Fiat Hitachi EX135 Excavator Complete Workshop Service Repair Manual

FIAT-HITACHI EXCAVATORS S.p.A. - ENGINEERING - FORM No. 604.06.837 Edition - XI - 1997 WORKSHOP MANUAL EXCAVATOR All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

IN-1 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 BOOK PART NUMBER - Technical Manual - Operational Principle 604.06.827 - Technical Manual - Troubleshooting 604.06.822 - Workshop Manual - Excavator 604.06.837 - Workshop Manual - Engine 604.06.832 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 EX135 Excavator consists of the following book/print numbers: ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this service manual: - The Operator’s Manual - The Spare Parts Catalog

IN-2 INTRODUCTION To To Quantity convert Into Multiply by Quantity convert Into Multiply by from (SI) (Others) from (SI) (Others) Lenght mm in 0.039 37 Pressure MPa kgf/cm 2 10.197 mm ft 0.003 281 MPa psi 145.0 L US gal 0.264 2 Power kW PS 1.360 Volume L US qt 1.057 kW HP 1.341 m yd 1.308 Temperature °C °F °C x 1.8 + 32 Weight Kg lb 2.205 Velocity Km/h mph 0.621 4 Force N kgf 0.101 97 min -1 rpm 1.0 N lbf 0.224 8 Flow rate L/min US gpm 0.264 2 Torque N.m Kgf.m 0.101 97 ML/rev Cc/rev 1.0 N.m lbf.ft 0.737 5 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 2 , 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposes. !

SAFETY PRECAUTIONS S-1 UNDERSTAND SIGNAL WORDS • In this Manual you will find the following words: - DANGER; - WARNING; - CAUTION. referring to different hazard risks. These words are always accompanied by the safety alert symbol. DANGER: indicates an imminent hazardous situation which, if not avoided, will result in death or serious injury. WARNING: indicated a potential hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: indicates a potential hazardous situation which, if not avoided, may result in minor or moderate injury. IMPORTANT: indicates a situation which, if not avoided, may cause damage to the machine. NOTE: indicates an additional explanation for information purposes. DANGER WARNING CAUTION IMPORTANT NOTE S0021 RECOGNISE SAFETY INFORMATION • This is your SAFETY ALERT SYMBOL. - When you see this symbol on your machine or in this Manual, be alert of the potential for personal injury. - Follow recommended precautions and safe operating practices. ENVIRONMENTAL PROTECTION • This Manual also contains this symbol accompanying instructions for correct behaviour as regards environmental protection. S0024

S-2 SAFETY PRECAUTIONS FOLLOW SAFETY PRECAUTIONS • Carefully read and observe all safety signs on the machine and read all safety precautions in this Manual. • Safety signs should be installed, maintained, and replaced when necessary. - If a safety sign or this Manual are damaged or missing, obtain a replacement from your FIAT- HITACHI Dealer in the same way you order a spare part (be sure to detail machine model and serial number upon ordering). • Learn how to operate the machine and its controls correctly and safely. • Allow only trained, qualified, authorised personnel to operate the machine. • Keep the machine in proper working conditions. - Unauthorised changes to the machine may impair function and/or safety and affect machine life. • Safety messages in this Chapter “SAFETY PRECAUTIONS” , are intended to illustrate basic safety procedures of the machine. However, it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any doubts, consult your direct supervisor prior to operating or servicing the machine. S0022 S0023 PREPARE FOR EMERGENCIES • Be prepared if a fire starts or an accident occurs. - Keep the first-aid kit and fire extinguisher on hand. - Thoroughly read and understand the label attached to the fire extinguisher to use it properly. - Establish emergency priority procedures to cope with fires and accidents. - Keep emergency numbers for doctors, ambulance service, hospitals and fire department posted near the telephone.

