Hitachi Zaxis 160LC-5G Excavator Workshop Repair Service Manual PDF (TM13199X19) - MHITTM13199X19.zip
The Complete Service and Repair Technical Guide for the Hitachi Zaxis 160LC-5G Excavator delivers everything a workshop needs to service, fix, and overhaul the machine with the skill of a factory-trained technician.
The Hitachi ZX160LC-5G Excavator shop technical manual (repair) contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM13199X19 - Hitachi Zaxis 160LC-5G Excavator Technical Manual - Repair.pdf
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PRODUCT DETAILS:
Total Pages: 719 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English Portuguese Spanish
Model: HITACHI - Excavator Zaxis160LC-5G - 1F9DBGG0__C230001
TABLE OF CONTENTS....1
Section 00: General Information....11
Group 01: Safety....11
Recognize Safety Information....15
Understand Signal Words....16
Follow Safety Instructions....17
Prepare for Emergencies....19
Wear Protective Clothing....20
Protect Against Noise....21
Inspect Machine....22
General Precautions for Cab....23
Use Handholds and Steps....24
Adjust the Operator's Seat....25
Ensure Safety Before Rising From or Leaving Operator’s Seat....26
Fasten Your Seat Belt....27
Move and Operate Machine Safely....28
Operate Only From Operator's Seat....29
Jump Starting....30
Keep Riders Off Machine....31
Precautions for Operations....32
Investigate Job Site Beforehand....33
Install OPG Guard....35
Provide Signals for Jobs Involving Multiple Machines....36
Confirm Direction of Machine to be Driven....37
Drive Machine Safely....38
Avoid Injury From Rollaway Accidents....42
Avoid Injury From Back-Over and Swing Accidents....43
Keep Person Clear From Working Area....45
Never Position Bucket Over Anyone....46
Avoid Undercutting....47
Avoid Tipping....48
Never Undercut a High Bank....50
Dig With Caution....51
Operate With Caution....52
Avoid Power Lines....53
Precautions for Lightning....54
Object Handling....55
Protect Against Flying Debris....56
Park Machine Safely....57
Handle Fluids Safely−Avoid Fires....58
Transport Safely....59
Practice Safe Maintenance....60
Warn Others of Service Work....62
Support Machine Properly....63
Stay Clear of Moving Parts....64
Prevent Parts From Flying....65
Store Attachments Safely....66
Prevent Burns....67
Replace Rubber Hoses Periodically....68
Avoid High-Pressure Fluids....69
Prevent Fires....71
Evacuating in Case of Fire....73
Beware of Exhaust Fumes....74
Precautions for Welding and Grinding....75
Avoid Heating Near Pressurized Fluid Lines....76
Remove Paint Before Welding or Heating....77
Beware of Asbestos and Silicon Dust and Other Contamination....78
Prevent Battery Explosions....79
Service Air Conditioning System Safely....80
Handle Chemical Products Safely....81
Dispose of Waste Properly....82
Never Ride Attachment....83
Precautions for Communication Terminal....84
FCC Notifications to User....85
Notes on Protection of Operator’s Station When the Machine Rolls Over....86
Group 3: Torque Values....12
Metric Bolt and Cap Screw Torque Values....90
Additional Metric Cap Screw Torque Values....92
Unified Inch Bolt and Cap Screw Torque Values....94
Service Recommendations for 37° Flare and 30° Cone Seat Connectors....96
Service Recommendations for O-Ring Boss Fittings....98
Service Recommendations for Flared Connections—Straight or Tapered Threads....100
Service Recommendations for Flat Face O-Ring Seal Fittings....102
O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators....104
O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations....107
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations....109
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations....112
Service Recommendations for Metric Series Four Bolt Flange Fitting....115
