Hitachi Excavator EX150, EX150LC-5, EX160LC-5 Hydraulic Excavators Service Repair Manuals + Operator's Manuals
Hitachi EX150, EX150LC-5, EX160LC-5 Hydraulic Excavators Service Repair Manuals + Operator's Manuals
Complete service repair manual with electrical wiring diagrams for Hitachi EX150, EX150LC-5, EX160LC-5 Hydraulic Excavators, with all the shop information to maintain, diagnose, repair, and service like professional mechanics.
Hitachi Construction EX150, EX150LC-5, EX160LC-5 Hydraulic Excavators workshop service & repair manual includes:
* 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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.
T165E00 - Hitachi EX150LC-5, EX160LC-5 Excavator Technical Manual
W165E00 - Hitachi EX150LC-5, EX160LC-5 Excavator Workshop Manual
EM13KNA21 - Hitachi EX160LC-5 Excavator Operator's Manual.pdf
EM13314 - Hitachi EX150 Excavator Operator's Manual.pdf
KM10100 - Hitachi EX150 Excavator Technical Manual (Service & Repair).pdf
EM13314 - Hitachi Excavator EX150 Operator's Manual.pdf
KM10100 - Hitachi Excavator EX150 Hydraulic Excavator Technical Service Manual.pdf
Total Pages: 3,951 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
TABLE OF CONTENTS
GENERAL INFORMATION
UPPERSTRUCTURE
UNDERCARRIAGE
FRONT ATTACHMENT
ENGINE ASSEMBLY
MAINTENANCE
LUBRICATING SYSTEM
FUEL SYSTEM
TURBOCHARGER
AIR COMPRESSOR
ENGINE ELECTRICALS
TROUBLESHOOTING
...
CD-ROM.......2
EX150LC-5cir.......3
T165E-ELC1.......4
T165E-ELC2.......5
T165E-HARNESS1.......6
T165E-HARNESS2.......7
T165E-HARNESS3.......8
T165E-HARNESS4.......9
T165E-HYD.......10
TM.......11
INDEX.......12
Cover.......12
Introduction.......13
Safty.......15
T1.......41
CONTENTS(165T-1-1).......42
SECTION 1 GENERAL.......42
Group 1 Specification.......44
Specification.......44
Working Range and Machine Dimensions for Transportation.......45
Component Specifications.......46
Group 2 Component Layout.......52
Main Components.......52
Electrical System (Overall System).......53
Electrical System (Relays).......54
Electrical System (Monitor and Switch Panels).......55
Pump and Related Parts.......56
Other Components.......57
T2.......58
CONTENTS(165T-2-1).......59
SECTION 2 SYSTEM.......59
Group 1 Control System.......61
Outline.......61
Engine Control.......62
Pump Control.......68
Valve Control.......70
Other Control Function.......73
Group 2 Hydraulic System.......75
Main Circuit.......75
Pilot Circuit.......76
Neutral Circuit.......77
Single Actuator Operation.......77
Combined Operation.......78
Group 3 Electrical System.......81
Outline.......81
Electric Power Circuit.......82
Bulb Check Circut.......83
Preheat Circuit.......84
Starting Circuit.......86
Charging Circuit.......88
Surge Voltage Prevention Circuit.......91
Accessory Cirucuit.......92
Engine Stop Circuit.......93
T3.......95
CONTENTS(165T-3-1).......96
SECTION 3 COMPONENT OPERATION.......96
Group 1 Pump Device.......98
Outline.......98
Main Pump.......99
Regulator.......102
Pilot Pump.......110
N Sensor.......110
Pump Delevery Pressure Sensor.......110
Group 2 Swing Device.......112
Outline.......112
Swing Motor.......113
Valve Unit.......115
Swing Parking Brake.......117
Swing Reduction Gear.......118
Group 3 Control Valve.......120
Outline.......120
Hydraulic Circuit.......125
Flow Combiner Valve.......127
Pump Control Valve.......128
Main Relief Valve.......130
Overload Relief Valve.......130
Arm Regenerative Valve.......131
Boom Anti-Drift Valve, Arm Anti-Drift Valve.......133
Bucket Flow Control Valve.......133
Travel Flow Control Valve.......135
Travel/Boom lower Selector Valve.......135
Boom Regenerative Valve.......137
Group 4 Pilot Valve.......138
Outline.......138
