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Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop Manual (W482E-02) – PDF Download
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- Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop Manual
- Part No:W482E-02
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Description
Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop Manual (W482E-02)
FILE DETAILS:
Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop Manual (W482E-02)
- Manual Language:English
- Downloadable:Yes
- Pages: 603
- Size: 43.3 MB
- Format:PDF
HITACHI LX100-2 LX120-2 LX150-2 WHEEL LOADER WORKSHOP MANUAL (W482E-02) – PDF DOWNLOAD:
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DESCRIPTION:
Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop Manual (W482E-02)
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools. service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
- Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TABLE OF CONTENTS:
Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop Manual (W482E-02)
COVER................................................................................................................. 1 INTRODUCTION...................................................................................................... 2 CONTENTS ........................................................................................................ 4 SECTION 00 GENERAL INFORMATION................................................................................ 8 SAGROUP 0001 FETY INFORMATION ........................................................................... 10 HANDLE FLUIDS SAFELY -AVOID FIRES..................................................................... 10 PREVENT BATTERY EXPLOSIONS............................................................................ 10 PREPARE FOR EMERGENCIES............................................................................... 10 PREVENT ACID BURNS.................................................................................... 11 HANDLE CHEMICAL PRODUCTS SAFELY....................................................................... 12 AVOID HIGH-PRESSURE FLUIDS............................................................................ 12 PARK MACHINE SAFELY................................................................................... 13 SUPPORT MACHINE PROPERLY.............................................................................. 13 WEAR PROTECTIVE CLOTHING.............................................................................. 13 WORK IN CLEAN AREA.................................................................................... 14 SERVICE MACHINES SAFELY............................................................................... 14 WORK IN VENTILATED AREA............................................................................... 14 ILLUMINATE WORK AREA SAFELY........................................................................... 14 REPLACE SAFETY SIGNS.................................................................................. 15 USE PROPER LIFTING EQUIPMENT.......................................................................... 15 REMOVE PAINT BEFORE WELDING OR HEATING................................................................ 15 AVOID HEATING NEAR PRESSURIZED FLUID LINES............................................................ 16 KEEP ROPS INSTALLED PROPERLY.......................................................................... 16 SERVICE TIRES SAFELY.................................................................................. 17 AVOID HARMFUL ASBESTOS DUST........................................................................... 17 PRACTICE SAFE MAINTENANCE............................................................................. 18 USE PROPER TOOLS...................................................................................... 18 DISPOSE OF WASTE PROPERLY ............................................................................ 19 LIVE WITH SAFETY...................................................................................... 19 GROUP 02 GENERAL SPECIFICATIONS ......................................................................... 20 LX100 SPECIFICATIONS.................................................................................. 21 LX100 DRAIN AND REFILL CAPACITIES..................................................................... 24 LX100 SPECIFICATIONS.................................................................................. 25 LX100 DRAIN AND REFILL CAPACITIES..................................................................... 28 LX100 SPECIFICATIONS.................................................................................. 29 LX100 DRAIN AND REFILL CAPACITIES..................................................................... 32 LX120 SPECIFICATIONS.................................................................................. 33 LX120 DRAIN AND REFILL CAPACITIES..................................................................... 36 LX150 SPECIFICATIONS.................................................................................. 37 LX150 DRAIN AND REFILL CAPACMIES...................................................................... 40 GROUP 003 TORQUE VALUES ................................................................................ 42 HARDWARE TORQUE SPECIFICATIONS........................................................................ 42 KEEP ROPS INSTALLED PROPERLY.......................................................................... 42 METRIC BOLT AND CAP SCREW TORQUE VALUES............................................................... 43 ADDITIONAL METRIC CAP SCREW TORQUE VALUES............................................................. 45 UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES......................................................... 46 CHECK OIL LINES AND FITTINGS.......................................................................... 47 SERVICE RECOMMENDATIONS FOR O-RING BOSS FITTINGS...................................................... 