TECHNICAL MANUAL OPERATIONAL PRINCIPLE
Allinformation,illustrationsandspecificationsinthismanualarebasedonthelatestproductinformationavailable at the time of publication.
The right is reserved to make changes at any time without notice.
EXCAVATORS S.p.A.
ENGINEERING
No.
FIAT-HITACHI
-
- FORM
604.06.867
Edition - IX - 1998 EXCAVATOR
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INTRODUCTION
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:
FIAT-HITACHI EXCAVATORS S.p.A. Strada Settimo, 323 San Mauro Torinese (TO) 10099 ITALIA
PRODUCT SUPPORT
ADDITIONAL REFERENCES
•Please refer to the materials listed below in addition to this service manual:
- Operator’s Manual
- Spare Parts Catalog
SERVICE MANUAL COMPOSITION
•The complete service manual consists of three books:
- Technical Manual - Operational Principle
- Technical Manual - Troubleshooting
- Workshop Manual
-The Technical Manual-Operational Principle includes the technical information concerning the operation of main devices and systems.
-The Technical Manual -Troubleshooting includes the technical information needed for operational
Fax. ++39 011 6877357 BOOKPRINT
performance tests, and troubleshooting procedures.
-The Workshop Manual includes information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, removal/installation and assembly/disassembly procedures.
•The Service Manual for EX165 Excavator consists of the following book/print numbers:
IN-1
NUMBER
Manual - Operational Principle 604.06.867
Manual - Troubleshooting 604.06.862
Manual 604.06.877
-Technical
-Technical
-Workshop
PAGE NUMBER
•Each page has a number, located on the external upper corner of the page. Each page number contains the following information:
Example: T 1-2-3
Consecutive page number for each group
Group number (if exist)
Section number
T :Technical Manual
W :Workshop Manual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury or machine damage.
This is the safety alert symbol.
When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attentio in to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.
UNITS USED
SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parentheses just behinds SI units.
Example: 24.5 Mpa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system units is shown below for reference purposes.
ToTo
QuantityconvertIntoMultiply byQuantityconvertIntoMultiply by from (SI)(Others)from (SI)(Others)
Lenghtmmin0.039 37PressureMPakgf/cm2 10.197
mmft0.003 281MPapsi145.0
LUS gal0.264 2PowerkWPS1.360
VolumeLUS qt1.057kWHP1.341
myd1.308Temperature°C°F°C x 1.8 + 32
WeightKglb2.205VelocityKm/hmph0.621 4
ForceNkgf0.101 97min-1 rpm1.0
Nlbf0.224 8Flow rateL/minUS gpm0.264 2
TorqueN.mKgf.m0.10197ML/revCc/rev1.0
N.mlbf.ft0.737 5
IN-2
INTRODUCTION
TECHNICAL MANUAL EX165
OPERATIONAL PRINCIPLE
SECTION AND GROUP CONTENTS
Section 1 -GENERAL
Group 1
Group 2
Specifications
Component Layout
Section 2 -SYSTEM
Group 1
Group 2
Group 3
Control System
Hydraulic System
Electrical System
Section 3 -COMPONENT OPERATION
Group 1
Group 2
Group 3
Group 4
Group 5
Group 6
Group 7
Pump Device
Swing Device
Control Valve
Pilot Valve
Travel Device
Other components (Upperstructure)
Other components (Undercarriage)
EXCAVATOR DIMENSIONS (Monoblock version)
SPECIFICATIONS
T1-1-1
VERSIONSABCDD’ (*)EF (**)GHIL EX165 3100392092024402440839525002800860460 EX165 LC 3290411092024402440839525002800860460 (*) Rear swing radius (**) Arm 1) 1800 mm, 2) 2200 mm, 3) 2570 mm, 4) 3075 mm EX165 EX165 LC M-Track shoe width 500600700800900500600700800900 N-Maximum width 2490259026902790289026902790289029903090 Working weight 15900160301615016270164001655016680168001692017050 Spec. Ground Press. 0.470.390.340.300.270.460.380.330.290.26
OM0467 DIGGING DATA OM0466 (mm) (mm) (mm) (mm) (kg) (bar) 1) 2936 2) 3051 3) 2768 4) 2978 5100 mm Boom Armmm1800220025703075 A mm8360852088709330 A’ mm8180834087009160 B mm5290568060506520 B’ mm5040538057706300 C mm8920858088309080 D mm6100600062006430 E mm3320329029102920
EXCAVATOR DIMENSIONS (Triple articulation version)
T1-1-2
VERSIONSABCDD’ (*)EF (**)GHIL EX165 3100392092024402440839525002800860460 EX165 LC 3290411092024402440839525002800860460 (*) Rear swing radius (**) Arm 1) 1800 mm, 2) 2200 mm, 3) 2570 mm, 4) 3075 mm EX165 EX165 LC M-Track shoe width 500600700800900500600700800900 N-Maximum width 2490259026902790289026902790289029903090 Working weight 16200163201644016555166751685016970170901702517325 Spec. Ground Press. 0.470.400.350.300.270.470.390.340.300.27
SPECIFICATIONS
OM0468 DIGGING DATA OM0465 (mm) (mm) (mm) (mm) (kg) (bar) 1) 2955 2) 3053 2450 mm Boom Armmm1800220025703075 A mm8130829086409100 A’ mm7950811584808950 B mm4985526056506140 B’ mm4855513555306035 C mm9355925095309865 D mm6500644067057035 E mm2530262020352225 3) 2756 4) 2990
EXCAVATOR PERFORMANCE
SPECIFICATIONS
ISUZU Model A-4BG1T
.............................................Diesel, 4 cycle, vertical, 4-cylinder inline, water-cooled, direct injection type
COOLING SYSTEM
Cooling fan.................................................................................................Dia. 540 mm, 8 blad es, draw-in type
pulley ratio......................................................................................................................Engine rpm x 0.89
Thermostat ........................................................................................................Cracking temp. : 82 °C (180 °F) (under atmospheric pressure)Full open (Stroke: 10 mm or larger) temp. : 95 °C (203 °F)
Water pump.............................................................................................................Centrifu gal type, belt driven
LUBRICATION SYSTEM
Lubrication pump type.......................................................................................................................Gear pump
Oil filter..................................................................................Full-flow paper element type with b ypass function
Oil cooler...........................................................................................................................Water-cooled, built-in
STARTING SYSTEM