Operation.......139
Group 5 Travel Device.......148
Outline.......148
Travel Reduction Gear.......149
Travel Motor.......150
Travel Brake Valve.......155
Parking Brake.......157
Group 6 Others (Upperstructure).......158
Pilot Shut-Off valve.......158
Shockless Valve.......159
Solenoid Valve Unit.......161
Pilot Relief Valve.......163
EC Motor.......163
Group 7 Others (Undercarriage).......164
Swing Bearing.......164
Center Joint.......165
Track Adjuster.......166
T4.......168
CONTENTS(165T-4-1).......169
SECTION 4 OPERATIONAL PERFORMANCE TEST.......169
Group 1 Introducution.......171
Operational Performance tests.......171
Preparation for Performance tests.......172
Group 2 Engine Test.......173
Engine Speed.......173
Engine Compression Pressure.......175
Valve Clearance Adjustment.......176
Nozzle Check.......178
Injection Timing.......180
Group 3 Excavator Test.......181
Travel Speed.......181
Track Revolution Speed.......182
Mistrack Check.......183
Travel Parking Function Check.......184
Swing Speed.......185
Swing Function Drift Check.......186
Swing Motor Leakage.......187
Swing Bearing Play.......188
Maximum Swingable Slant Angle.......189
Hydraulic Cylinder Cycle Time.......190
Dig Function Drift Check.......191
Control Lever Operating Force.......192
Control Lever Stroke.......193
Combined Boom Raise/Swing Function Check.......194
Group 4 Component Test.......195
Primary Pilot Pressure.......195
Secondary Pilot Pressure.......197
Solenoid Valve Set Pressure.......198
Main Pump Delivery Pressure.......200
Main Relief Valve Set Pressure.......201
Overload Relief Valve Set Pressure.......205
Main Pump Flow Test.......208
Swing Motor Drainage.......212
Travel Motor Drain Oil Pressure.......214
Group 5 Standard.......217
Operational Performance Standard Table.......217
Main Pump P-Q Diagram.......220
Injection Pump.......221
T5.......223
CONTENTS(165T-5-1).......224
SECTION 5 TROUBLESHOOTING.......224
Group 1 Diagnosing Procedure.......226
Introduction.......226
Diagnosing Procedure.......227
Dr.EX.......229
Dr.EX Start-Up Procedure.......229
Dr.EX Fault Code.......230
Dr.EX Monitoring Function.......231
Dr.EX Special Function (Service Mode).......232
Adjustable Data list.......239
Group 2 Component Layout.......240
Main Components.......240
Electrical System (Overall Syatem).......241
Electrical System (Relays).......242
Electrical System (Monitor and Switch Panels).......243
Pump and Related Parts.......244
Control Valve.......245
Others Components.......249
Group 3 Troubleshooting A.......250
Troubleshooting A Procedure.......250
Fault Codes.......251
Fault Code 01.......253
Fault Code 02, 03.......254
Fault Code 04, 05.......255
Fault Code 06.......256
Fault Code 07.......257
Sensor Operating Range List.......258
Group 4 Troubleshooting B.......260
Troubleshooting B Procedure.......260
Relationship Between Machine Trouble Symptoms and Parts in Trouble.......261
Correlation Between Trouble Symptoms and Part Failures.......271
Engine Troubleshooting.......277
Actuator Control Syatem Troubleshooting.......291
Front Attachment Control System Troubleshooting.......297
Swing System Troubleshooting .......309
Travel System Troubleshooting.......312
Troubleshooting for Other Functions.......317
Engine Speed Adjustment and Engine Learning.......319
Exchange Inspection Method.......320
Group 5 Troubleshooting C.......322
Traubleshooting C Procedure.......322
Malfunction of Coolant Temperature Gauge.......323
Malfunction of Fuel Gauge.......325
Malfunction of Indecator Light Check System.......327
Malfunction of Level Check Switch.......327
Malfunction of Engine Oil Level Indicator.......329
Malfunction of Coolant Level Indicator.......331