48 SERVICE RECOMMENDATIONS FOR FLAT FACE O-RING SEAL FITTINGS............................................ 49 SERVICE RECOMMENDATIONS FOR METRIC SERIES FOUR BOLT FLANGE FITTING.................................... 50 SERVICE RECOMMENDATIONS FOR INCH SERIES FOUR BOLT FLANGE FITTINGS..................................... 51 GROUP 0004 FUELS AND LUBRICANTS .......................................................................... 54 FUEL SPECIFICATIONS................................................................................... 54 STORING FUEL.......................................................................................... 54 DO NOT USE GALVANIZED CONTAINERS...................................................................... 55 FUEL TANK............................................................................................. 55 ENGINE OIL............................................................................................ 56 HYDRAULIC SYSTEM OIL AND DIFFERENTIAL OIL............................................................. 57 TRANSMISSION OIL...................................................................................... 58 GREASE................................................................................................ 59 ALTERNATIVE AND SYNTHETIC LUBRICANTS.................................................................. 59 LUBRICANT STORAGE..................................................................................... 60 MIXING OF LUBRICANTS.................................................................................. 60 ENGINE COOLANT........................................................................................ 60 GROUP 0005 INSPECTION PROCEDURES.......................................................................... 62 PLANNED INSPECTION PROGRAM 1 (PIP 1).................................................................. 62 PLANNED INSPECTION PROGRAM II (PIP II)................................................................ 62 USING THE CHECKLISTS.................................................................................. 63 DELIVERY SERVICE...................................................................................... 63 LX100,LX120 AND LX150 LOADER.......................................................................... 64 LX100, LX120,AND LX150 LOADER......................................................................... 67 SECTION 01 WHEELS CONTENTS.................................................................................... 70 GROUP 0100 POWERED WHEELS AND FASTENINGS.................................................................. 72 OTHER MATERIAL........................................................................................ 72 SPECIFICATIONS........................................................................................ 72 REMOVE TIRE........................................................................................... 73 INSTALL TIRE.......................................................................................... 74 LX100................................................................................................. 75 LX120................................................................................................. 76 LX150................................................................................................. 76 SECTION 02 AXLES AND SUSPENSION SYSTEMS....................................................................... 78 GROUP 0200 REMOVAL AND INSTALLATION ...................................................................... 80 JOHN DEERE 1200 AND 1400 SERIES AXLES-USE CTM43....................................................... 80 OTHER MATERIAL........................................................................................ 80 SPECIFICATIONS........................................................................................ 81 REMOVE AND INSTALL FRONT AXLE AND DIFFERENTIAL........................................................ 82 REMOVE REAR AXLE AND DIFFERENTIAL..................................................................... 84 INSTALL REAR AXLE AND DIFFERENTIAL ASSEMBLY........................................................... 86 GROUP 0225 AXLE SHAFTS, BEARINGS AND U-JOINTS............................................................. 88 OTHER MATERIAL........................................................................................ 88 SPECIFICATIONS........................................................................................ 88 DISASSEMBLE, INSPECT, AND ASSEMBLE SUPPORT BEARING AND DRIVE SHAFT.................................... 89 REMOVE AND ISNTALL REAR DIFFERENTIAL DRIVE LINE....................................................... 90 GROUP 0260 HYDRAULIC SYSTEM............................................................................... 92 SPECIFICATIONS........................................................................................ 92 REMOVE AND INSTALL DIFFERENTIAL LOCK SOLENOID VALVE................................................... 92 SECTION 03 TRANSMISSION CONTENTS.............................................................................. 94 GROUP 0300 REMOVAL AND INSTALLATION ...................................................................... 96 ESSENTIAL TOOLS....................................................................................... 96 SERVICE EQUIPMENT AND TOOLS........................................................................... 96 SPECIFICATIONS........................................................................................ 97 REMOVE AND INSTALL TRANSMISSION....................................................................... 