel Filter Head - Removal (0-18)..................................134 Fuel Lines - Removal (0-20)........................................134 Dipstick - Removal (0-24)..........................................137 Manifold Cover - Removal (0-15)....................................137 Valve Covers - Removal (0-17)......................................138 Injector Nozzles - Removal (0-28)..................................138 Push Rods - Removal (0-30).........................................139 Rocker Levers - Removal (0-29).....................................139 Front Cover- Removal (0-32)........................................140 Cylinder Head - Removal (0-31).....................................140 Flywheel - Removal (0-34)..........................................141 Water Pump- Removal (0-33).........................................141 Flywheel Housing - Removal (0-35)..................................141 Accessories - Removal (0-36).......................................142 Injection Pump - Removal (In-Line) (0-41)..........................142 Tappet Cover - Removal (0-45)......................................144 Fuel Transfer Pump - Removal (0-44)................................144 Side Oil Fill - Removal (0-46).....................................145 Water Inlet Connection - Removal (0-48)............................145 Oil Cooler - Removal (0-47)........................................145 Oil Pan - Removal (0-49)...........................................146 Rear Seal Housing - Removal (0-51).................................146 Suction Tube - Removal (0-50)......................................146 Camshaft - Removal (0-52)..........................................147 Lube Pump - Removal (0-55).........................................148 Valve Tappets - Removal (0-54).....................................148 Timing Pin Housing - Removal (0-57)................................150 Gear Housing - Removal (0-58)......................................150 Balancer - Removal (0-59)..........................................151 Piston and Rod Assemblies - Removal (0-64).........................153 Crankshaft - Removal (0-65)........................................155 Turbocharger Drain Tube -Removal (0-66)............................157 Cylinder Block- Removing From the Rollover Stand (0-67)............157 Cylinder Block - Prepare for Assembly (0-69).......................157 Crankshaft - Installation (0-71)...................................158 Valve Tappets - Installation (0-70)................................158 Piston and Rod Assemblies -Installation (0-72).....................163 Gear Housing - Installation (0-73).................................170 Lube Pump - Installation (0-74)....................................171 Camshaft - Installation (0-75).....................................172 Timing Pin - Installation (0-78)...................................175 Balancer - Installation (0-79).....................................178 Crankshaft End Play - Measuring (0-80).............................182 Rear Seal - Installation (0-81)....................................182 Suction Tube - Installation (0-82).................................183 Oil Pan - Installation (0-83)......................................184 Oil Pan Sealing Surfaces...........................................184 Oil Cooler - lnstallation (0-84)...................................185 Side Oil Fill - Installation (0-85)................................185 Fuel Transfer Pump - Installation (0-86)...........................185 Tappet Cover - Installation (0-87).................................186 Injection Pump - Installation (0-88)...............................187 Accessories - Installation (0-94)..................................191 Flywheel Housing - Installation (0-95).............................192 Flywheel - Installation (0-96).....................................192 Water Pump - Installation (0-97)...................................193 Front Cover - Installation (0-98)..................................194 Cylinder Head - Installation (0-99)................................195 Push Rods - Installation (0-100)...................................196 Rocker Levers - Installation (0-101)...............................197 Cylinder Head - Tightening (0-102).................................198 Valve Clearance - Adjustment (0-103)...............................200 Injector Nozzles (0 - 104).........................................202 Manifold Cover - Installation (0-106)..............................203 Valve Covers - Installation (0-105)................................203 Fuel Lines - Installation (0-108)..................................204 Fuel Drain Manifold - Installation (0-110).........................204 Fuel Filter Head - Installation (0-114)............................206 Exhaust Manifold - Installation (0-113)............................207 Turbocharger - Installation (0-116)................................208 Thermostat - Installation (0-117)..................................211 Fan Hub - Installation (0-119).....................................212 Vibration Damper - Installation (0-118)............................212 Alternator - Installation (0-122)..................................213 Water Inlet Connection - Installation (0-121)......................213 Belt Tensioner - Installation (0-120)..............................213 Rollover Stand - Engine Removal (0-125)............................215 Drive Belt - Installation (0 -1 2 3 )..............................215 Oil Filter - Installation (0-124)..................................215 Starter - Installation (0-126).....................................216 Cylinder Block - Exploded View.....................................218 Cylinder Block - General Information...............................221 Cylinder Block - Service Tools.....................................222 Cylinder Block Group Inspection Checklist..........................223 Cylinder Block - Precheck Before Disassembly (1-01)................224 Cylinder Block- Disassembly (1-02).................................224 Cylinder Block - Cleaning (1-03)...................................226 Cylinder Block - Inspection (1-01).................................229 Cylinder Block - De-Glazing (1-05).................................231 Expansion and Pipe Plug -Installation (1-06).......................234 Camshaft Expansion Plug - Installation (1-07)......................236 Camshaft Bushing - Installation (1-08).............................237 Cylinder Block - Storing (1-20)....................................239 Dipstick Tube - Replacement (1-09).................................239 Crankshaft - Inspection (1-12).....................................240 Crankshaft - Cleaning (1-11).......................................240 Crankshaft Gear - Replacement (1-13)...............................241 Camshaft - Cleaning (1-14).........................................243 Camshaft and Gear - Inspection (1-15)..............................243 Camshaft Gear - Replacement (1-18).................................248 Camshaft Capscrew - Installation (1-22)............................252 Rubber Element Vibration Damper -Cleaning and Inspection (1-23)....253 Piston and Connecting Rod -Disassembly (1-24)......................255 Piston, Pin and Connecting Rod -Cleaning (1-25)....................255 Piston Inspection (1-26)...........................................256 Piston Pin - Inspection (1-27).....................................257 Connecting Rod - Inspection (1-28).................................258 Rod Bearing Clearance -Checking (1-29).............................258 Piston and Connecting Rod - Assembly (1-30)........................259 Piston Ring Gap - Checking (1-31)..................................260 Piston Rings - Installation (1-32).................................261 Balancer - Disassembly (1-33)......................................262 Balancer - Assembly (1-34).........................................265 Gear Housing and Timing Pin Assembly - Inspection (1-35)...........271 Fuel Pump Stud - Replacement (1-37)................................272 Gear Housing - Disassembly (1-36)..................................272 Data Plate - Replacement (1-38)....................................273 Cylinder Head - Service Tools......................................276 Exploded View......................................................277 General Information................................................279 Cylinder Head - Precheck Before Disassembly (2-01).................280 Cylinder Head - Disassembly (2-02).................................280 Cylinder Head - Cleaning (2-03)....................................281 Valve - Inspection (2-04)..........................................283 Valve Guide Inspection (2-05)......................................285 Cylinder Head Combustion Face Inspection (2-06)....................285 Valve Seat Inspection (2-07).......................................285 Valve Spring Inspection (2-09).....................................286 Cylinder Head Cracks - Reuse Guidelines (2-08).....................286 Cup Plug Replacement (2-10)........................................287 Valves - Grinding (2-11)...........................................289 Valve Seats - Grinding (2-12)......................................290 Calculating the Grinding Depth.....................................290 Cylinder Head - Assembly (2-13)....................................295 Rocker Lever Assembly - Exploded View..............................298 Rocker Lever Assembly - General Information........................300 Rocker Levers - Disassembly (3-01).................................301 Rocker Lever - Inspection (3-03)...................................302 Rocker Levers and Pedestals -Cleaning (3-02).......................302 Rocker Levers - Assembly (3 - 05)..................................303 Rocker Lever Pedestals - Inspection (3 - 04).......................303 Tappets and Push Rods - Exploded View..............................306 General Information................................................307 Tappets and Push Rods - General Information........................307 Push Rods - Inspection (4 - 02)....................................308 Valve Tappets - Inspection (4- 01).................................308 Exploded View - Fuel System........................................310 Injection Pump - General Information...............................311 Injection Pump - Identification....................................311 Injection Pump Repairs.............................................312 Service Tools - Injection Pump.....................................320 Injector Group - Exploded View.....................................321 General Information - Injectors....................................322 Fuel Transfer Pump - General Information...........................323 Fuel Transfer Pump - Identification................................323 