Malfunction of Hydraulic Oil Level INdicator.......333
Malfunction of Alternator Indicator.......335
Malfunction of Engine Oil Pressure Indicator.......337
Malfunction of Overheat Indicator.......339
Malfunction of Fuel Level Indicator.......341
Malfunction of Air Filter Restriction Indicator.......343
Malfunction of Buzzer.......345
Malfunction of Hour Meter.......347
Group 6 Electrical System Inspection.......348
Precautions for Inspection and Maintenace.......348
Instructions for Disconnecting Connectors.......350
Fuse Continuity Test.......351
Inspection and Replacement of Fusible Links.......352
Battery Voltage Check.......353
How to Troubleshoot Alternator Malfunctions.......354
Continuity Check.......355
Voltage and Current Check.......357
Replacement of Relay.......361
Group 7 Harness Check.......362
Circuit Check.......362
WM.......364
INDEX.......365
Cover.......365
Introduction.......366
Safty.......368
W1.......394
CONTENTS(165W-1-1).......395
SECTION 1 GENERAL INFORMATION.......395
Group 1 Precautions for Disassembling and Assembling.......397
Precautions for Disassembling and Assembling.......397
Maintenance Standard Terminology.......400
Group 2 Tightening Torque.......401
Tightening Torque Specifications.......401
Torqr Chart.......402
Piping Joint.......405
W2.......409
CONTENTS(165W-2-1).......410
SECTION 2 UPPERSTRUCTURE.......410
Group 1 Cab.......412
Remove and Install Cab.......412
Dimensions of the Cab Glass.......418
Group 2 Counterweight.......420
Remove and Install Couterweight.......420
Group 3 Main Frame.......422
Remove and Install Main Frame.......422
Group 4 Pump Device.......430
Remove and Install Pump Device.......430
Desassemble Pump Device.......433
Assemble Pump Device.......437
Disassemble Regulator Cover.......441
Assemble Regulator Cover.......443
Disassemble and Assemble Pilot Pump.......445
Group 5 Control Valve.......448
Remove and Install Control Valve.......448
Disassemble Control Valve 1.......451
Assemble Control Valve 1.......453
Disassemble Control Valve 2.......457
Assemble Control Valve 2-1.......461
Assemble Control Valve 2-2.......463
Disassemble Control Valve 3.......467
Assemble Control Valve 3.......469
Disassemble Control Valve 4.......473
Assemble Control Valve 4-1.......477
Assemble Control Valve 4-2.......481
Group 6 Swing Device.......484
Remove and Install Swing Device.......484
Disssemble Swing Device.......487
Assemble Swing Device.......491
Disassemble Swing Motor.......497
Assemble Swing Motor.......501
Maintenance Standard.......505
Group 7 Pilot Valve.......508
Remove and Install Right Pilot Valve.......508
Remove and Install Left Pilot Valve.......512
Remove and Install Travel Pilot Valve.......516
Disassemble Right and Left Pilot Valve.......519
Assemble Right and Left Pilot Valve.......521
Disassemble Travel Pilot Valve.......525
Assemble Travel Pilot Valve.......527
Group 8 Pilot Shut-Off Valve.......532
Remove and Install Pilot Shut-Off Valve.......532
Disassemble Pilot Shut-Off Valve.......535
Assemble Pilot Shut-Off Valve.......537
Group 9 Shockless Valve.......540
Remove and Install Shockless Valve.......540
Disassemble and Assemble Front Shockless Valve.......543
Group 10 Solenoid Valve.......546
Remove and Install Solenoid Valve Unit.......546
Disassemble Proportional Solenoid Valve.......549
Assemble Proportional Solenoid Valve.......551
Group 11 Pilot Relief Valve Unit.......554
Remove and Install Pilot Relief Valve Unit.......554
Disassemble Pilot Relief Valve.......557
Assemble Pilot Relief Valve.......559
W3.......562
CONTENTS(165W-3-1).......563
SECTION 3 UNDERCARRIAGE.......563
Group 1 Swing Bearing.......565
Remove and Install Swing Bearing.......565