Motor............................................................Magnetic pinion shift system, reduction type (with starter rel ay)
Voltage ⋅ Output............................................................................................................................24 V 4.5 kW
PRE-HEAT SYSTEM
Heating method................................................................................................................. ..................Glow plug
ENGINE STOP SYSTEM
Stop method..........................................................................................................................................Fuel cut
ALTERNATOR
Type ..............................................................................................................................AC type (with regulator)
Voltage Output......................................................................................................24 V 40 A (Brush-less type)
SUPERCHARGING SYSTEM
Type ..................................................................................................................Exhaust-gas-t urbo type TD04H
FUEL SYSTEM
Injection pump model....................................................................................................................Bosch A type Governor .........................................................................................................Centrifugal all speed control RSV
Injection nozzle.........................................................................................................................Multihole nozzle
T1-1-3
TRAVEL
-Slow .....................................................................................................................0
-Fast.....................................................................................................................0
SWING
Manufacturer
Number
Bore
Displacement
Rated
Compression
Dry
Firing
Rotation
GRADEABILITY..........................................................................................................35° (70%) in continuous
SPEED....................................................................................................1.9 / 3.3 mph (3.1/5.3 km/h)
to 1.9 mph (0 to 3.1 km/h)
to 3.3 mph (0 to 5.3 km/h)
SPEED....................................................................................................................................13.2 rpm ENGINE MAIN SPECIFICATIONS
Type
of cylinders.........................................................................................................................................4
x stroke........................................................................................................................105 mm x 125 mm
........4329 cm3
output..................................73.6 kW (98.6 HP) (2150 rpm); HP Mode: 76.5 kW (102 HP) (2300 rpm)
ratio...................................................................................................................................... 17.0
weight.................................................................................................................................360 kg (796 lb)
order.............................................................................................................................................1-3-4-2
direction.............................................................................................Clockwise (view from fan side)
Fan
ENGINE
ACCESSORIES
RADIATOR ASSEMBLY
SPECIFICATIONS
HYDRAULIC DEVICES MAIN PUMP
CONTROL VALVE -Model MVX20 -Type .....................................................................................Pilot pressure operated type (4-spool + 5 -spool) -Main relief pressure..................................................................................34.3 MPa (350 kgf/cm 2) @ 80 L/min -Overload relief pressure...........................................................................37.3 MPa (380 kgf/cm2) @ 50 L/min (Boom raise / lower, Arm roll-in, Bucket roll-in) 39.2 MPa (400 kgf/cm2) @ 50 L/min (Arm roll-out, Bucket roll-out)
SWING DEVICE -Type .........................................................................................................Two-stage planetary reduction type
SWING MOTOR -Model M2X146B -Type ...............................................................................Swash-plate type, fixed-displacement plunger mot or
SWING BRAKE VALVE -Type ..............................................................................................................Non counter balance valve type
pressure.........................................................................................31.9 MPa (325 kgf/cm 2) @ 90 L/min
SWING PARKING BRAKE -Type ..............................................................................................................Multiple-wet-plat e negative type
pressure for release.......................................................................................2.64 MPa ( 27 kgf/cm2)
T1-1-4
-Type
-Weight
-Radiator Capacity............................................................................................................. .......................5.8 L -Oil Cooler Capacity.................................................................................................................................4.4 L BATTERY -Capacity ...........75
-Voltage
..............................................................................................Radiator/Oil Cooler tandem type a ssembly
........67 kg (148 lb)
Ah x 2
................12V x 2
-Model
-Type .................................................................Variable
-Max. flow (Theoretical value).....................................................................................................126 L/min x 2
A8V59
displacement plunger pump: regulator attached type
-Model
G2-C5Z10NR-10 -Type ........................................................................................................Fixed
-Max. flow (Theoretical value).......................................................................23.0 L/min;
L/min
PILOT PUMP
.....................................................................................................................................
