Hitachi Zaxis 160LC-5N Excavator Repair Technical Manual (TM12369)
Complete Repair Service Technical Manual for Hitachi Zaxis 160LC-5N Excavator, with all the shop information to maintain, repair, and rebuild like professional mechanics.
Hitachi Excavator ZX 160LC-5N workshop technical manual (repair) 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.
* 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.
TM12369 - Hitachi Zaxis160LC-5N Excavator Repair Technical Manual.pdf
TM12371 - Hitachi Excavadora Zaxis160LC-5N.pdf
TM12369 - Hitachi Zaxis 160LC-5N Excavator.pdf
TM12370 - Hitachi Excavatrice Zaxis 160LC-5N.pdf
PRODUCT DETAILS:
Total Pages: 767 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English Spanish French
Models: John Deere HITACHI - Zaxis 160LC-5N Excavator - 1FFDBC70__E230001 (iT4/S3B)
TABLE OF CONTENTS....1
Section 00: General Information....12
Group 0001: Safety....12
Recognize Safety Information....16
Understand Signal Words....17
Follow Safety Instructions....18
Prepare for Emergencies....20
Wear Protective Clothing....21
Protect Against Noise....22
Inspect Machine....23
General Precautions for Cab....24
Use Handholds and Steps....25
Adjust the Operator's Seat....26
Ensure Safety Before Rising From or Leaving Operator’s Seat....27
Fasten Your Seat Belt....28
Move and Operate Machine Safely....29
Operate Only From Operator's Seat....30
Jump Starting....31
Keep Riders Off Machine....32
Precautions for Operations....33
Investigate Job Site Beforehand....34
Install OPG Guard....36
Provide Signals for Jobs Involving Multiple Machines....37
Confirm Direction of Machine to be Driven....38
Drive Machine Safely....39
Avoid Injury From Rollaway Accidents....43
Avoid Injury From Back-Over and Swing Accidents....44
Keep Person Clear From Working Area....46
Never Position Bucket Over Anyone....47
Avoid Undercutting....48
Avoid Tipping....49
Never Undercut a High Bank....51
Dig With Caution....52
Operate With Caution....53
Avoid Power Lines....54
Precautions for Lightning....55
Object Handling....56
Protect Against Flying Debris....57
Park Machine Safely....58
Handle Fluids Safely−Avoid Fires....59
Transport Safely....60
Practice Safe Maintenance....61
Warn Others of Service Work....63
Support Machine Properly....64
Stay Clear of Moving Parts....65
Prevent Parts From Flying....66
Store Attachments Safely....67
Prevent Burns....68
Replace Rubber Hoses Periodically....69
Avoid High-Pressure Fluids....70
Prevent Fires....72
Evacuating in Case of Fire....74
Beware of Exhaust Fumes....75
Precautions for Welding and Grinding....76
Avoid Heating Near Pressurized Fluid Lines....77
Remove Paint Before Welding or Heating....78
Beware of Asbestos and Silicon Dust and Other Contamination....79
Prevent Battery Explosions....80
Service Air Conditioning System Safely....81
Handle Chemical Products Safely....82
Dispose of Waste Properly....83
Never Ride Attachment....84
Notes for Muffler Filter....85
Precautions for Communication Terminal....86
FCC Notifications to User....87
Before Returning the Machine to the Customer....88
Group 0003: Torque Values....13
Metric Bolt and Cap Screw Torque Values....91
Additional Metric Cap Screw Torque Values....93
Unified Inch Bolt and Cap Screw Torque Values....95
Service Recommendations for 37° Flare and 30° Cone Seat Connectors....97
Service Recommendations for O-Ring Boss Fittings....99
Service Recommendations for Flared Connections—Straight or Tapered Threads....101
Service Recommendations for Flat Face O-Ring Seal Fittings....103
O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators....105
O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations....108
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations....110
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations....113
Service Recommendations for Metric Series Four Bolt Flange Fitting....116
Service Recommendations For Inch Series Four Bolt Flange Fittings....118
Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations....120
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings....122
Service Recommendations For O-Ring Boss Fittings With Shoulder....125