SAFETY PRECAUTIONS S-3 WEAR PROTECTIVE CLOTHING • Wear close-fitting clothing and safety equipment appropriate to the job. You need: - A hard hat; - Safety shoes; - Safety glasses or face shield; - Heavy gloves; - Ear protection; - Reflective clothing; - Waterproof clothing; - Respirator or filter mask; Be sure to correctly wear equipment and clothing for the job. - Do not take any chances. - Avoid wearing loose clothing, jewellery, or other items that can catch on control levers or other parts of the machine. • Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. S0025 S0026 S0027 PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. - Wear a suitable hearing protection such as earmuffs or earplugs to protect objectionable or uncomfortably loud noise. INSPECT THE MACHINE • Inspect the machine carefully every day or work- shift by an attentive visual inspection of machine outside prior to starting it to prevent damages and personal injuries. - In the walk-around inspection, be sure to cover all points detailed in the OPERATION AND MAINTENANCE INSTRUCTION MANUAL.

S-4 SAFETY PRECAUTIONS USE HAND HOLDS AND STEPS • Falling is one of the major causes of personal injury. - When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. - Do not use any control as a handhold. - Never jump off the machine. Never get on and off a moving machine, - Be careful of slippery conditions of platforms, steps, and handrails when leaving the machine. S0028 ADJUST THE OPERATOR'S SEAT • A seat poorly adjusted for operator or work requirements may quickly fatigue the operator leading to improper operations. - The seat should be adjusted whenever machine operator changes. - The operator should be able to fully press the pedals and correctly move the control levers with his back resting against the seat back. - If not, move the seat fore and aft, and check again. S0029

SAFETY PRECAUTIONS S-5 MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. - Pay the utmost attention not to run over bystanders. - Be sure and aware of the location of bystanders before moving, swinging or operating the machine. - If fitted, keep the travel alarm and horn sounding to warn people that the machine is about to move. - When operating, swinging, or moving the machine in a congested area use a signal man. - Co-ordinate hand signals before starting the machine. S0031 FASTEN SEAT BELT • Should the machine overturn, the operator may become injured and/or thrown from the cab. Not only, the operator may be crushed by the overturning machine resulting in serious injury or even death. - Prior to operating the machine, thoroughly examine belt webbing, buckle, and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. - Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimise injury hazard in case of accident. - After a significant accident, replace the seat belts even though they do not look damaged. S0030

S-6 SAFETY PRECAUTIONS S0001 STARTING THE ENGINE WITH BOOSTER BATTERIES • Battery gas may explode causing serious damages and injuries. - If the engine is to be started using booster batteries, ensure to comply with all procedures detailed in the OPERATION AND MAINTE- NANCE INSTRUCTION MANUAL. - The operator should be sitting in the driver’s seat to keep the machine under control when the engine starts. Starting the engine with booster batteries is a two man operation. - Do not use batteries that have been stored in the cold for a long time. - Mistakes in following procedures detailed for starting the engine with slave batteries may cause the batteries to explode or machine to move unexpectedly. OPERATE ONLY FROM THE DRIVER'S SEAT • Inappropriate engine starting procedures may cause the machine unexpected movement, possibly resulting in serious injury and even death. - Start the engine only from the operator’s seat. - NEVER start the engine while standing on the track or on the ground. - Do not start the engine by shorting across starter motor terminals. - Before starting the engine, ensure that all control levers are in the neutral position. S0032 DON'T CARRY RIDERS ON THE MACHINE • Riders on the machine are subject to injuries such as being struck by foreign objects and being thrown off the machine. - Only machine operator is allowed on the machine. Keep riders off. - Riders also obstruct the operator’s visibility, resulting in the machine being operated unsafely. S0033

SAFETY PRECAUTIONS S-7 PROVIDE SIGNALS FOR JOBS INVOLVING A NUMBER OF MACHINES • For jobs involving several machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to co-ordinate the job site. Make sure that all personnel obey the signal person’s directions. CONFIRM DIRECTION WHERE THE MACHINE IS TO BE DRIVEN • Incorrect travel controls operation may result in serious injury and even death. - Before driving the machine, be aware of the undercarriage position relative to the operator’s position. If travel motors are located at the front of the cab, the machine will move reverse when travel controls are moved towards cab front. S0036 S0037

Fiat Hitachi EX135 Excavator Complete Workshop Service Repair Manual

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