Fiat Hitachi Excavator EX165W Workshop Manual – PDF DOWNLOAD
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Fiat Hitachi Excavator EX165W Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 873
Downloadable : Yes
File Type : PDF
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Fiat Hitachi Excavator EX165W Workshop Manual – PDF DOWNLOAD
TO THE READER
• This manual has been written for a skilled technician, in order to give him the information necessary to repair this machine.
– Read this manual carefully for correct information about repair procedures.
– For any question or comment, or in case you notice a mistake in this manual content, please contact:
INTRODUCTION
2.1 NTRODUCTION
- This service manual has been prepared in order to increase repair quality, providing to the technicians the elements for a good knowledge of the product and showing the proper procedures to carry out the maintenance operations. We recommend to thoroughly read the content and follow it when necessary.
- It is a concise guide for a specific machine. It covers construction features, operation principle, troubleshooting, disassembly and assembly of components and repair action. Using this manual in systematic and rational way it is possible to reduce the repairing errors and delay that could cause machine stop with a detriment of cost management.
- The information quoted in this service manual are supplied also to be used for training aids. Therefore it is advisable to be used in the training of new personnel that will be employed in the machine maintenance
SAFETY PRECAUTIONS
INFORMATION SECTION
GENERALITIES
INFORMATION SECTION
GENERALITIES
Manual carefully before starting, operating, maintaining, fuelling or servicing the machine. Carefully read the explanation to each and all safety signs in the special section of this Manual before starting, operating, maintaining, fuelling or servicing the machine.
- Machine-mounted safety plates are colour coded yellow with black borders when they refer to points where special ATTENTION must be paid and failure to observe them may cause a serious DANGER to the integrity of machine operators. They are white with red borders and black lettering when they refer to a FORBIDDEN practice.
- It is fundamental that all machine operators know very well the meaning of each safety plate as this considerably decreases operating hazards and accidents. Do not allow unauthorised personnel to operate or service this machine. Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts.
- Wear certified safety clothes such as: hard hat, no-slip footwear, heavy gloves, ear protection, safety glasses , reflector vests, respirators every time the job requires it. Ask your employer about safety regulations in force and protective equipment. Always keep the operator’s compartment, step plates, grab-rails and handles clean and clear of foreign objects, oil, grease, mud or snow to minimise the danger of slipping or stumbling. Remove mud or grease from your shoes before operating the machine. Do not jump on or off the machine.
- Always keep both hands and one foot, or both feet and one hand in contact with steps and/or grab rails. Do not use controls or hoses as hand holds. Hoses and controls are movable parts and do not provide solid support. Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments. Never operate the machine or its attachments from any position other than sitting in the driver’s seat. Keep head, body, limbs, hands and feet inside the operator’s compartment at all times to reduce exposure to external hazards. Be careful of possible slippery conditions of the steps and hand rails as well as of the ground around the machine.
- Wear protective boots or shoes with the soles made of highly no-slip rubber. Do not leave the machine until it has come to a complete stop. Always check height, width and weight limitations which may be encountered in the working site and ensure the machine does not exceed them. Assess exact paths of gas ducts, water mains, telephone lines, sewers, overhead and underground electric lines and all other possible obstacles. Such paths should be opportunely defined by competent Authorities.
- If necessary, require that the service is interrupted or said installations are moved prior to starting the work. You must know the working capacity of the machine. Define the rear upperstructure swing area and provide for opportune barriers to prevent access into it. Never exceed machine lifting capacity. Remain within the limits shown in the loading capacity chart located on the machine
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Fiat Hitachi Excavator EX165W Workshop Manual – PDF DOWNLOAD
EXCAVATOR EX165W...................................................................................................................... 1 WORKSHOP MANUAL....................................................................................................................... 1 INDEX................................................................................................................................. 5 SECTION 1 HOW TO USE.............................................................................................................. 4 1. SECTIONS AND GROUPS INDEXES PAGE........................................................................................... 5 2. INTRODUCTION............................................................................................................... 7 2.1 NTRODUCTION........................................................................................................... 7 2.2 MANUAL HANDLING....................................................................................................... 7 2.3 SYMBOLS AND INDICATIONS............................................................................................... 8 3. FEATURES OF THE MANUAL..................................................................................................... 9 3.1 MANUAL COMPOSITION.................................................................................................... 9 3.2 BRIEF INFORMATION FOR MANUAL CONSULTATION ............................................................................ 11 SECTION 2 SAFETY RULES............................................................................................................ 12 INFORMATION SECTION GENERALITIES.............................................................................................. 13 STARTING.................................................................................................................. 13 STOPPING.................................................................................................................. 16 MAINTENANCE............................................................................................................... 17 SAFETY PRECAUTIONS............................................................................................................ 21 SAFETY SIGNS.................................................................................................................. 49 SECTION 3 SPECIFICATIONS.......................................................................................................... 57 1. GENERALITY................................................................................................................. 58 1.1 INTRODUCTION.......................................................................................................... 