displacement type gear pump
HP Mode: 24.6
-Relief
-Cracking
SPECIFICATIONS TRAVEL
T1-1-5
DEVICE
......................................................................................................Three-stage planetary reduction gear
MOTOR -Model .........MSF-85VP-11 -Type ..........................................................................Swash plate type, variable displacement plunger motor
BRAKE VALVE -Type .....................................................................................................................Counter balance valve type -Relief pressure............................................................................................................35. 3 MPa (360 kgf/cm2)
PARKING BRAKE -Type ..............................................................................................................Multiple-wet-plat e negative type -Cracking pressure for release.......................................................................................1.37 MPa ( 14 kgf/cm2) CYLINDERS BoomArm BucketPositioning (*) Rod diameter80 mm85 mm75 mm85 mm Cylinder bore110 mm115 mm105 mm135 mm Stroke1110 mm1365 mm935 mm890 mm Fully retracted length 1655 mm1905 mm1460 mm 1500 mm (*) Triple articulation version
ATTACHMENT PILOT VALVE -Model ................................................................................................................................... HVP04S-040-101 TRAVEL PILOT VALVE -Model HVP05D-040-101 SOLENOID VALVE UNIT -Functions...............................................................................................SC:Arm regenerative control SE:Speed sensing control SI:Travel motor swash angle control OIL COOLER BYPASS CHECK VALVE -Cracking pressure...........................................................................................392 KPa (4 kgf/cm2) at 5 L/min
EQUIPMENT BATTERY RELAY -Voltage - Current............................................................................................................................24V - 100A GLOW RELAY -Voltage ......................24V HORN -Specifications.....................................................................................................................24V - 1.5A, 113dB LIGHT -Specifications............................................................................................Work lights:Halogen 24V - 70W Dome light:24V - 10W
-Type
TRAVEL
TRAVEL
TRAVEL
FRONT
ELECTRICAL
T1-1-6
SPECIFICATIONS NOTES
MAIN COMPONENTS
COMPONENT LAYOUT
T1-2-1
Bearing 6-Swing Device 7-Fuel
Oil Tank 9-Control Valve 10-Pump Device 11-Engine 12-Radiator 13-Oil Cooler 14-Battery 15-Travel Device 16-Shockless Valve 17-Pilot Shut-Off Valve 18-Travel Pilot Valve 19-Front/Swing Pilot Valve SM4001 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 19 3 2 1
1-Bucket Cylinder 2-Arm Cylinder 3-Boom Cylinder 4-Center Joint 5-Swing
Tank 8-Hydraulic
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Overall system)
T1-2-2
SM4002 1-Wiper Motor 2-Monitor Panel 3-Relays 4-Work Light 5-Fuel Sensor 6-Low Fuel Level Switch 7-Pressure Switch (Front) 8-Hydraulic Oil Level Switch 9-Pressure Switch (Travel) 10-Solenoid Valve Unit 11-EC Sensor 12-EC Motor 13-PC Pressure Sensor 14-Pump Delivery Pressure Sensor 15-N Sensor 16-Engine Oil Pressure Switch 17-Engine Oil Level Switch 18-Alternator 19-Overheat Switch 20-Coolant Temperature Sensor 21-Battery Relay 22-Coolant Level Switch 23-Battery 24-Air Restriction Switch 25-Windshield Washer Tank 26-Pressure Switch and Sensor 27-MC (Main Controller) 28-Fuse Box 21 20 19 18 17 16 15 14 At the bottom of the pump device 13 11, 12 10 9 8 7 5, 6 4 3 2 1 28 27 26 25 24 23 22
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Monitor and Switch panels)
T1-2-3
1-Monitor Panel 2-Switch Panel 3-Key Switch 4-Cigar Lighter 5-HP Mode Switch 6-E Mode Switch 7-Engine Control Dial 8-Air Conditioner Panel 9-Warm Up Complete Indicator 10-Fuel Gauge 11-E Mode Indicator 12-Auto-Idle Indicator 13-Hydraulic Oil Level Indicator 14-Preheat Indicator 15-Air Filter Restriction Indicator 16-Fuel Level Indicator 17-Overheat Indicator 18-Alternator Indicator 19-Engine Oil Pressure Indicator 20-Engine Oil Level Indicator 21-Coolant Level Indicator 22-HP Mode Indicator 23-Coolant Temperature Gauge 24-Work Light Switch 25-Wiper Switch 26-Travel Mode Switch 27-Work Mode Switch 28-Buzzer Stop Switch 29-Auto-Idle Switch 30-Washer Switch 31-Level Check Switch 4 5 6 7 8 1 2 3 9 23 22 21 20 19 18 17 10 11 12 13 14 15 16 24 25 26 27 31 30 29 28 T157-01-01-009 T157-01-01-018 T157-07-02-001 SM0611 SM0612 SM0610
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
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CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
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