Disassemble Swing Bearing.......568
Assemble Swing Bearing.......570
Group 2 Travel Device.......573
Remove and Install Travel Device.......573
Disassemble Travel Motor.......576
Assemble Travel Motor.......580
Disassemble Travel Device.......584
Assemble Travel Device.......588
Disassemble Base Plate.......592
Assemble Base Plate.......594
Maintenance Standard.......596
Group 3 Center Joint.......599
Remove and Install Center Joint.......599
Disassemble Center Joint.......602
Assemble Center Joint.......604
Maintenance Standard.......607
Group 4 Track Adjuster.......609
Remove and Install Track Adjuster.......609
Disassemble Track Adjuster.......610
Assemble Track Adjuster.......618
Group 5 Front Idler.......625
Remove and Install Front Idler.......625
Disassemble Front Idler.......626
Assemble Front Idler.......630
Maintenance Standard.......632
Group 6 Upper and Lower Roller.......633
Remove and Install Upper Roller.......633
Remove and Install Lower Roller.......636
Disassemblel Lower Roller.......640
Assemble Lower Roller.......642
Maintenance Standard.......644
Group 7 Track.......647
Remove and Install Tracks.......647
Maintenance Standard.......653
W4.......655
CONTENTS(165W-4-1).......656
SECTION 4 FRONT ATTACHMENT.......656
Group 1 Front Attachment.......658
Remove and Install Front Attachmet.......658
Maintenance Standare.......664
Standard Dimensions for Arm and Bucket Connection.......667
Group 2 Cylinder.......668
Remove and Install Cylinder.......668
Hydraulic Circuit Pressure Release Procedure.......676
Disassemble Cylinder.......677
Assemble Cylinder.......681
Maintenance Standards.......685
W5.......686
W05.......687
SECTION 5 ENGINE.......0
General Introduction.......689
General Repair Instructions.......690
Notes on the Format of this Manual.......690
Main Data and Specifications.......694
Performance Curve.......697
External View.......702
Tightening Torque Specifications.......705
Angular Nut and Bolt Tightening Method.......707
Major Parts Fixing Nuts and Bolts.......709
Identifications.......720
Maintenance.......721
Lubricating System.......722
Fuel System.......722
Cooling System.......726
Valve Clearance Adjustment.......726
Injection Timing.......728
Compression Pressure Measurement.......732
Turbocharger Inspection.......733
Engine Repair Kit.......734
Recommended Lubricants.......736
Engine Oil Viscosity Chart.......736
Engine Assembly (Disassembly).......737
External Parts Disassembly Steps.......738
Major Components.......744
Rocker Arm and Rocker Arm Shaft Disassembly Steps.......749
Cylinder Head Disassembly Steps.......750
Piston and Connecting Rod Disassembly Steps.......751
Engine Assembly (inspection and Repair).......752
Cylinder Head.......753
Valve Guide.......754
Valve Spring.......757
Tappet.......758
Push Rod.......759
Rocker Arm Shaft and Rocker Arm .......759
Idler Gear and Idler Gear Shaft.......760
Camshaft.......761
Cylinder Body and Liner.......762
Piston and Piston Ring.......767
Piston pin.......769
Connecting Rod.......770
Crankshaft.......772
Flywheel and Flywheel Housing.......779
Timing Gear Case Cover.......780
Engine Assembly (Reassenbly).......781
Piston and Connecting Rod Reassembly Steps.......782
Cylinder Head Reassembly Steps.......784
Rocker Arm and Rocker Shaft Reassembly Steps.......788
Major Component Reassembly Steps .......789
Major Component Reassembly Steps .......794
External Parts Reassembly Steps (Left-Hand Side).......798
External Parts Reassembly Steps (Right-Hand Side).......802
Engine Tuning Operation.......805
Engine Sectional View.......807
Lubricating System.......808
General Description.......809
Oil Pump.......810
Oil Cooler.......812
Cooling System.......814