58 1.2 BASIC COMPONENTS OF THE WHEELED EXCAVATOR WITH MONOBLOC............................................................... 59 1.3 BASIC COMPONENTS OF THE WHEELED EXCAVATOR WITH ARTICULATED ARM....................................................... 60 1.4 IDENTIFICATION DATA................................................................................................... 61 2. TECHNICAL SPECIFICATIONS................................................................................................... 62 2.1 GENERAL SPECIFICATIONS................................................................................................ 62 2.2 DIMENSIONS (mm) - (MONOBLOC VERSION).................................................................................. 67 2.3 DIGGING PERFORMANCES - (MONOBLOC VERSION)............................................................................. 68 2.4 DIMENSIONS (mm) - (TRIPLE ARTICULATION VERSION) Version with individual tyres: 600/40 - 22.5.......................... 69 2.5 DIGGING PERFORMANCES - (TRIPLE ARTICULATION VERSION).................................................................. 70 2.6 DIMENSIONS (mm) - (MONOBLOC VERSION WITH CLAMSHELL BUCKET) Version with individual tyres: 600/40 - 22.5............... 71 2.7 DIGGING PERFORMANCES - (MONOBLOC VERSION WITH CLAMSHELL BUCKET)....................................................... 72 2.8 DIMENSIONS (mm) - (TRIPLE ARTICULATION VERSION WITH CLAMSHELL BUCKET) Version with individual tyres: 600/40 - 22.5.... 73 2.9 DIGGING PERFORMANCES - (TRIPLE ARTICULATION WITH CLAMSHELL BUCKET).................................................... 74 2.10 BUCKET USEFULNESS DEPENDING ON BOOM UCKET B mm....................................................................... 75 2.11 LIFTING CAPACITY..................................................................................................... 76 3. FILLING CHART.............................................................................................................. 79 SECTION 4 SUPERSTRUCTURE.......................................................................................................... 80 1. SUPERSTRUCTURE............................................................................................................. 82 1.1 MAIN FRAME AND COUNTERWEIGHT.......................................................................................... 82 1.2 ENGINE GROUP.......................................................................................................... 83 1.3 HYDRAULIC OIL RESERVOIR............................................................................................... 88 1.4 FUEL RESERVOIR........................................................................................................ 92 1.5 COVERS AND PROTECTIONS................................................................................................ 93 1.6 CAB GROUP............................................................................................................. 96 1.7 CAB HEATER............................................................................................................ 99 1.8 CAB ELECTRIC COMPONENTS..............................................................................................100 1.9 CHASSIS ELECTRIC COMPONENTS...........................................................................................102 1.10 SUPERSTRUCTUE MAINTENANCE............................................................................................108 1.11 SUPERSTRUCTURE HYDRAULIC SYSTEM PIPING...............................................................................123 1.12 FLEXIBLE HOSES AND CONNECTIONS.......................................................................................131 2. HYDRAULIC PUMPS............................................................................................................150 2.1 HYDRAULIC PUMPS.......................................................................................................150 2.2 MAIN PUMP.............................................................................................................152 2.3 SECONDARY PUMP........................................................................................................159 2.4 GEAR DOUBLE PUMP......................................................................................................164 2.1 MAIN PUMP.............................................................................................................166 2.2 SECONDARY PUMP........................................................................................................180 2.3 GEAR DOUBLE PUMP......................................................................................................197 3. CONTROL VALVE..............................................................................................................202 3.1 CONTROL VALVE.........................................................................................................202 3.1 CONTROL VALVE.........................................................................................................222 4. SWING DEVICE...............................................................................................................230 4.1 SWING DEVICE..........................................................................................................230 4.2 SWING HYDRAULIC MOTOR.................................................................................................232 4.3 SWING REDUCTION DEVICE................................................................................................236 4.1 SWING HYDRAULIC MOTOR.................................................................................................238 4.2 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION DEVICE....................................................................250 5. PILOT VALVES...............................................................................................................266 5.1 HAND PILOT VALVE......................................................................................................266 5.2 TRAVEL PILOT VALVE....................................................................................................270 6. CENTER JOINT...............................................................................................................272 6.1 CENTER JOINT..........................................................................................................272 6.1 DISASSEMBLY AND ASSEMBLY OF CENTER JOINT..............................................................................274 7. STEERING VALVE.............................................................................................................276 7.1 STEERING VALVE........................................................................................................276 7.1 STEERING UNIT DISASSEMBLY AND ASSEMBLY................................................................................280 8. BRAKE PEDAL VALVE..........................................................................................................298 8.1 BRAKE PEDAL VALVE.....................................................................................................298 8.1 MAINTENANCE...........................................................................................................302 