Metric 24° O-Ring Seal DIN 20078 Service Recommendations....128
Section 01: Tracks....132
Group 0130: Track System....132
Track Roller Remove and Install....137
Track Roller Disassemble and Assemble....141
Track Roller Pressure Test....144
Track Carrier Roller Remove and Install....147
Metal Face Seals Repair....150
Track Shoe Remove and Install....153
Track Chain Remove and Install....156
Track Chain Disassemble and Assemble....163
Track Chain Repair to Replace Broken Part....166
Sprocket Remove and Install....172
Front Idler Remove and Install....175
Front Idler Disassemble and Assemble....177
Track Adjuster and Recoil Spring Remove and Install....181
Track Adjuster and Recoil Spring Disassemble and Assemble....183
Track Adjuster Cylinder Disassemble and Assemble....190
Section 02: Axles and Suspension Systems....192
Group 0250: Axle Shaft, Bearings, and Reduction Gears....192
Travel Gear Case Remove and Install....197
Travel Gear Case Disassemble and Assemble....201
Group 0260: Hydraulic System....192
Travel Motor and Park Brake Remove and Install....216
Travel Motor and Park Brake Disassemble and Assemble....220
Park Brake Valve Disassemble and Assemble....231
Travel Motor and Park Brake Start-Up Procedure....234
Metal Face Seal Install....235
Section 04: Engine....241
Group 0400: Removal and Installation....241
Engine Remove and Install....253
Section 05: Engine Auxiliary System....264
Group 0510: Cooling Systems....264
Radiator Remove and Install....270
Hydraulic Oil Cooler Remove and Install....275
Charge Air Cooler Remove and Install....281
Fuel Cooler Remove and Install....285
Cooling Package Remove and Install....287
Fan, Fan Guard, and Fan Shroud Remove and Install....292
Coolant Recovery Tank Remove and Install....295
Group 0520: Intake System....264
Air Cleaner Remove and Install....298
Group 0530: External Exhaust Systems....264
Exhaust Tube Remove and Install....302
Catalyzed Soot Filter (CSF) Remove and Install....304
Muffler Filter Remove and Install....305
Muffler Filter Disassemble and Assemble....310
Group 0560: External Fuel Supply Systems....264
Fuel Tank Remove and Install....321
Primary Fuel Filter and Water Separator Remove and Install....326
Final Fuel Filter Remove and Install....328
Auxiliary Fuel Filter Remove and Install (If Equipped)....330
Section 07: Damper Drive (Flex Coupling)....332
Group 0752: Elements....332
Damper Drive (Flex Coupling) Remove and Install....335
Section 17: Frame or Supporting Structure....337
Group 1740: Frame Installation....337
Welding on Machine....340
Group 1749: Chassis Weights....337
Counterweight Remove and Install....345
Section 18: Operator's Station....348
Group 1800: Removal and Installation....348
Cab Remove and Install....359
Monitor Remove and Install....369
Group 1810: Operator Enclosure....348
Windshield Remove and Install....375
Windshield Disassemble and Assemble....377
Sliding Windows Remove and Install....387
Windowpanes Remove and Install....389
Windowpanes Dimensions....390
Group 1821: Seat and Seat Belt....348
Seat Remove and Install....400
Seat Belt Remove and Install....402
Mechanical Suspension Seat Disassemble and Assemble....407
Air Suspension Seat Disassemble and Assemble....409
Left and Right Console Covers Remove and Install....411
Group 1830: Heating and Air Conditioning....348
Refrigerant Cautions and Proper Handling....421
Flush and Purge Air Conditioning System....422
R134a Refrigerant Oil Information....426
R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure....428
R134a Compressor Oil Charge Check....430
R134a Compressor Oil Removal....432
Recover R134a Refrigerant....433
Evacuate R134a System....434
Charge R134a System....436
Air Conditioner Compressor Remove and Install....438
Condenser Remove and Install....440
Heater and Air Conditioner Remove and Install....442
Heater and Air Conditioner Blower Motor Remove and Install....448
Receiver-Dryer Remove and Install....453
Section 19: Sheet Metal....455
Group 1910: Hood Remove and Install....459
Hood Remove and Install....459
Section 33: Excavator....462
Group 3302: Buckets....462
Bucket Remove and Install....465
Adjust Bucket Pivot End Play....466
Bucket Pin-Up Data....468