98 GROUP 0315 CONTROL LINKAGE................................................................................104 OTHER MATERIAL .......................................................................................104 SPECIFICATIONS........................................................................................104 REMOVE AND INSTALL TRANSMISSION SHIFT LEVER...........................................................105 TROUP 0325 INPUT DRIVE SHAFTS AND U-JOINTS................................................................106 SPECIFICATIONS........................................................................................106 REMOVE, DISASSEMBLE, ASSEMBLE AND INSTALL, TRANSMISSION DRIVE SHAFT...................................106 GROUT 0350 GEAR, SHAFTS, BEARINGS AND POWER SHIFT CLUTCH..................................................108 ESSENTIAL TOOLS.......................................................................................108 SERVICE EQUIPMENT AND TOOLS...........................................................................109 OTHER MATERIAL........................................................................................109 SPECIFICATIONS........................................................................................110 INSTALL REPAIR STAND..................................................................................111 REMOVE AND INSTALL TORQUE CONVERTER...................................................................113 REMOVE CLUTCH PACKS...................................................................................115 REMOVE AND INSTALL FORWARD AND FIRST DRIVE GEARS......................................................121 REMOVE AND ISNTALL REVERSE AND SECOND DRIVE GEARS.....................................................122 REMOVE AND INSTALL THIRD AND FOURTH DRIVE GEARS.......................................................123 DISSEMBLE AND ASSEMBLE CLUTCH PACKS...................................................................124 CLUTCH PACKS..........................................................................................133 REMOVE AND INSTALL FOURTH GEAR IDLER GEAR-LX120,LX150.................................................133 FOURTH GEAR IDLER GEAR SHAFT ORIFICE SIZES............................................................135 INSTALL FOURTH GEAR IDLER GEAR-LX100..................................................................136 INSTALL THIRD AND FOURTH GEAR CLUTCH PACK, ADJUST END PLAY............................................137 INSTALL SECOND AND REVERSE, FIRST AND FORWARD GEAR CLUTCH PACKS.......................................142 REMOVE AND INSTALL OUTPUT FLANGE......................................................................149 REMOVE AND INSTALL OUTPUT SHAFT AND SEALS.............................................................151 REMOVE AND INSTALL OUTPUT GEAR AND OIL SHIELDS........................................................158 REMOVE AND INSTALL SPEED CONTROL MAGNETIC PICKUP......................................................160 GROUP 0360 HYDRAULIC SYSTEM...............................................................................162 ESSENTIAL TOOLS.......................................................................................162 SERVICE EQUIPMENT AND TOOLS...........................................................................162 OTHER MATERIAL........................................................................................163 SPECIFICATIONS........................................................................................163 REMOVE OIL SUPPLY FLANGE AND OIL PUMP.................................................................164 DISASSEMBLE OIL SUPPLY FLANGE.........................................................................166 ASSEMBLE OIL SUPPLY FLANGE............................................................................168 INPUT DRIVE SHAFT ORIFICE SIZES.......................................................................169 DISASSEMBLE OIL PUMP..................................................................................170 ASSEMBLE OIL PUNP.....................................................................................171 INSTALL OIL PUMP ON OIL SUPPLY FLANGE.................................................................174 INTALL OIL SUPPLY FLANGE AND OIL PUMP ................................................................176 REMOVE AND INSTALL CONVERTER MINMUM PRESSURE REGULATOR................................................180 REMOVE AND INSTALL TRANSMISSION OIL FILTER............................................................181 REMOVE AND INTALL SUCTION OIL STRAINER................................................................181 REMOVE TRANSMISSION CONTROL VALVE.....................................................................182 REPAIR TRANSMISSION CONTROL VALVE LX100 (SN-542218),LX120 (XN-548398),LX150(SN-548302)................184 CONTROL VALVE W/6TH SOLENOID -LX100 (SN 548219-),LX120 (SN 548398-), LX150 (XN 548303-)...............187 INSTALL TRANSMISSION CONTROL VALVE....................................................................190 CROSS SECTION OF THERMAL BYPASS VALVE.................................................................192 DISASSEMBLE AND ASSEMBLE THERMAL BYPASS VALVE.........................................................193 SECTION 04 ENGINE CONTENTS....................................................................................194 TROUP 0400 REMOVAL AND INSTALLATION.......................................................................196 JOHN DEER 6059 ENGINE PEPAIR-USE CTM8.................................................................196 JOHN DEER 6068 ENGINE PEPAIR-USE CTM8.................................................................196 JOHN DEER 6076 ENGINE PEPAIR-USE CTM8.................................................................196 JOHN DEER 6081 ENGINE PEPAIR-USE CTM8.................................................................196 SPECIAL OR ESSENTIAL TOOLS............................................................................197 SERVICE EQUIPMENT AND TOOLS...........................................................................198 OTHER MATERIAL........................................................................................198 SPECIFICATIONS........................................................................................199 DISCONNECT TURBOCHARGER OIL INLET LINE................................................................201 REMOVE AND INSTALL ENGINE.............................................................................202 REMOVE AND INSTALL OIL