Fiat Hitachi EX215 Excavator Operational Principle Technical Manual – PDF DOWNLOAD by www.heydownloads.com

TECHNICAL MANUAL OPERATIONAL PRINCIPLE

Allinformation,illustrationsandspecificationsinthismanualarebasedonthelatestproductinformationavailable at the time of publication.

The right is reserved to make changes at any time without notice.

FIAT-HITACHI EXCAVATORS S.p.A. - ENGINEERING - FORM No. 604.06.807

X - 1997

Edition -

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 S.p.A.

San Mauro Torinese (TO) 10099 ITALIA PRODUCT SUPPORT

Fax. ++39 11 6877357

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 four books:

- Technical Manual - Operational Principle

- Technical Manual - Troubleshooting

- Excavator Workshop Manual

- Engine 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

performance tests, and troubleshooting procedures.

-The Excavator and the Engine Workshop Manuals include 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 EX215 Excavator consists of the following book/print numbers:

BOOKPART NUMBER

-Technical Manual - Operational Principle604.06.807

-Technical Manual - Troubleshooting604.06.812

-Workshop Manual - Excavator604.06.817

-Workshop Manual - Engine604.06.832

IN-1

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 :Excavator Workshop Manual

EW :Engine 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/cm, 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.m1.0197ML/revCc/rev1.0

N.mlbf.ft0.737 5

IN-2

INTRODUCTION

OPERATIONAL PRINCIPLE

SECTION AND GROUP CONTENTS

Section 1 -GENERAL

Group 1

Specifications

Group 2 Component Layout

Section 2 -SYSTEM

Group 1

Group 2

Group 3

Control System

Hydraulic System

Electrical System

Section 3 -COMPONENT OPERATION

Group 1

Pump Device

Group 2 Swing Device

Group 3 Control Valve

Group 4 Pilot Valve

Group 5 Travel Device

Group 6 Others (Upperstructure)

Group 7 Others (Undercarriage)

EX215

TECHNICAL MANUAL

GENERAL CONTENTS

Group 1 -Specification

Excavator Dimensions

(Monoblock version)............................T1-1-1

Excavator Dimensions

(Triple articulation version)..................T1-1-2

Excavator performance.......................T1-1-3

Engine.................................................T1-1-3

Engine accessory................................T1-1-3

Hydraulic Device.................................T1-1-4

Electrical Equipment............................T1-1-5

Group 2 -Components layout

Main components................................T1-2-1

Electrical system

(Overall system)..................................T1-2-2

Electrical system (Relays)...................T1-2-3

Electrical system

(Monitor and Switch panels)................T1-2-4

Electrical system (Fuses)....................T1-2-5

Pump and related parts.......................T1-2-6

Other components...............................T1-2-7

SECTION 1 EX215

EXCAVATOR DIMENSIONS (Monoblock version)

T1-1-1

VERSIONSABCDD’ (*)EFGHIL EX215 3 3714 1711 0302 7202 7509 5002 9702 4552 870915450 EX215 E 3 3714 1711 0302 7202 7509 5002 9702 4552 870915450 EX215 LC 3 6584 4581 0302 7202 7509 5002 9702 4552 870915450

SPECIFICATIONS

EX215 EX215 E EX215 LC M-Track shoe width 600700800900500600700600700800900 N-Maximum width 2 8002 9003 0003 1002 4802 5802 6802 9903 0903 1903 290 Working weight 19 44019 69019 94020 19019 23519 48519 73520 00020 27020 54020 810 Spec. Ground Press. 0.440.390.330.300.510.460.400.420.370.310.28

(*) Rear swing radius

OM0254 5 680 mm Boom Armmm2 0002 4002 910 3 500 A mm9 2809 4809 91010 460 A’ mm9 1109 3009 75010 300 B mm5 7006 0806 670 7 160 B’ mm5 4805 8806 490 7 000 C mm9 3809 2809 600 9 780 D mm6 6406 4606 780 6 920 E mm3 6003 6003 540 3 560 Break out force: • Bucketkg12 00012 00012 00012 000 • Armkg12 50011 500 9 500 7 900 Power Boost ON • Bucketkg13 00013 00013 00013 000 • Armkg13 40012 40010 200 8 500 DIGGING DATA D/D' E F C A B H N M L G I OM0253 (mm) (mm) (mm) (mm) (mm) (kg) (bar)