Group 3340: Frames....462
Bucket Links Remove and Install....473
Arm Remove and Install....476
Boom Remove and Install....480
Inspect Pins, Bushings, and Bosses—Front Attachment....488
Cylinder Specifications....491
Bushings and Seal Remove and Install....492
Group 3360: Hydraulic System....462
Apply Vacuum to Hydraulic Oil Tank....496
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy....498
Pump 1 and 2 Remove and Install....500
Pump 1 and 2 Disassemble and Assemble....505
Pump 1 and 2 Inspection....523
Pump 1 and 2 Start-Up Procedure....528
Pump 1 and 2 Regulator Remove and Install....530
Pump 1 and 2 Regulator Disassemble and Assemble....532
Pilot Pump Remove and Install....535
Pilot Pump Disassemble and Assemble....538
Pilot Pressure Regulating Valve and Filter Remove and Install....540
Pilot Pressure Regulating Valve and Filter Disassemble and Assemble....542
Pilot Shutoff Solenoid Valve Remove and Install....544
Pilot Shutoff Solenoid Valve Disassemble and Assemble....547
Solenoid Valve Manifold Remove and Install....549
Solenoid Valve Remove and Install—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves....551
Solenoid Valve Disassemble and Assemble—Power Dig/Travel Speed (SG), Arm Regenerative (SC), and Dig Regenerative (SF) Valves....554
Pilot Valve (Left and Right) Remove and Install....556
Pilot Valve (Left and Right) Disassemble and Assemble....559
Travel Pilot Valve Remove and Install....568
Travel Pilot Valve Disassemble and Assemble....571
Pilot Signal Manifold Remove and Install....575
Pilot Signal Manifold Disassemble and Assemble....577
Control Valve Remove and Install....580
Control Valve Halves Disassemble and Assemble....585
Control Valve (5-Spool) Disassemble and Assemble....587
Control Valve (4-Spool) Disassemble and Assemble....599
Hydraulic Oil Tank Remove and Install....610
Hydraulic Oil Tank Disassemble and Assemble....615
Restriction Valve Remove and Install....619
Hydraulic Oil Cooler Bypass Valve Remove and Install....622
Boom Cylinder Remove and Install....624
Boom Cylinder Disassemble and Assemble (S.N. —230045)....629
Boom Cylinder Disassemble and Assemble (S.N. 230046— )....635
Arm Cylinder Remove and Install....641
Arm Cylinder Disassemble and Assemble (S.N. —230046)....645
Arm Cylinder Disassemble and Assemble (S.N. 230047— )....650
Bucket Cylinder Remove and Install....656
Bucket Cylinder Disassemble and Assemble (S.N. —230056)....660
Bucket Cylinder Disassemble and Assemble (S.N. 230057— )....665
Hydraulic Cylinder Bleed Procedure....671
Section 43: Swing or Pivoting System....672
Group 4350: Mechanical Drive Elements....672
Swing Gear Case Remove and Install....676
Swing Gear Case Disassemble and Assemble....679
Swing Gear Case Start-Up Procedure....689
Upperstructure Remove and Install....691
Swing Bearing Remove and Install....696
Swing Bearing Disassemble and Assemble....699
Swing Bearing Upper Seal Install....702
Swing Bearing Lower Seal Install....703
Group 4360: Hydraulic System....672
Center Joint Remove and Install....709
Center Joint Disassemble and Assemble....713
Center Joint Air Test....717
Swing Motor and Park Brake Remove and Install....718
Swing Motor and Park Brake Disassemble....721
Swing Motor and Park Brake Inspection....725
Swing Motor and Park Brake Assemble....730
Swing Motor and Park Brake Start-Up Procedure....734
Crossover Relief Valve and Make-Up Check Valve Remove and Install....735
Make-Up Check Valve Disassemble and Assemble....739
Swing Park Brake Check Valve and Orifice Remove and Install....741
Section 99: Dealer Fabricated Tools....744
Group 9900: Dealer Fabricated Tools....744
DF1063 Lift Bracket....747
ST4920 Track Recoil Spring Disassembly and Assembly Tool....749
DFT1087 Track Recoil Spring Disassembly and Assembly Guard Tool....754
DFT1110 Spacer....755
DFT1130 Adapter....756
DFT1036A Travel Gear Case Nut Wrench....757
DFT1109 Holding Bar....758
Center Joint (Rotary Manifold) Lifting Tool....759
DFT1119 Pump Support....761
DFT1220 Swing Gear Case Nut Spanner Wrench....762
DFT1342 Exhaust Differential Pressure Sensor Alignment Tool....764
Hitachi Zaxis160LC-5N Excavator Repair Technical Manual (TM12369)