PAN............................................................................204 REMOVE FUEL INJECTION PUMP-LX100, LX120...............................................................205 INSTALL FUEL INJECTION PUMP-LX100,LX120...............................................................206 REMOVE FUEL INJECTION PUMP-LX150......................................................................208 INSTALL FUEL INJECTION PUMP-LX150.....................................................................210 REMOVE AND INSTALL FUEL FILTER CHECK VALVE-LX150......................................................213 BLEED FUEL SYSTEM-LX100,LX120.........................................................................214 BLEED FUEL SYSTEM-LX150...............................................................................214 REMOVE AND INSTALL TURBOCHARGER.......................................................................215 REMOVE AND INSTALL WATER PUMP-LX100,LX120.............................................................216 REMOVE AND INSTALL WATER PUMP-LX150...................................................................217 REMOVE AND INSTALL FAN DRIVE -LX150...................................................................218 SECTION 05 ENGINE AUXILIARY SYSTEMS...........................................................................220 GROUP 0505 COLD WEATHER STARTING AIDS.....................................................................222 SPECIFICATIONS........................................................................................222 REMOVE AND INSTALL STARTING AID SOLENOID AND NOZZLE...................................................222 REMOVE AND INSTALL ENGINE COOLANT HEATER..............................................................223 SPECIFICATIONS........................................................................................224 OTHER MATERIAL........................................................................................224 REMOVE AND INSTALL COMPRESSOR BELT (IF EQUIPPED) AND FAN BELTS-LX100,LX120,LX150 (SN-557738)..........225 REMOVE AND INSTALL SERPENTINE BELT....................................................................226 REMOVE AND INSTALL FAN................................................................................227 REMOVE AND INSTALL RADIATOR...........................................................................228 REMOVE AND INSTALL OIL COOLER.........................................................................230 REMOVE AND INSTALL COOLANT LEVEL SENSOR...............................................................232 TROUP 0515 SPEED CONTROLS.................................................................................234 OTHER MATER1AL........................................................................................234 SPECIFICATIONS........................................................................................234 REMOVE AND INSTALL SPEED CONTROL LINKAGE..............................................................235 SPEED CONTROL LINKAGE ADJUSTMENT......................................................................237 FUEL SHUT-OFF SOLENOID ADJUSTMENT-LX150...............................................................238 GROUP 0520 INTAKE SYSTEM..................................................................................240 SPECIFICATIONS........................................................................................240 REMOVE AND INSTALL AIR FILTER ELEMENTS-LX100,LX120....................................................240 TIGHTEN AIR CLEANER HOSE CLAMPS.......................................................................241 REMOVE AND INSTALL AIR FILTER ELEMENTS-LX150..........................................................241 TEST AIR INTAKE SYSTEM FOR LEAKS......................................................................242 GROUP 0560 EXTERNAL FUEL SUPPLY SYSTEM....................................................................244 OTHER MATERIAL........................................................................................244 SPECIFICATIONS........................................................................................245 REMOVE AND INSTALL FUEL TANK..........................................................................247 REMOVE AND INSTALL PRIMARY FILTER (WATER SEPARATOR)...................................................248 DISASSEMBLE AND ASSEMBLE PRIMARY FILTER (WATER SEPARATOR).............................................249 BLEED FUEL SYSTEM-LX100,LX120.........................................................................250 BLEED FUEL SYSTEM-LX150...............................................................................250 REMOVE AND INSTALL FUEL SHUT-OFF SOLENOID-LX150.......................................................251 FUEL SHUT-OFF SOLENOID ADJUSTMENT-LX150...............................................................252 SECTION 07 DAMPENER DRIVE.....................................................................................254 GROUP 0752 ELEMENTS.......................................................................................256 SPECIFICATIONS........................................................................................256 REMOVE AND INSTALL DRAMPENER..........................................................................256 SECTOIN 09 STEERING SYSTEM....................................................................................258 GROUP 0930 SECONDARY STEERING.............................................................................260 SPECIFICATIONS........................................................................................260 REMOVE AND INSTALL SECONDARY STEERING PUMP, MOTOR AND RELAY (IF EQUIPPED).............................260 REMOVE AND INSTALL SECONDARY STEERING INLET MEANIFOLD (IF EQUIPPED)...................................261 IDSASSEMBLE AND ASSEMBLE SECONDARY STEERING INLET MANIFOLD (IF EQUIPPED)..............................262 GROUP 0960 HYDRAULIC SYSTEM...............................................................................264 SERVICE EQUIPMENT AND TOOLS...........................................................................264 