EXCAVATOR DIMENSIONS (Triple articulation version)

T1-1-2

VERSIONSABCDD’ (*)EFGHIL EX215 E 3 3714 1711 0302 7202 7509 3703 1002 4552 870915450 EX215 LC 3 6584 4581 0302 7202 7509 3703 1002 4552 870915450 (*) Rear swing radius EX215 E EX215 LC M-Track shoe width 500600700600700800900 N-Maximum width 2 4802 5802 6802 9903 0903 1903 290 Working weight 19 85020 10020 35020 61520 88521 15521 425 Spec. Ground Press. 0.530.470.410.460.390.350.32

SPECIFICATIONS

5 680 mm Boom Armmm2 0002 4002 9103 500 A mm9 1219 4009 78010 300 A’ mm8 9209 1809 60010 120 B mm5 4405 7806 2506 850 B’ mm5 3205 6606 1406 760 C mm10 32210 35010 68011 020 D mm7 4057 3607 7408 080 E mm2 6972 6402 2802 300 Break out force: • Bucketkg12 00012 00012 00012 000 • Armkg12 50011 500 9 500 7 900 Power Boost ON • Bucketkg13 00013 00013 00013 000 • Armkg13 40012 40010 200 8 500 OM0256 DIGGING DATA H N M L G I D/D' E F C A B OM0255 (mm) (mm) (mm) (mm) (kg) (bar)

SPECIFICATIONS

T1-1-3

EXCAVATOR PERFORMANCE GRADEABILITY...........................................................................................................35° (70%) in continuous TRAVEL SPEED....................................................................................................2.2 / 3.4 mph (3.5/5.5 km/h) -Slow....................................................................................................................0 to 2.2 mph (0 to 3.5 km/h) -Fast.....................................................................................................................0 to 3.4 mph (0 to 5.5 km/h) ENGINE MAIN SPECIFICATIONS -Manufacturer........................................................................................................................................IVECO -Model..........................................................................................................................................8065.25.085 -Type.................................................................................4 stroke Diesel type, direct injection, turbocharged -Net power to flywheel (DIN 6 271).......................................................................................................135-145 HP (*)/99-107 kW (*) -Net power to flywheel (SAE J1 349).............................................................................................................................99-107 kW (*) -Net power to flywheel (ISO 9249).................................................................................................................................99-107 kW (*) -Net power to flywheel (CEE 80/1 269).........................................................................................................................99-107 kW (*) -Rated Speed..................................................................................................................1 950 - 2 150 rpm (*) -Displacement..................................................................................................................................5 861 cm3 -Number of cylinders......................................................................................................................................6 -Bore and stroke.........................................................................................................................104 x 115 mm (*) With HP mode switch on. STARTER MOTOR -Voltage - Output.............................................................................................................................24V - 4 kW INTAKE AIR HEATER (PRE-HEAT) CIRCUIT -Intake air Heater Controller..................................................................................................................IVECO -Voltage......................................................................................................................................................24V ALTERNATOR -Voltage - Output..............................................................................................................................28V - 55A ENGINE ACCESSORY RADIATOR ASSEMBLY -Type.............................................................................................Radiator/Oil Cooler tandem type assembly -Weight.......................................................................................................................................82 kg (181 lb) -Radiator Capacity....................................................................................................................................6.7 L -Oil Cooler Capacity.................................................................................................................................5.1 L BATTERY -Capacity.........................................................................................................................................100 Ah x 2 -Voltage................................................................................................................................................12V x 2

SPECIFICATIONS

HYDRAULIC DEVICE

MAIN PUMP

-Model...........................................................................................................................................HPV102FW

-Type...............................................................Variable displacement plunger pump: regulator attached type

-Max. flow (Theoretical value).....................................................................................................185 L/min x 2

PILOT PUMP

-Model.....................................................................................................................................HY/ZFS 11/16.8

-Type.......................................................................................................Fixed displacement type gear pump

-Max. flow (Theoretical value)......................................................................32.8 L/min; HP Mode: 36.1 L/min

CONTROL VALVE

-Model..........................................................................................................................................KVMG-200H

-Type...................................................................................................................Pilot pressure operated type (4-spool + 5-spool)