Service Recommendations For Inch Series Four Bolt Flange Fittings....117
Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations....119
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings....121
Service Recommendations For O-Ring Boss Fittings With Shoulder....124
Metric 24° O-Ring Seal DIN 20078 Service Recommendations....127
Section 01: Tracks....131
Group 0130: Track System....131
Track Roller Remove and Install....136
Track Roller Disassemble and Assemble....140
Track Roller Pressure Test....143
Track Carrier Roller Remove and Install....146
Metal Face Seals Repair....149
Track Shoe Remove and Install....152
Track Chain Remove and Install....155
Track Chain Disassemble and Assemble....162
Track Chain Repair to Replace Broken Part....165
Sprocket Remove and Install....171
Front Idler Remove and Install....174
Front Idler Disassemble and Assemble....176
Track Adjuster and Recoil Spring Remove and Install....180
Track Adjuster and Recoil Spring Disassemble and Assemble....182
Section 02: Axles, Differentials, and Suspension Systems....191
Group 0250: Axle Shaft, Bearings, and Reduction Gears....191
Travel Gear Case Remove and Install....196
Travel Gear Case Disassemble and Assemble....200
Group 0260: Hydraulic System....191
Travel Motor and Park Brake Remove and Install....215
Travel Motor and Park Brake Disassemble and Assemble....219
Park Brake Valve Disassemble and Assemble....230
Travel Motor and Park Brake Start-Up Procedure....233
Metal Face Seal Install....234
Section 04: Engine....240
Group 0400: Removal and Installation....240
Engine Remove and Install....251
Section 05: Engine Auxiliary System....261
Group 0510: Cooling Systems....261
Radiator Remove and Install....266
Hydraulic Oil Cooler Remove and Install....270
Charge Air Cooler Remove and Install....274
Fan, Fan Guard, and Fan Shroud Remove and Install....276
Coolant Recovery Tank Remove and Install....279
Group 0560: External Fuel Supply Systems....261
Fuel Tank Remove and Install....286
Section 07: Damper Drive (Flex Coupling)....291
Group 0752: Elements....291
Damper Drive (Flex Coupling) Remove and Install....296
Section 17: Frame or Supporting Structure....300
Group 1740: Frame Installation....300
Welding on Machine....303
Group 1749: Chassis Weights....300
Counterweight Remove and Install....309
Section 18: Operator's Station....313
Group 1800: Removal and Installation....313
Cab Remove and Install....325
Group 1810: Operator Enclosure....313
Windshield Remove and Install....338
Windshield Disassemble and Assemble....340
Sliding Windows Remove and Install....350
Windowpanes Remove and Install....352
Windowpanes Dimensions....353
Group 1821: Seat and Seat Belt....313
Seat Remove and Install....363
Seat Belt Remove and Install (KAB Mechanical Suspension Seat)....365
Seat Belt Remove and Install (Sears Mechanical Suspension Seat)....367
Mechanical Suspension Seat Disassemble and Assemble (KAB Seat)....369
Mechanical Suspension Seat Disassemble and Assemble (Sears Seat)....371
Group 1830: Heating and Air Conditioning....313
R134a Refrigerant Cautions and Proper Handling....374
R134a Refrigerant Oil Information....375
R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure....377
Recover R134a Refrigerant....379
Flush and Purge Air Conditioning System....380
Evacuate R134a System....383
Charge R134a System....385
Air Conditioner Compressor Remove and Install....387
Condenser Remove and Install....389
Heater and Air Conditioner Remove and Install....390
Heater and Air Conditioner Blower Motor Remove and Install....395
Receiver-Dryer Remove and Install....401
Section 19: Sheet Metal and Styling....403
Group 1910: Hood or Engine Enclosure....403
Hood Remove and Install....406
Section 33: Excavator....408
Group 3302: Buckets....408
Bucket Remove and Install....411
Adjust Bucket Pivot End Play....412