OTHER MATERIAL........................................................................................264 SPECIFICATIONS........................................................................................265 REMOVE AND INSTALL STEERING VALVE.....................................................................267 DISASSEMBLE STEERING VALVE............................................................................269 CROSS SECTION OF STEERING VALVE.......................................................................272 ASSEMBLE STEERING VALVE...............................................................................273 REMOVE AND INSTALL STEERING COLUMN....................................................................275 REMOVE AND INTALL STEERING CYLINDERS..................................................................277 DISASSEMBLE STEERING CYLINDER.........................................................................278 CROSS SECTION OF STEERING CYLINDER....................................................................282 ASSEMBLE STEERING CYLINDER............................................................................282 REMOVE AND INSTALL STEERING CYLINDER BUSHINGS.........................................................288 REMOVE AND INSTALL PRIORITY VALVE.....................................................................289 CROSS SECTION OF PRIORITY VALVE.......................................................................290 DISASSEMBLE AND ASSEMBLE PRIORITY VALVE...............................................................291 SECTION 10 SERVICE BRAKES.....................................................................................292 TROUP 1011 ACTIVE ELEMENTS................................................................................294 ESSENTIAL TOOLS.......................................................................................294 INSPECTING SERVICE BRAKE PADS.........................................................................294 REMOVE AND ISTALL BRAKE ASSEMBLY'.....................................................................296 GROUP 1060 HYDRAULIC SYSTEM...............................................................................300 SERVICE TOOLS AND EQUIPMENT...........................................................................300 SPECIFICATIONS........................................................................................300 REMOVE AND INSTALL BRAKE VALVE........................................................................301 DISASSEMBLE AND ASSEMBLE BRAKE VALVE..................................................................302 REMOVE AND INSTALL BRAKE PUMP.........................................................................304 DISASSEMBLE BRAKE PUMP................................................................................305 ASSEMBLE BRAKE PUMP...................................................................................310 DISASSEMBLE AND ASSEMBLE BRAKE PUMP PRESSURE COMPENSATOR..............................................315 REMOVE AND INSTALL BRAKE ACCUMULATOR..................................................................316 CHARGE BRAKE ACCUMULATOR..............................................................................318 HYDRAULIC BRAKE BLEEDING PROCEDURE....................................................................320 REMOVE AND INSTALL PRESSURE REDUCING VALVE MAINIFOLD..................................................322 SECTION 11 PARK BRAKE CONTENTS................................................................................324 GROUP 1111 SPECIFICATIONS ................................................................................326 SPECIFICATIONS........................................................................................326 REMOVE AND INSTALL PARK BRAKE PADS....................................................................327 DISASSEMBLE AND ASSEMBLE PARK BRAKE ................................................................328 ADJUST PARK BRAKE.....................................................................................329 GROUP 1160 HYDRAULIC SYSTEM...............................................................................332 SPECIFICATIONS........................................................................................332 REMOVE AND INSTALL PARK BRAKE RELEASE SOLENOID VALVE..................................................333 REMOVE AND INSTALL PARK BRAKE PRESSURE SWITCH.........................................................334 SECTION 15 EQUIPMENT ATTACHING CONTENTS.......................................................................336 GROUP 1511 DRAWBAR........................................................................................338 SPECIFICATIONS........................................................................................338 INSTALL COUNTERWEIGHT/DRAWBAR.........................................................................338 SECTION 16 ELECTRICAL SYSTEMS.................................................................................340 GROUP 1671 BATTERIES, SUPPORT AND CABLES..................................................................342 SPECIFICATIONS........................................................................................342 SERVICE BATTERIES CAREFULLY...........................................................................343 TEST BATTERIES USING COOLANT AND BATTERY TESTER.......................................................344 TEST BATTERIES USING HIGH RATE DISCHARGE TEST.........................................................345 CHARGE BATTERY .......................................................................................346 REMOVE AND INSTALL BATTERIES..........................................................................347 REMOVE AND INSTALL BATTERY DISCONNECT SWITCH..........................................................349 MOTROLA 8EM AND 8MR ALTERNATOR REPAIR-USE CTM77.......................................................350 SPECIFICATIONS........................................................................................350 REMOVE AND INSTALL