-Main relief pressure.................................................................Normal: 34.3 MPa (350 kgf/cm2) @ 110 L/min

Power Boost: 36.3 MPa (370 kgf/cm2) @ 110 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 motor

SWING BRAKE VALVE

-Type..............................................................................................................Non counter balance valve type

-Relief pressure.......................................................................................30.9 MPa (315 kgf/cm2) @ 40 L/min

SWING PARKING BRAKE

-Type..............................................................................................................Multiple-wet-plate negative type

-Cracking pressure for release.................................................................1.96 to 2.64 MPa (20 to 27 kgf/cm2)

TRAVEL DEVICE

-Type.....................................................................................................Three-stage planetary reduction gear

TRAVEL MOTOR

-Model................................................................................................................................................HMV116

-Type..............................................................................Bent-axis type, variable displacement plunger motor

TRAVEL BRAKE VALVE

-Type.....................................................................................................................Counter balance valve type

-Relief pressure...........................................................................................................34.8 MPa (355 kgf/cm2)

TRAVEL PARKING BRAKE

-Type..............................................................................................................Multiple-wet-plate negative type

-Cracking pressure for release.............................................................0.95 to 1.02 MPa (9,7 to 10.4 kgf/cm2)

T1-1-4

CYLINDERS

SPECIFICATIONS

Cylinder

Fully retracted length1759 mm2040 mm1590 mm1670 mm

(*) Triple articulation version

FRONT ATTACHMENT PILOT VALVE

- Model HVP04S-040-101

TRAVEL PILOT VALVE

- Model HVP05D-040-101

SOLENOID VALVE UNIT -Functions...............................................................................................SC:Arm regenerative control

SD:Speed sensing control

SG:Power boost control

SI:Travel motor swash angle control

OIL COOLER BYPASS CHECK VALVE

T1-1-5

BoomArmBucketPositioning (*)

Rod diameter85 mm95 mm75 mm90 mm

bore120 mm130 mm110 mm145 mm

Stroke1221 mm1475 mm1060 mm1050 mm

pressure...........................................................................................392 KPa (4 kgf/cm2) at 5 L/min

-Cracking

BATTERY RELAY - Voltage - Current 24V - 50A HORN -Specifications.....................................................................................................................24V - 1.5A, 113dB LIGHT -Specifications............................................................................................Work lights:Halogen 24V - 70W Dome light:24V - 10W

-Type.....................................................................................................................................................IVECO -Voltage......................................................................................................................................................24V

ELECTRICAL EQUIPMENT

INTAKE AIR HEATER CONTROLLER

T1-1-6

SPECIFICATIONS NOTES

MAIN COMPONENTS

COMPONENT LAYOUT

T1-2-1

1-Bucket Cylinder 2-Arm Cylinder 3-Boom Cylinder 4-Center Joint 5-Swing Bearing 6-Swing Device 7-Fuel Tank 8-Hydraulic Oil Tank 9-Control Valve 10-Pump Device 1 19 16 15 10 11 12 13 14 6 7 8 9 4 5 3 2 18 17 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 SM0607

4 5 6 7-8 9 10 11-12 13 14 15 16 17 18 30 29 28 27 26 25 22 24 21 23 20 19 1 3 2

1-Wiper Motor 2-Monitor Panel 3-Relays 4-Pressure Switch (Front) 5-Pressure Switch (Travel) 6-Work Light 7-Fuel Sensor 8-Low Fuel Level Switch 9-Solenoid Valve Unit 10-Hydraulic Oil Level Switch 11-PC Pressure Sensor (Upper: 5-Spool Side) 12-PC Pressure Sensor (Lower: 4-Spool Side) 13-EC Sensor 14-EC Motor 15-N Sensor 16-Pump Delivery Pressure Sensor 17-Engine Oil Pressure Switch 18-Engine Oil Level Switch 19-Alternator 20-Overheat Switch 21-Coolant Temperature Sensor 22-Battery Relay 23-Coolant Level Switch 24-Battery 25-Starter Relay 26-Pressure Switch and Sensor 27-Windshield Washer Tank 28-MC (Main Controller) 29-Fuse Box 30-Intake Air Heater Controller SM0608

T1-2-2 COMPONENT LAYOUT ELECTRICAL SYSTEM (Overall system)

T157-01-01-016

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