Fiat Hitachi Excavator EX135 EX215 Engine Workshop Manual - PDF DOWNLOAD

WORKSHOP MANUAL ENGINE

Allinformation,illustrationsandspecificationsinthismanualarebasedonthelatestproductinformationavailable at the time of publication. The right is reserved to make changes at any time without notice.

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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

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/cm2, 3560 psi)

A table for conversion from SI units to other system units is shown below for reference purposes.

5

ENGINES

LIST OF SECTIONS

Section 1 – Diagnostics

EW–1–1

Section 2 – Removing–refitting engine EX135

EW–2–1

Section 3 – Engine EX135 overhaul

EW–3–1

Section 4 – Removing–refitting engine EX215 EW–4–1

Section 5 – Engine EX215 overhaul

EW–5–1

Section 6 – Recharge and start–up EX135–EX215 EW–6–1

DIAGNOSTICS

DIAGNOSTICS

Main engine troubles:

1 –The engine does not start;

2 –The engine overheats;

3 –The engine lacks power;

4 –Exhaust fumes are black or dark grey;

5 –Exhaust fumes are grey (tending towards white);

1 THE ENGINE DOES NOT START

Battery terminals efficient

Batteries efficient

6 –Exhaust fumes are blue;

7 –The engine functions irregularly;

8 –The engine stops;

9 –The engine exceeds the maximum rpm;

10 –Oil pressure is too high or too low;

11 –Fuel consumption is too high.

Clean, check and tighten the nuts of the terminals or replace them.

Carry out the checks described in the repair manual ” Electrical System ”.

Starter mtor workingCarry out the checks described in the repair manual ” Electrical System ”.

Glow plug workingSubstitute.

Injection pump deliveringCheck the entire set up as described in the appropriate chapter.

(to be continued)

No air bubbles in the fuel pipes or injection pump.

Check and bleed.

No traces of water in the fuel pipes or the fuel pump

Check and clean the fuel feed circuit, including the tank.

Compression ratio correctCheck the engine or carry out only the essential checks (valves, split rings, etc...).

Fuel filters clearReplace.

Automatic spark lead governor and engine STOP device efficient Check and replace the necessary parts.

THE ENGINE OVERHEATS

Coolant level correct

DIAGNOSTICS

Water pump and ventilator working correctly

Check for leakage and top up the level.

Check and register the tension, if necessary replace the parts.

Water pump working correctlyCheck and replace the group.

Thermostat efficientReplace.

Radiator efficientFlush carefully, check for leakage, replace if necessary.

Air filter and piping efficientClean or replace damaged parts.

DIAGNOSTICS

Injection pump adjusted correctlyCheck the setting as described in the appropriate paragraph.

YES

Cylinder head seal efficientReplace.

YES

Fan working correctlyReplace.

Fuel filters efficientReplace, following the procedure described in the “Use and Maintenance” manual.

Fuel feed circuit efficientCheck and carry out the necessary repairs.

Thermostat efficientReplace.

Fuel pump efficientReplace.

(to be continued)

3 THE ENGINE LACKS POWER

DIAGNOSTICS

Injectors efficientCheck and register.

Injection pump timing correctCheck the registration as described in the corresponding paragraph.

Injection pump regulated correctlyCheck and calibrate the injection pump in the workshop.

Compression ratio correctCheck using tool 75301463 Motometer and carry out necessary repairs.

Turbosupercharger working correctlyRepair or replace the group.

L.D.A. circuit and device working correctlyCheck.

DIAGNOSTICS

Air filter efficientReplace.

YES

Glow plug efficientReplace.

YES

Automatic spark lead governor workingCheck and replace if necessary. YES

Injectors efficientOverhaul and register as described.

YES

Injection pump adjusted correctlyCheck thesetting as described in the appropriate paragraph. YES

L.D.A. device efficientCheck the setting of the L.D.A. device

4 THE EXHAUST FUMES ARE BLACK OR DARK GREY YES

Injection pump settings correctCheck and calibrate the injection pump in the workshop. NO

(to be continued)

DIAGNOSTICS

Compression ratio correctCheck using tool 75301430 Motometer and carry out necessary repairs.