Injector- Disassembly..............................................324 Injector - Clean and Inspect.......................................325 Injector - Assembly................................................327 Injector - Testing.................................................329 Fuel Transfer Pump - Piston Style Rebuild..........................330 Fuel Lines - Clean and Inspect High................................332 High Pressure Fuel Lines...........................................332 Fuel Drain Manifold................................................333 Low Pressure Fuel Lines............................................334 Oil Pan and Suction Tube - Exploded View...........................336 Oil Pan and Suction Tube - General Information.....................337 Oil Pan and Suction Tube - Cleaning and Inspection (7 - 01)........338 Lubricating Oil Cooler - Exploded View.............................339 General Information - Lubrication System...........................340 Pressure Regulator Valve - Inspection (7 - 03).....................341 Pressure Regulator Valve -Disassembly (7 - 02).....................341 Filter Bypass Valve - Replace (7 - 05).............................342 Pressure Regulator Valve - Assembly (7 - 04).......................342 Oil Cooler - Cleaning (7- 06)......................................343 Oil Cooler - Inspection (7 - 07)...................................343 Lubricating Oil Pump - Exploded View...............................345 Lubrication Oil Pump - General Information.........................346 Oil Pump - Inspection (7 - 08).....................................347 Water Pump - Exploded View.........................................350 Water Pump - General Information...................................351 Water Pump - Inspection (8-01).....................................352 Belt Tensioner and Fan Hub - Exploded View.........................353 Belt Tensioner and Fan Hub - General Information...................354 Fan Hub - Inspection (8-02)........................................355 Fan Hub - Disassembly (8-03).......................................355 Fan Hub Assembly (8-04)............................................356 Belt Tensioner - Inspection (8-05).................................358 Thermostat Housing Assembly - Exploded View........................359 Thermostat Housing Assembly - General Information..................360 Thermostat - Inspection (8-06).....................................361 General Information About Fans.....................................362 Accessory Drive Adapter - Exploded View............................364 Drive Units - General Information..................................365 Accessory Drive - Cleaning (9-01)..................................366 Accessory Drive Adaptor - Disassembly (9-03).......................366 Accessory Drive - Inspection (9-02)................................366 Accessory Drive Adaptor - Assembly (9 - 04)........................367 Air Intake System - Exploded View..................................370 Air Intake System - General Information............................372 Turbocharger - Cleaning and Inspection for Reuse (10-01)...........373 Air Transfer Pipe - Cleaning and Inspection for Reuse (10-04)......374 Air Crossover Tube - Cleaning and Inspection for Reuse (10-05).....375 Exhaust Manifold - Exploded View...................................376 General Information................................................377 Exhaust Manifold Inspection (11-01)................................378 Turbocharger Mounting Stud Replacement (11-02).....................378 Electrical Equipment - General Information.........................380 Alternator Inspection (13-01)......................................381 Starter Inspection (13-02).........................................381 Engine Testing - Service Tools.....................................382 Engine Testing - Engine Side Views.................................384 Engine Testing - General Information...............................386 Blowby Measurement.................................................387 Engine Dynamometer Test - Installation of the Engine (14- 01)......388 Engine Dynamometer Test - Engine Run-In (14-02)....................394 Engine Dynamometer Test - Performan-ce Checking (14-03)............398 Engine - Painting (14-08)..........................................402 Engine Storage - Short Term (14-09)................................403 Engine Storage - Long Term (14-10).................................405 Removing the Engine from Long-Term Storage.........................408 General Information................................................412 Flywheel and Ring Gear Inspection (16- 01).........................413 Ring Gear Replacement (16-02)......................................413 Flywheel Housing Assembly (16-04)..................................414 Flywheel Housing Inspection (16-03)................................414 GENERALITIES...........................................................418 Specifications - General Information...............................419 Engine Component Torque Values.....................................420 Component Specifications and Torque Values.........................423 Drive Belt Tension.................................................453 Capscrew Markings and Torque Values................................458 Pipe Plug Torque Values............................................459
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