9. ACCUMULATORS...............................................................................................................304 9.1 ACCUMULATORS..........................................................................................................304 9.1 DISASSEMBLY AND ASSEMBLY OF ACCUMULATOR...............................................................................308 10. SOLENOID VALVES...........................................................................................................310 10.1 SELECTOR SOLENOID VALVES.............................................................................................310 10.2 SERVICES SOLENOID VALVES GROUP.......................................................................................313 SECTION 5 UNDERCARRIAGE...........................................................................................................318 1. UNDERCARRIAGE..............................................................................................................320 1.1 OUTLINES..............................................................................................................320 1.2 LOWER FRAME...........................................................................................................321 1.3 SWING BEARING.........................................................................................................322 1.4 TRAVEL UNIT...........................................................................................................325 1.5 WHEELS................................................................................................................326 1.6 BLADE ASSEMBLY........................................................................................................338 1.7 LATERAL STABILIZERS...................................................................................................339 1.8 HYDRAULIC HOSES AND UNDERCARRIAGE COMPONENTS..........................................................................340 2. TRAVEL HYDRAULIC MOTOR.....................................................................................................358 2.1 TRAVEL HYDRAULIC MOTOR................................................................................................358 2.1 DISASSEMBLY AND ASSEMBLY..............................................................................................362 3. TRANSMISSION...............................................................................................................386 3.1 TRANSMISSION..........................................................................................................386 3.1 TRANSMISSION ASSEMBLY AND DISASSEMBLY.................................................................................396 3.2 GEAR UNIT BROKEN, INSERTION OF 1 st GEAR TO FINISH WORK...............................................................439 3.3 SPECIFIC TOOLS........................................................................................................439 4. AXLES 4.1 REAR AXLE........................................................................................................440 5. TRANSMISSION SHAFT.........................................................................................................487 5. 1 TRANSMISSION SHAFT...................................................................................................487 SECTION 6 FRONT-END ATTACHMENT....................................................................................................491 1. FRONT-END ATTACHMENT.......................................................................................................492 1.1 BOOM ASSEMBLY.........................................................................................................492 1.2 ARM ASSEMBLY..........................................................................................................497 1.3 BUCKET ASSEMBLY.......................................................................................................500 1.4 FRONT PIPINGS.........................................................................................................502 2. HYDRAULIC CYLINDERS........................................................................................................530 2.1 CONSTRUCTION AND FUNCTION.............................................................................................530 SECTION 7 HYDRAULIC SYSTEM........................................................................................................532 1. GENERALITIES...............................................................................................................534 2. MAIN HYDRAULIC SYSTEM......................................................................................................536 2.1 GENERALITIES..........................................................................................................536 2.2 SUCTION CIRCUIT AND DELIVERY CIRCUIT..................................................................................537 2.3 RETURN CIRCUIT........................................................................................................543 2.4 DRAINAGE CIRCUIT......................................................................................................545 3. PILOT/BRAKES SYSTEM........................................................................................................548 3.1 GENERALITIES..........................................................................................................548 3.2 SUCTION DELIVERY AND RETURN CIRCUIT...................................................................................548 4. STEERING SYSTEM............................................................................................................556 4.1 GENERALITIES..........................................................................................................556 4.2 SUCTION DELIVERY AND RETURN CIRCUIT...................................................................................557 5. BRAKES SYSTEM..............................................................................................................560 5.1 GENERALITIES..........................................................................................................560 5.2 DESCRIPTION OF BRAKES SYSTEM..........................................................................................560 5.3 OPERATION OF BRAKE PEDAL VALVE........................................................................................562 6. OPERATION OF CIRCUITS......................................................................................................566 6.1 GENERALITIES..........................................................................................................566 6.2 CIRCUIT WITH CONTROLS IN NEUTRAL......................................................................................567 6.3 BOOM CIRCUIT..........................................................................................................569 6.4 DIPPER STICK CIRCUIT..................................................................................................571 6.5 BUCKET CIRCUIT........................................................................................................573 6.6 POSITIONER ARM CIRCUIT................................................................................................575 6.7 TRAVEL