General Description.......815
Water Pump.......816
Thermostat.......821
Fuel Sistem.......822
General Description.......823
Injection Nozzle.......824
Injection Pump Calibration.......829
Turbocharger.......838
General Description.......839
Turbocharger Identification.......840
Inspection and Repairs.......841
Air Compressor.......842
General Description.......843
Disassembly Steps.......844
Inspection and Repairs.......845
Reassembly Steps.......847
Engine Electrials.......849
Starter Motor Identification.......850
Starter Main Data and Spectifications.......851
Starter Motor Sectional View.......852
Starter Motor Exploded View.......853
Alternator Identifications.......854
Alternator Sectional View.......856
Alternator Exploded View.......857
Troubleshooting.......858
Hard Starting.......859
1) Starter Inoperative.......859
2) Starter Operates but Engine Does not Turn Over.......860
3) Engine Turns Over but Does not Start Though Fuel is Bearing Delivered to the Injection Pump.......861
4) Engine Turns Over but Does not Start .......862
Unstable Low Idling.......863
Insufficient Power.......866
Excessive Fuel Consumption.......869
Excessive Oil Consumption.......871
Overheating.......872
Warkish Exhaust Smoke.......874
Darkish Exhaust Smoke.......875
Oil Pressure does not Rise.......876
Abnormal Engine Noise.......878
Special Tool List.......881
Special Tool List.......882
Conversion Table.......884
Length.......885
Area.......886
Volume.......887
Mass.......888
Pressure.......889
Torque.......890
Temperature.......891
ex150-5cir.......892
index.......893
EM13314 - Hitachi EX150 Excavator Operator's Manual.......894
EM13314 - Hitachi Excavator EX150 Operator's Manual.......1040
EM13KNA21 - Hitachi EX160LC-5 Excavator Operator's Manual.......1186
KM10100 - Hitachi EX150 Excavator Technical Manual (Service & Repair).......1428
KM10100 - Hitachi Excavator EX150 Hydraulic Excavator Technical Service Manual.......2366
EX150 HYDRAULIC EXCAVATOR SERVICE MANUAL.......0
SECTION 01 HOW TO USE.......2366
Group 01 Section & Group Contents.......2367
Group 02 Introduction.......2370
Introduction .......2370
Care of the Handling.......2370
Symbols.......2371
Group 03 Features of This Manual.......2372
Construction.......2372
Tab .......2373
Page.......2373
Contents.......2373
Group 04 Safty Informations .......2374
SECTION 02 SPECIFICATIONS.......2377
Group 01 General Specifications.......2379
Dimensions.......2379
Weights and Ground Pressure.......2380
Capability.......2380
Backhoe Buckets.......2381
Other Attachments.......2381
Working Ranges.......2382
Lifting Capacities.......2383
Group 02 Components Specifications.......2384
Engine.......2384
Main Pump.......2388
Pilot Pump .......2389
Control Valve.......2390
Swing Motor.......2390
Travel Motor .......2391
Center Joint.......2391
Pilot Valve (for Travel).......2391
Pilot Valve (for Swing,Boom,Arm,Bucket).......2392
Control Neutralizer Valve.......2392
Shockless Valve.......2392
Accumulator.......2392
Hydraulic Tank.......2392
Suction Filter.......2393
Full-Flow Filter.......2393
Air Breezer.......2393
Bypass Check Valve.......2393
Pilot Filter.......2393
Oil Cooler.......2393
Restriction Valve.......2393
Solenoid Valve.......2394
Mode Selection Cylinder.......2394
Boom Cylinder.......2394
Arm Cylinder.......2394
Bucket Cylinder.......2394
Group 03 Torque Reference.......2395
Group 04 Others.......2400
maintenance Intervals.......2400
Group 05 Conversion Table.......2403
Section 03 General .......2409
Group 01 Introduction.......2410
Introduction.......2410
Group 02 Construction.......2411
Construction.......2411
Group 03 Hydraulic System.......2414
Hydraulic System.......2414