ALTERNATOR.........................................................................351 GROUP 1673 LIGHTING SYSTEM................................................................................352 SPECIFICATIONS........................................................................................352 REPLACE HALOGEN BULBS.................................................................................352 REMOVE AND INSTALL LIGHTS.............................................................................354 GROUP 1674 WIRING HARNESS AND SWITCHES....................................................................356 SPECIAL OR ESSENTIAL TOOLS............................................................................356 OTHER MATERIAL........................................................................................356 SPECIFICATIONS........................................................................................357 CLUTCH CUT-OFF SWITCH ADJUSTMENT......................................................................357 RETURN-TO-DIG ADJUSTMENT..............................................................................358 BOOM HEIGHT KICKOUT ADJUSTMENT........................................................................359 REMOVE AND INSTALL BRAKE LIGHT SWITCH.................................................................360 REMOVE AND INSTALL BRAKE LOW PRESSURE SWITCH..........................................................361 REMOVE AND INSTALL HYDRAULIC OIL FILTER RESTRICTION SWITCH............................................362 REMOVE AND INSTALL ENGINE COOLANT LEVEL SWITCH........................................................363 REMOVE AND INSTALL ENGINE OIL PRESSURE SWITCH.........................................................364 REMOVE AND INSTALL AIR FIL TER RESTRICTION SWITCH.....................................................365 REMOVE AND INSTALL TRANSMISSION OIL PRESSURE SWITCH...................................................366 REPLACE DEUTSCHTM CONNECTORS..........................................................................367 INSTALL DEUTSCHTM CONTACT.............................................................................368 REPLACE WEATHER PACK CONNECTOR........................................................................369 INSTALL WEATHER PACK TM CONTACT.......................................................................370 REMOVE CONNECTOR BODY FROM BLADE TERMINALS............................................................371 REMOVE BLADE TERMINALS FROM FUSE BLOCK................................................................371 STARTING MOTOR REPAIR-USE CTM77.......................................................................372 SPECIAL OR ESSENTIAL TOOLS............................................................................372 SPECIFICATIONS........................................................................................372 REMOVE AND INSTALL STARTING MOTOR.....................................................................373 SECTION 17 FRAME OR SUPPORTING STRUCTURE CONTENTS.............................................................374 GROUP 1740 FRAME INSTALLATION.............................................................................376 SPECIFICATIONS........................................................................................376 WELDING REPAIR OF MAJOR STRUCTURE.....................................................................377 SEPARATE ENGINE AND LOADER FRAME......................................................................378 REMOVE AND INSTALL UPPER PIVOT BEARING AND SEALS......................................................383 REMOVE AND INSTALL LOWER PIVOT BEARING AND SEALS......................................................385 GROUP 1746 FRAME BOTTOM GUARDS............................................................................388 SPECIFICATIONS........................................................................................388 REMOVE AND INSTALL GUARDS.............................................................................389 SPECIFICATIONS........................................................................................390 REMOVE AND INSTALL COUNTERWEIGHTS.....................................................................391 SECTION 18 OPERATOR'S STATION.................................................................................392 GROUP 1800 REMOVAL AND INSTALLATION.......................................................................394 SPECIAL OR ESSENTIAL TOOLS............................................................................394 SPECIFICATIONS........................................................................................394 REMOVE AND INSTALL CAB OR CANOPY......................................................................395 GROUP 1810 OPERATOR ENCLOSURE.............................................................................400 SPECIAL OR ESSENTIAL TOOLS............................................................................400 OTHER MATERIAL........................................................................................400 SPECIFICATIONS........................................................................................401 REMOVE AND INSTALL WINDOWPANE AND MOLDING.............................................................402 REMOVE AND INSTALL WINDSHIELD WASHER..................................................................403 REMOVE, DISASSEMBLE, ASSEMBLE AND INSTALL FRONT WINDSHIELD WIPER......................................404 ADJUST FRONT WINDSHIELD WIPER.........................................................................405 REMOVE, DISASSEMBLE, ASSEMBLE AND INSTALL REAR WINDSHIELD WIPER.......................................406 REMOVE AND INSTALL DEFROSTER FAN-(SN-545144)..........................................................407 REMOVE AND INSTALL DEFROSTER FAN - (SN 545145-).......................................................408 REMOVE AND ISNTALL DOOR HANDLE AND DOOR/WINDOW RELEASE................................................409 GROUP 1821 SEAT AND SEAT BELT.............................................................................412 