Fuel of good qualityClean the tank and replace the fuel filters.

5 THE EXAUST FUMES ARE GREY (TENDING TOWARDS WHITE)

Thermostat working properlyReplace.

Injectors working properlyCheck and calibrate as described in S.I. 1094.

Injection pump adjusted correctlyCheck the settings as described in the relative paragraph.

Coolant level correctProbable leakage of the coolant into the combustion chamber; replace the cylinder head gasket or overhaul the engine.

Fuel of good qualityClean the tank and replace the diesel filters.

DIAGNOSTICS

6 THE EXHAUST FUMES ARE BLUE

Excessive oil consumptionCheck: air–oil bath filter; cylinder compression. Overhaul cylinder head or engine as necessary.

7 ENGINE KNOCKS OR FUNCTIONS IRREGULARLY

Knocking located in the drive shaftCheck for: excessive clearance in one or more big end bearings; loose fixings in the headblock and flywheel; oil pressure. Replace the damaged parts or overhaul the engine.

Knocking located in the tie rods Check for: excessive clearance or misshaping in the crankpins; loose fixings in the connecting rod; misalignment of the connecting rods. Replace the damaged parts or overhaul the engine.

Knocking located in the pistonsCheck clearance of the pistons – piston barrels; split rings; piston pins – piston hubs. Replace damaged parts or overhaul the engine.

Knocking located in the cylinder headCheck the equalisers and the valves; injection pump settings, valve train settings. Calibrate.

Kocking located in the valve trainCheck and if necessary replace the gears.

(to be continued)

DIAGNOSTICS

Knocking located in the injectorsCheck and calibrate them according to S.I. 1094 or replace.

8 THE ENGINE STOPS

Fuel in the tankFill tank and, if necessary, flush.

Fuel filters efficientReplace.

Fuel supply circuit efficientCheck the pipes and flush.

Engine timing correctCalibrate.

Injection pumps set correctlyCheck the flow rate in the workshop.

Injection pump controls working properlyReplace damaged parts and calibrate.

DIAGNOSTICS

9 THE ENGINE EXCEEDS THE MAXIMUM RPM

Speed regulator working correctly

Check and if necessary replace worn out parts.

Pressure valve working correctlyCheck and replace if necessary.

YES

Oil pump and supply pipes efficientCheck and replace if necessary. YES

Bearings efficient.Replace the bearings and if necessary grind the driving shaft.

10 OIL PRESSURE TOO LOW OR TOO HIGH YES

Viscosity of SAE motor oil correctReplace the engine oil with oil of correct viscosity.

11 EXCESSIVE FUEL CONSUMPTION

DIAGNOSTICS

Tank and fuel pipes efficientEliminate any leakage and replace the worn out parts.

Air filter efficientReplace.

Injectors calibrated correctlyCheck and calibrate.

Injection pump calibrated correctlyCheck and calibrate in the workshop.

L.D.A. device efficientCalibrate the L.D.A. device.

Injection pump adjusted correctlyCheck static fit of the injection pump.

ENGINE/PUMPS ASSEMBLY REMOVAL

Park the machine on a level surface and lower the bucket to the ground

CAUTION !

Keep people not involved in the maintenance work outside the working area. Wear adequate personal clothes and glasses with side shields as a protection against flying debris.

WARNING !

The hydraulic oil reservoir is under pressure. Press the pressure relieve button (1) on the filler plug to relieve pressure before maintenance. Danger of personal injuries.

Remove cover (2) and remove hydraulic oil using a suction pump. Loosen the drain plug on the reservoir bottom side, allowing oil to flow out into a suitable container.

NOTE: Hydraulic oil quantity approximately is 120 liters

CAUTION !

The engine reaches high working temperatures. Therefore, it is necessary to let the machine cool down prior to carrying out this operation.

Remove the lower cover (3) located under the engine, and the lower cover (4) located under the radiator.

Remove the engine hood, the covers on control valve and behind the cab; remove the bulkhead between engine and control valve; remove support (5) complete of the muttler guard from the hydraulic pumps room.

• 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

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.