Main Hydraulic Circuit.......2415
Pilot Hydraulic Circuit.......2419
Group 04 Electric System.......2423
Main Circuit.......2423
Control System.......2424
Monitor System.......2424
Group 05 Maintenance.......2425
Removal and Instrallation (Cab,Front Attachment,Superstructure) .......2425
Maintenance.......2438
Name Plate.......2450
SECTION 04 SUPERSTRUCTURE.......2453
Group 01 Superstructure.......2455
Main Frame and Counter-Weight.......2455
Engine.......2456
Maintenance Standard.......2459
Hydraulic Oil Tank.......2461
Fuel Tank.......2465
Swing Device.......2466
Electric Parts.......2471
Cab Heater.......2475
Engine Control Lever.......2477
Main Piping .......2478
Oil Cooler Piping.......2480
Cover.......2485
Main Pump.......2488
Control Box.......2494
Cab Group.......2496
Pilot Piping.......2500
Control Lever.......2507
Group 02 Hydraulic Pump Device.......2509
O/P, Hydraulic Pump.......2509
Outline.......2509
Function.......2511
Operation.......2516
D/A, Main Pump .......2526
Disassembry.......2526
Assembly.......2538
Parts List.......2550
Regukator.......2551
Upper Cover.......2552
Lower Cover.......2553
Gear Pump.......2553
Group 03 Control Valve.......2554
O/P, Control Valve.......2554
General.......2554
Construction and Function.......2558
D/A, Control Valve.......2575
Dissasembly.......2575
Inspection.......2586
Assembly.......2587
Group 04 Swing Device.......2610
O/P, Swing Motor .......2610
Outline.......2610
Function.......2613
D/A, Swing Motor .......2622
Disassembly.......2622
Inspection.......2631
Assembly.......2633
Special Tools.......2645
D/A, Swing Reduction Device.......2650
Disassembly.......2650
Assembly.......2655
Special Tools.......2661
Group 05 Pilot Valve.......2664
O/P, Pilot Valve.......2664
Outline.......2664
Function.......2666
D/A, HV Type Pilot Valve (Front-End Attachment) .......2671
Disassembly.......2671
Assembly.......2677
Special Tools.......2683
D/A, HV Type Pilot Valve (Travel).......2685
Disassembly.......2685
Assembly.......2691
Special Tools.......2697
Group 06 Control Neutralizer Valve.......2699
O/P, Control Neutralizer Valve .......2699
Outline.......2699
D/A, Control Neutralizer Valve.......2701
Disassembly.......2701
Assembly.......2703
Group 07 Shockless Valve.......2706
O/P, Shockless Valve.......2706
Outline.......2706
Function.......2707
D/A, Shockless Valve.......2711
Disassembly.......2711
Inspection.......2714
Assembly.......2715
Group 08 Accumulator.......2720
O/P, Accumulator.......2720
Outline.......2720
Function.......2721
Group 09 Solenoid Valve.......2722
O/P, Solenoid Valve.......2722
Outline.......2722
Function.......2723
D/A, Solenoid Valve.......2727
Disassembly.......2727
Inspection.......2731
Assembly.......2732
Group 10 Mode Selection Cylinder.......2737
D/A, Mode Selection Cylinder.......2737
Disassembly.......2737
Assembly.......2738
SECTION 05 UNDERCARRIAGE.......2741
Group 01 Undercarriage.......2742
Track Frame.......2742
Swing Bearing .......2744
Travrl Device and Piping.......2751
Front Idler.......2760
Adjuster.......2767
Upper Roller and Lower Roller.......2779
Track Link.......2793
Center Joint.......2803
Group 02 Travel Devece.......2810
O/P, Travel Motor.......2810
Outline.......2810
Travel.......2810
Brake Valve Assembly.......2813
D/A, Travel Motor and Travel Device.......2816
Disassemble Travel Motor.......2816
Inspect Travel Motor.......2820
Assemble Travel Motor.......2822
Disassemble Travel Device.......2827
Assemble TravelDevice.......2830
Special Tools.......2834
D/A, Travel Motor and Travel Divice.......2841
Remove and Install Travel Device.......2841
Disassemble Travel Device (Serial No.3074 and Up).......2842
Assemble Travel Device.......2845