SPECIFICATIONS........................................................................................412 DISASSEMBLE AND ASSEMBLE SEAT.........................................................................413 DISASSEMBLE AND ASSEMBLE SEAT BELT....................................................................419 SPECIAL OR ESSENTIAL TOOLS............................................................................420 SERVICE EQUIPMENT AND TOOLS ..........................................................................422 OTHER MATERIAL........................................................................................422 SERVICE PARTS KITS FOR COMPRESSOR.....................................................................423 SPECIFICATIONS........................................................................................424 PROPER REFRIGERANT HANDLING...........................................................................425 R12 AND R134A REFRIGERANT CAUTIONS....................................................................425 R12 COMPONENT OIL CHARGE..............................................................................426 R12 REFRIGERANT EVACUATION AND CHARGING STATION INSTALLATION PROCEDURE................................427 RECOVER R12 SYSTEM....................................................................................428 EVCUATE R12 SYSTEM....................................................................................429 CHARGE R12 SYSTEM.....................................................................................431 R134A COMPRESSOR OIL INFORMATION......................................................................432 R134A COMPRESSOR OIL CHARGE CHECK.....................................................................432 R134A COMPRESSOR OIL REMOVAL..........................................................................433 R134A COMPONENT OIL CHARGE............................................................................434 R134A REFRIGERANT RECOVERY/RECYCLING AND CHARGING STATION INSTALLATION PROCEDURES.....................435 R134A REFRIGERANT RECOVERY............................................................................436 EVACUATE R134A SYSTEM.................................................................................437 CHARGE R134A SYSTEM...................................................................................439 LEAK TESTING..........................................................................................440 REMOVE AND INSTALL COMPRESSOR AND HIGH PRESSURE SWITCH................................................441 VOLUMETRIC EFFICIENCY TEST-R12........................................................................442 SHAFT SEAL LEAK TEST..................................................................................444 DISASSEMBLE AND INSPECT COMPRESSOR....................................................................445 CLUTCH PULLEY, BEARING AND HUB INSPECTION.............................................................449 REPLACE CLUTCH PULLEY BEARING.........................................................................450 REPLACE SHAFT SEAL SEAT...............................................................................451 ASSEMBLE COMPRESSOR...................................................................................452 REMOVE AND INSTALL CONDENSER..........................................................................455 REMOVE AND INSTALL EVAPORATOR AND EXPANSION VALVE.....................................................457 REMOVE AND INSTALL RECEIVER/DRYER AND LOW PRESSURE SWITCH.............................................459 REMOVE AND INSTALL CONDENSER FAN MOTORS...............................................................461 FREEZE CONTROL TEMPERATURE CYCLING SWITCH BENCH TEST..................................................462 DISASSEMBLE AND ASSEMBLE BLOWER MOTOR.................................................................463 REMOVE AND INSTALL HEATER CORE........................................................................464 REMOVE AND INSTALL CAB HEATER HOSES AND CONTROLS......................................................465 SECTION 31 LOADER CONTENTS....................................................................................466 GROUP 3102 BUCKET.........................................................................................468 SPECIFICATIONS........................................................................................468 REMOVE AND INSTALL BUCKET TOOTH SHANKS AND TIPS ......................................................469 REMOVE AND INSTALL BUCKET.............................................................................470 REPLACE WELDED BUCKET CUTTING EDGES .................................................................471 REMOVE AND INSTALL CUTTING EDGES (FOR BUCKET WITH WEAR PLATES) .......................................471 REPAIR CRACKED CUTTING EDGE...........................................................................472 GROUP 3140 FRAMES.........................................................................................474 SERVICE EQUIPMENT AND TOOLS...........................................................................474 OTHER MATERIAL........................................................................................474 SPECIFICATIONS........................................................................................475 REMOVE AND INSTALL BUCKET TILT LINKAGE-LX100,LX120 AND LX150..........................................476 REMOVE AND INSTALL BUCKET LINKAGE SEALS AND BUSHINGS-LX100,LX120 AND LX150............................477 DISASSEMBLE AND ASSEMBLE BUCKET TILT LINKAGE-LX100....................................................477 DISASSEMBLE ASSEMBLE TOOL CARRIER-LX100...............................................................479 REMOVE AND INSTALL BOOM BUSHINGS AND SHIMS-LX100,LX120AND LX150.......................................480 REMOVE AND INSTALL BOOM BUSHINGS AND SHIMS-LX100......................................................482 GROUP 3160 HYDRAULIC SYSTEM...............................................................................484 