CIRCUIT........................................................................................................577 6.8 BLADE (SMALL DOZER) BLADE CONTROL.....................................................................................579 6.9 SIDE STABILISERS CONTROL CIRCUIT......................................................................................581 6.10 TURRET SWING CIRCUIT.................................................................................................583 7. TRAVEL CIRCUIT.............................................................................................................586 7.1 DESCRIPTION...........................................................................................................586 7.2 TRAVEL HYDRAULIC MOTOR CONTROL CIRCUIT................................................................................586 8. HYDRAULIC SYSTEM DIAGRAM...................................................................................................595 SECTION 8 ELECTRICAL SYSTEM.......................................................................................................597 1. SAFETY RULES...............................................................................................................599 2. SPECIFICATIONS AND DATA 2.1 SPECIFICATIONS AND DATA........................................................................600 3. LOCATION AND FUNCTIONS OF COMPONENTS 3.1 CONSTRUCTION......................................................................601 4. ARRANGEMENTS AND OPERATION 4.1 ELECTRICAL SYSTEM...........................................................................621 5 . ELECTRONIC CONTROL UNITS AND DIODES.......................................................................................639 6. ELECTRIC COMPONENTS 6.1 THROTTLE CONTROL...................................................................................671 7 CONTROL LINE................................................................................................................677 SECTION 9 TROUBLESHOOTING.........................................................................................................709 1. INTRODUCTION...............................................................................................................710 2. HYDRAULIC SYSTEM TROUBLESHOOTING 2.1 GENERALITIES..........................................................................713 3. ELECTRICAL SYSTEM TROUBLESHOOTING..........................................................................................751 3.1 ELECTRICAL SYSTEM COMPONENTS..........................................................................................751 3.2 RELAYS AND FUSES......................................................................................................760 3.4 PILOT ELECTRONICAL CIRCUIT CHECKS.....................................................................................766 3.5 BRAKE SYSTEM ELECTRICAL CIRCUIT CHECKS................................................................................768 3.6 TRAVEL CONTROL ELECTRICAL CIRCUITS CHECKS.............................................................................776 3.7 STABILIZERS CONTROL ELECTRICAL CIRCUITS CHECKS........................................................................782 3.8 BLADE CONTROL ELECTRICAL CIRCUIT CHECKS...............................................................................786 3.9 POSITIONING CONTROL ELECTRICAL CIRCUIT CHECKS.........................................................................788 3.10 HAMMER CONTROL ELECTRICAL CIRCUIT CHECKS.............................................................................790 3.11 AXLE LOCK ELECTRICAL CIRCUIT CHECKS..................................................................................792 3.12 MONITOR FAILED TO OPERATE WITH START-UP KEY IN "ON" POSITION.........................................................794 3.13 THROTTLE CONTROL ELECTRICAL CIRCUIT CHECKS...........................................................................795 3.14 DIESEL ENGINE FAILED TO START........................................................................................802 3.15 TRANSMISSION CONTROL ELECTRONIC UNIT (APC 50) CHECKS.................................................................803 3.16 TEST HARNESSES KIT 75301702..........................................................................................818 SECTION 10 OPERATIONAL PERFORMANCE TEST...........................................................................................826 1. INTRODUCTION...............................................................................................................827 1.1 GENERAL INFORMATION TESTING OF THE MACHINE............................................................................827 2. PERFORMANCE STANDARD.......................................................................................................828 2.1 TABLE OF EXCAVATOR PERFORMANCE STANDARD...............................................................................828 2.2 TABLE OF HYDRAULIC COMPONENTS PERFORMANCE STANDARD....................................................................831 2.3 MAIN PUMP P-Q DIAGRAM.................................................................................................832 3. PREPARATION FOR PERFORMANCE TEST...........................................................................................834 4. EXCAVATOR PEFORMANCE TEST..................................................................................................836 4.1 ENGINE PERFORMANCE....................................................................................................836 4.2 SWING PERFORMANCE.....................................................................................................837 4.3 FRONT ATTACHMENT PERFORMANCE..........................................................................................841 4.4 CONTROL LEVER PERFORMANCE.............................................................................................843 4.5 LIFT/SWING PERFORMANCE................................................................................................844 4.6 STEERING..............................................................................................................845 4.7 BRAKES SYSTEM.........................................................................................................846 5. COMPONENTS PERFORMANCE TEST................................................................................................850 5.1 PILOT PRESSURE........................................................................................................850 5.2 PRESSURE RELIEF VALVES................................................................................................852 5.3 FLOW CONTROL PRIORITY VALVE...........................................................................................859 5.4 TRANSMISSION DRIVE SHAFT..............................................................................................860 5.5 HYDRAULIC PUMPS.......................................................................................................863 SECTION 11 APPENDIX...............................................................................................................868 11. APPENDIX 11.1 ASSEMBLY AND HYDRAULIC DIAGRAM OF SERVICE SOLENOID VALVE GROUP..............................................869
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