Disassemble Travel Motor (Serial No.3074 and Up).......2851
Assemble Travel Motor (Serial No.3074 and Up).......2854
Disassemble Brake Valve (Serial No.3074 and Up).......2856
Assemble Brake Valve (Serial No.3074 and Up).......2859
Maintenance Standard (Serial No.3074 and Up).......2861
Group 03 Center Joint.......2864
O/P, Center Joint.......2864
Outline.......2864
D/A, Center Joint .......2865
Disassembly.......2865
Assembly.......2868
Special Tools.......2871
SECTION 06 FRONT-END ATTACHMENT .......2873
Group 01 FRONT-END ATTACHMENT .......2874
Boom Assembly.......2874
Arm Assembly.......2876
Bucket Assembly.......2879
Front Pipings.......2887
Group 02 Hydraulic Cylinder.......2901
Operational Principle.......2901
Disassembly and Assembly.......2902
Group 03 Pin and Bushing.......2914
Specifications.......2914
Group 04 Point and Side Cutter.......2916
Maintenance.......2916
SECTION 07 HYDRAULIC SYSTEM.......2918
Group 01 Outline.......2920
Outline.......2920
Group 02 Main Hydraulic Circuit.......2921
Suction Circuit and Delivery Circuit.......2921
Return Circuit.......2925
Drain Circuit.......2927
Group 03 Pilot Circuit.......2930
Suction,Delivery and Return Circuit.......2931
Accumulator.......2933
Control Neutralizer Valve.......2933
Pump Displacement Control Circuit.......2935
Relief pressure Change Circuit .......2938
Switch Valve Circuit.......2938
Heat-Run Circuit.......2939
Swing Parking Brake .......2941
Group 04 Single Operation.......2943
Boom Raise Circuit Operation.......2943
Boom Lower Circuit Operation .......2944
Arm Roll-In Circuit Operation.......2945
ArmRoll-Out Circuit Operation.......2946
Bucket Circuit Operation.......2947
Swing Circuit Operation.......2948
Swing Operation.......2950
Travel Circuit Operation.......2951
Travel Forward and Reverse Operation.......2953
Group 05 Combined Operation.......2955
Outline.......2955
Combined Swing and Boom Operation.......2956
Combined Swing and Arm Operation.......2957
Combined Swing and Bucket Operation.......2958
Combined Swing, Boom, Arm and Buket Operation.......2959
Combined Swing and Travel Operation.......2960
Combined Boom and Travel Operation .......2961
Combined Arm and Travel Operation .......2962
Combined Bucket and Travel Operation .......2963
Group 06 Extra Control Circuit.......2964
Outline .......2964
Single Operation.......2966
Combined Extra and Arm Roll-In Operation.......2967
Combined Extra and Arm Roll-Out Operation.......2968
SECTION 09 ELECTRICAL SYSTEM.......2970
Group 01 Safety Precautions.......2971
Safety Precautions.......2971
Group 02 Specifications .......2972
Battery, Starter, Safety, Relay, Alternator, Regulator, Headlight, Wiper Motor, Speaker, Fuse.......2972
Group 03 Construction and Function.......2974
Construction of Electrical System.......2974
Monitor.......2976
Control (E-P Control) System.......2985
Function of Seneors and Relays.......2994
Group 04 Circuit Operations.......2999
Characteristics of Electrical Circuit.......2999
Electrical Circuit.......3000
Battery Circuit.......3001
Preheat Circuit.......3002
Starting Circuit.......3003
Charging Circuit.......3005
Safety Circuit.......3009
Accessory Circuit.......3010
Gauge Panel Circuit.......3011
Control Circuit.......3012
Group 05 Maintenance.......3013
Gauge Panel .......3013
Assembly and Adjustment of Auto-idle Device.......3021
SECTION 10 TROUBLESHOOTING.......3023
Group 01 Introduction.......3025
General Infomation.......3025
Notes on Performance Measurement.......3027
Group 02 Diagnose Malfunctions.......3030
Malfunctions Phenomena.......3030
Hydraulic System.......3032
Electric System.......3047
Group 03 Excavator Performance Test.......3076
introduction.......3076