ESSENTIAL TOOLS.......................................................................................484 SERVICE EQUIPMENT AND TOOLS...........................................................................484 OTHER MATERIAL........................................................................................485 SPECIFICATIONS........................................................................................486 REMOVE AND INSTALL MAIN HYDRAULIC PUMP................................................................490 DISASSEMBLE, INSPECT AND ASSEMBLE MAIN HYDRAULIC PUMP.................................................490 REMOVE AND INSTALL LOADER CONTROL VALVE...............................................................494 DISASSEMBLE AND ASSEMBLE LOADER CONTROL VALVE.........................................................495 DISASSEMBLE AND ASSEMBLE BOOM VALVE (ALL UNITS) AND BUCKET SECTION (LX100)............................496 DISASSEMBLE AND ASSEMBLE AUXILIARY VALVE (ALL UNITS ) AND BUCKET SECTION (LX100,LX120K, AND LX150)....501 DISASSEMBLE AND ASSEMBLE SYSTEM RELIEF VALVE..........................................................504 DISASSEMBLE AND ASSEMBLE ANTI-CAVITATION VALVE........................................................505 DISASSEMBLE AND ASSEMBLE SCREW ADJUSTABLE CIRCUIT RELIEF VALVE........................................507 SERVICE BUCKET AND BOOM SECTION PILOT ORIFICE CHECK VALVE.............................................508 REMOVE AND INSTALL BOOM CYLINDER......................................................................509 REMOVE AND INSTALL BUCKET CYLINDER....................................................................511 DISASSEMBLE BOOM OR BUCKET CYLINDER...................................................................512 ASSEMBLE BOOM OR BUCKET CYLINDER......................................................................515 REMOVE AND INSTALL BUCKET OR BOOM CYLINDER BUSHINGS AND SEALS.........................................520 REMOVE AND INSTALL HYDRAULIC AESRVOIR.................................................................521 HYDRAULIC OIL CLEAN-UP PROCEDURE USING PORTABLE FIL TER CADDY.........................................523 REMOVE AND INSTALL PILOT CONTROL VALVES (TWO LEVER CONTROLLER)........................................524 DISASSEMBLE AND ASSEMBLE PILOT CONTROL VALVE (TWO-LEVER CONTROLLER)...................................527 DISASSEMBLE AND ASSEMBLE PILOT CONTROL VALVE (TWO LEVER CONTROLLER)...................................528 REMOVE AND INSTALL PILOT CONTROLLER (SINGLE LEVER CONTROLLER)-LX100,LX120,LX150 (XN-563542)...........532 DISASSEMBLE SINGLE LEVER PILOT CONTROLLER-LX100,LX120,LX150 (SN-563542)...............................534 ASSEMBLE SINGLE LEVER CONTROLLER-LX100,LX120 (XN-563542)..............................................540 REMOVE AND INSTALL PILOT CONTROLLER VALVE (SWINGLE LEVER CONTROLLER)-LX150 (XN 563543-)...............546 PILOT CONTROLLER VALVE (SWINGLE LEVER CONTROLLER), CROSS SECTION-LX150 (SN 563543-)...................547 DISASSEMBLE AND ASSEMBLE VALVE (SINGLE LEVER CONTROLLER)-LX150 (XN 563543-)...........................548 REPLACING QUICKSHIFT SWITCH IN CONTROLLER LEVER-LX150 (XN 563543-)....................................550 REPLACE PILOT CONTROL LEVER BOOT (JOYSTICK)-LX150 (XN 536543-)........................................554 REPLACE PILOT CONTROL LEVER BOOT (SINGLE LEVER)-LX150 (XN 563543-)....................................555 REPLACE UNIVERSAL JOINT -LX150 (XN 563543-)...........................................................555 REPLACE SEALS ON SPOOL RETAINERS AND INSPECT SPOOL ASSEMBLY-LX150 (XN 563543-)........................558 PILOT CONTROL VALVE PRESSURE TEST (BENCH)-LX150 (SN 563543-)..........................................562 REMOVE AND INSTALL PRESSURE REDUCING VALVE............................................................565 REMOVE AND INSTALL BOOM BOWN SOLENOID VALVE...........................................................567 DISASSEMBLE AND ASSEMBLE PIN DISCONNECT CYLINDER-LX100................................................569 DISASSEMBLE AND ASSEMBLE PIN DISCONNECT SOLENOID VALVE-LX100..........................................570 REMOVE AND INSTALL RIDE CONTROL (IFEQUIPPED)..........................................................571 DISASSEMBLE AND ASSEMBLE RIDE CONTROL VALVE...........................................................573 DISASSEMBLE AND ASSEMBLE RIDE CONTROL VALVE SOLENOID..................................................575 DISASSEMBLE AND ASSEMBLE RIDE CONTROL ACCUMULATOR.....................................................575 CHARGE RIDE CONTROL ACCUMULATOR.......................................................................580 SECTION 99 DEALER FABRICATED TOOLS CONTENTS...................................................................582 GROUP 9900 DEALER FABRICATED TOOLS........................................................................584 DF1055 AND JD38002 YOKE HOLDING TOOL..................................................................584 DF1056 INPUT PINION SHAFT ADJUSTING TOOL..............................................................585 DF1057 AXLE ADJUSTING TOOL............................................................................586 DF1025 OIL SUPPLY FLANGE BACK-OFF BRACKETS............................................................587 DF1026 PRE-LOAD CLUTCH PACK COMPRESSION RING ASSEMBLY JIG.............................................588 DF1027 STAND MOUNTING BRACKET.........................................................................589 JDG588 SHAFT ALIGNMENT TOOL...........................................................................590 DF1044 AIR DEFLECTOR BUSHING..........................................................................591 DFT1118 SPANNER WRENCH................................................................................592 INDEX.............................................................................................................594 SERVICE MANUAL REVISION REQUES FORM...............................................................................602
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