Bucket Pin-Up Data....414
Group 3340: Frames....408
Bucket Links Remove and Install....419
Arm Remove and Install....422
Boom Remove and Install....426
Inspect Pins, Bushings, and Bosses—Front Attachment....434
Cylinder Specifications....437
Bushings and Seal Remove and Install....438
Group 3360: Hydraulic System....408
Apply Vacuum to Hydraulic Oil Tank....442
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy....444
Pump 1 and 2 Remove and Install....445
Pump 1 and 2 Disassemble and Assemble....450
Pump 1 and 2 Inspection....468
Pump 1 and 2 Start-Up Procedure....473
Pump 1 and 2 Regulator Remove and Install....475
Pump 1 and 2 Regulator Disassemble and Assemble....477
Pilot Pump Remove and Install....480
Pilot Pump Disassemble and Assemble....483
Pilot Pressure Regulating Valve and Filter Remove and Install....485
Pilot Pressure Regulating Valve and Filter Disassemble and Assemble....487
Pilot Shutoff Solenoid Valve Remove and Install....489
Pilot Shutoff Solenoid Valve Disassemble and Assemble....492
Solenoid Valve Manifold Remove and Install....494
Solenoid Valve Remove and Install—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves....496
Solenoid Valve Disassemble and Assemble—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves....499
Pilot Valve (Left and Right) Remove and Install....501
Pilot Valve (Left and Right) Disassemble and Assemble....504
Travel Pilot Valve Remove and Install....513
Travel Pilot Valve Disassemble and Assemble....516
Pilot Signal Manifold Remove and Install....520
Pilot Signal Manifold Disassemble and Assemble....522
Control Valve Remove and Install....525
Control Valve Halves Disassemble and Assemble....530
Control Valve (5-Spool) Disassemble and Assemble....532
Control Valve (4-Spool) Disassemble and Assemble....558
Hydraulic Oil Tank Remove and Install....581
Hydraulic Oil Tank Disassemble and Assemble....587
Restriction Valve Remove and Install....591
Hydraulic Oil Cooler Bypass Valve Remove and Install....593
Boom Cylinder Remove and Install....595
Boom Cylinder Disassemble and Assemble....600
Arm Cylinder Remove and Install....606
Arm Cylinder Disassemble and Assemble....610
Bucket Cylinder Remove and Install....616
Bucket Cylinder Disassemble and Assemble....620
Hydraulic Cylinder Bleed Procedure....626
Section 43: Swing or Pivoting System....627
Group 4350: Mechanical Drive Elements....627
Swing Gear Case Remove and Install....631
Swing Gear Case Disassemble and Assemble....634
Swing Gear Case Start-Up Procedure....644
Upperstructure Remove and Install....646
Swing Bearing Remove and Install....651
Swing Bearing Disassemble and Assemble....654
Swing Bearing Upper Seal Install....657
Swing Bearing Lower Seal Install....658
Group 4360: Hydraulic System....627
Center Joint Remove and Install....664
Center Joint Disassemble and Assemble....668
Center Joint Air Test....672
Swing Motor and Park Brake Remove and Install....673
Swing Motor and Park Brake Disassemble....676
Swing Motor and Park Brake Inspection....680
Swing Motor and Park Brake Assemble....685
Swing Motor and Park Brake Start-Up Procedure....689
Crossover Relief Valve and Make-Up Check Valve Remove and Install....690
Make-Up Check Valve Disassemble and Assemble....694
Swing Park Brake Check Valve and Orifice Remove and Install....696
Section 99: Dealer Fabricated Tools....699
Group 9900: Dealer Fabricated Tools....699
DF1063 Lift Bracket....702
ST4920 Track Recoil Spring Disassembly and Assembly Tool....704
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool....709
DFT1110 Spacer....710
DFT1130 Adapter....711
DFT1036A Travel Gear Case Nut Wrench....712
DFT1109 Holding Bar....713
Center Joint (Rotary Manifold) Lifting Tool....714
DFT1220 Swing Gear Case Nut Spanner Wrench....716
Hitachi Zaxis 160LC-5G Excavator Repair Service Manual (TM13199X19