Engine Performance Measurement.......3076
Travel Performance Measurement.......3079
Swing Performance Measurement.......3086
Front-end Attachment.......3090
Control Lever Performance Measurement.......3094
Group 04 Components Performance Standard.......3098
introduction.......3098
Pilot Relief Valve.......3098
Main Relief Valve.......3100
Overload Relief Valve.......3102
Swing Overload Relief Valve.......3104
Travel Crossover Relief Valve.......3105
Main Hydraulic Pump.......3106
Travel Motor.......3115
Swing Motor.......3116
SECTION 11 ENGINE.......3132
Group 01 General Information.......3135
General Repair Instructions.......3135
Notes on the Format of this Manual.......3135
Main Data and Specifications.......3139
Design Features and General Outline.......3143
Tightening Torque Specifications.......3146
Anglular Nut and Bolt Tightening Method.......3147
Major Parts Fixing Nuts and Bolts.......3149
Identifications.......3160
Group 02 Maintenance.......3161
Lubricating System.......3161
Fuel System.......3162
Cooling System.......3166
Valve Clearance Adjustment.......3166
Injection Timing.......3168
Compression Pressure Measurement.......3174
Turbocharger Inspection.......3175
Engine Repair Kit.......3176
Recommended Lubricants.......3178
Engine Oil Viscosity Chart.......3178
Group 03 Engine Disassembly.......3179
External Parts.......3179
Major Components.......3187
Rocker Arm and Rocker Arm Shaft.......3189
Cylinder Head.......3190
Piston and Connection Rod.......3191
Group 04 Inspection and Repair.......3193
Cylinder Head.......3193
Valve Guide.......3194
Valve Spring.......3194
Tappet.......3198
Push Rod.......3199
Rocker Arm Shaft and Rocker Arm.......3199
Idler Gear and Idler Gear Shaft.......3200
Cam Shaft.......3201
Cylinder Body and Liner.......3202
Piston and Piston Ring.......3207
Piston Pin.......3208
Connecting Rod.......3209
Crank Shaft.......3211
Fly Wheel and Fly Wheel Housing.......3219
Timing Gear Case Cover.......3220
Group 05 Engine Assembly.......3221
Piston and Connecting Rod.......3221
Cylinder Head.......3223
Rocker Arm and Rocker Arm Shaft.......3227
Major Components.......3228
External Parts.......3238
Engine Tuning Operation.......3245
Engine Section View.......3247
Group 06 Lubricating System.......3248
General Description.......3248
Oil Pump.......3249
Main Oil Pump.......3251
Oil Cooler.......3253
Group 07 Cooling System.......3255
General Description.......3255
Water Pump.......3256
Thermostat.......3261
Group 08 Fuel System.......3262
General Descrintion.......3262
Fuel Filter.......3263
Injection Nozzle.......3265
Group 09 Turbo Charger.......3270
General Description.......3270
Identification.......3271
Roter Shaft Play Inspection.......3272
Group 10 Engine Electricals.......3273
Starter Motor.......3273
Alternator.......3276
Group 11 Troubleshooting.......3280
Hard Staeting.......3280
Unstable Low Idring.......3284
Insufficient Power.......3287
Excessive Fuel Consumption.......3290
Overheating.......3293
White Exhaust Smoke.......3295
Darkish Exhaust Smoke.......3296
Not Rising Oil Pressure.......3297
Abnormal Engine Noise.......3299
Group 12 Special Tool List.......3302
Special Tool List.......3302
T165E00 - Hitachi EX150LC-5, EX160LC-5 Excavator Technical Manual.......3304
Index.......3305
Section 1-General.......3334
Section 2-System.......3350
Section 3-Component Operation.......3386
Section 4-Operational Performance Test.......3458
Section 5-Troubleshooting.......3512
W165E00 - Hitachi EX150LC-5, EX160LC-5 Excavator Workshop Manual.......3652
Index.......3653
Section 1-General Information.......3682
Section 2-Upperstructure.......3696
Section 3-Undercarriage.......3848
Section 5-Engine and Accessory.......3940
