Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop+Technical+Operator’s+Parts Catalog Manual – PDF Download

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Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop+Technical+Operator’s+Parts Catalog Manual

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Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop+Technical+Operator’s+Parts Catalog Manual

This Manual Includes:

• Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop Manual
• Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Technical Manual
• Hitachi LX100-2 LX120-2 Lx150-2 Wheel Loader Operator’s Manual
• Hitachi LX150-2 Wheel Loader Parts Catalog Manual

HITACHI LX100-2 LX120-2 LX150-2 WHEEL LOADER WORKSHOP+TECHNICAL+OPERATOR’S+PARTS CATALOG MANUAL – PDF DOWNLOAD:

SCREENSHOTS OF THE MANUAL:

DESCRIPTION:

Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop+Technical+Operator’s+Parts Catalog Manual

• This manual ls written for an experienced technician. Essential tools required in perionning certain service work are identified in this manual and are reconunended 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 concise guides for specific machines.
• They are on-thc-iob 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.
• Read this manual Carelully to learn how to operate and service your machine ccrreclly. Failure to do so could resUt in personal injury or machine damage.
• This manual should be considered a permanent part of your machine and slluuid remain with the machine when you sell ll. Right-hand and loll-hand sides are determined by losing it the direction at forward travel.
• Write product Identification numbers in the Ma chine Numbers section. Amuralety record all the numbers to help in tracing the mach‘ne should it be stolen.
• Your dealer also needs these numbers when you order parts. ll this manual is kept on the machine. also file the idonliicalion numbers in a secure.

TABLE OF CONTENTS:

Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Workshop Manual

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

Hitachi LX100-2 LX120-2 Lx150-2 Wheel Loader Operator’s Manual

COVER…………………………………….. 1
INTRODUCTION…………………………… 2
INDEX…………………………………. 3
CONTENTS………………………………. 4
SAFETY…………………………….. 5
SAFETY SIGNS……………………….. 25
OPERATOR’S STATION………………….. 29
BREAK-IN…………………………… 55
PRE-START INSPECTION………………… 56
OPERATING THE ENGINE………………… 57
DRIVING THE MACHINE…………………. 64
OPERATING THE MACHINE……………….. 71
TRANSPORTING……………………….. 78
MAINTENANCE………………………… 84
MAINTENANCE – EVERY 10 HOURS OR DAILY….102
MAINTENANCE – EVERY 100 HOURS…………106
MAINTENANCE – EVERY 250 HOURS…………110
MAINTENANCE – EVERY 500 HOURS…………113
MAINTENANCE – EVERY 1000 HOURS………..123
MAINTENANCE – EVERY 2000 HOURS………..132
MAINTENANCE – EVERY 3000 HOURS………..138
MAINTENANCE – AS REQUIRED…………….143
MAINTENANCE…………………………161
STORAGE…………………………….169
TROUBLESHOOTING……………………..170
SPECIFICATIONS………………………202
MACHINE NUMBERS……………………..205

Hitachi LX100-2 LX120-2 LX150-2 Wheel Loader Technical Manual

LX100-2 LX120-2 LX150-2 Wheel Loader…………….. 1
Introduction………………………………….. 4
Contents……………………………………… 7
Section 9000 General Information………………… 9
Group 01 Safety Information…………………. 11
Group 02 General Specifications……………… 21
Group 03 Torpue Values……………………… 41
Group 04 Fuels And Lubricants……………….. 51
Section 9005 Oparational Checkout Procedure………. 59
Group 10 Operational Checkout Procedure………. 61
Section 9010 Engine Operation And Tests…………..111
Group 05 Theory Of Operation…………………113
Group 10 System Operational Checks……………117
Group 15 Diagnostic Information………………127
Group 20 Adjustments………………………..145
Group 25 Tests……………………………..159
Section 9015 Electrical System…………………..179
Group 05 System Information………………….183
Group 10 System Diagrams…………………….205
Group 15 Sub System Diagnostics………………297
Group 20 References…………………………421
Section 9020 Pwer Train Operation And Tests……….449
Group 05 Theory Of Operation…………………451
Group 10 System Operational Checks……………561
Group 15 Diagnostic Information………………575
Group 20 Adjustments………………………..599
Group 25 Tests……………………………..609
Section 9025 Hydraulic System Operation And Tests….657
Group 05 Theory OF Operation…………………659
Group 10 System Operational Checks……………705
Group 15 Diagnostic Information………………717
Group 20 Adjustments………………………..731
Groyp 25 Test………………………………737
Section 9031 Air Conditioning System……………..785
Groyp 05 Theory Of Operation…………………787
Group 10 System Oparational Checks……………803
Group 15 Diagnostic Information………………817
Group 20 Adjustments………………………..821
Group 25 Tests……………………………..845
Index…………………………………………863

Hitachi LX150-2 Wheel Loader Parts Catalog Manual

COVER…………………………………………………………. 1
CONTENTS ………………………………………………… 10
WHEEL ASSEMBLY………………………………………….. 18
AXLES …………………………………………….. 20
SPIRAL BEVEL INPUT PINION AND RING GEAR SET (OSCLLATING)…….. 22
SPIRAL BEVEL INPUT PINION AND RING GEAR SET (NON-OSCLLATING)…. 24
INPUT YOKE……………………………………………… 26
DIFFERENTIAL CASE……………………………………….. 28
DIFFERENTIAL BEARING QUILLS………………………………. 30
DIFFERENTIAL BEARING QUILLS………………………………. 32
INPUT QUILL ASSEMBLY (OSCILLATING)………………………… 34
INPUT QUILL ASSEMBLY (NON-OSCILLATING)…………………….. 36
OSCILLATING DUAL PIVOT…………………………………… 38
PLANETARY FINAL DRIVE……………………………………. 40
DIFFERENTIAL CASE OIL LINES <DIFFERENTIAL LOCK>…………….. 42
STANDARD DIFFERENTIAL……………………………………. 44
STANDARD DIFFERENTIAL <DIFFERENTAIL LOCK>………………….. 46
DIFFERENTIAL SUPPORT AND LUBRICATION LINES…………………. 50
TRANSMISSION TO FRONT DIFFERENTIAL UNIVERSAL JOINTS…………. 52
TRANSMISSION TO REAR AXLE UNIVERSAL……………………….. 54
AXLE STOP ……………………………………………. 56
AXLE HOUSING AND SHAFT…………………………………… 58
DIFFERENTIAL LOCK LINES …………………………………. 60
DIFFERENTIAL LOCK LINES …………………………………. 64
DIFFERENTIAL LOCK PEDAL AND SWITCH………………………… 66
ENGINE TO TRANSMISSION UNIVERSAL JOINT…………………….. 68
DRIVE DAMPENER AND COVER…………………………………. 70
TRANSMISSION MOUNTING BRACKETS ………………………….. 72
TRANSMISSION……………………………………………. 74
CONVERTER HOUSING AND DRIVE………………………………. 76
TRANSMISSION FILTER……………………………………… 78
INPUT SHAFT , HOUSING AND CHARGE PUMP……………………… 80
GEARBOX HOUSING…………………………………………. 84
OIL SUCTION PIPES ………………………………………. 86
FILTER TUBE , DIPSTICK AND MAGNETIC PICKUP…………………. 88
CONVERTER PRESSURE REGULATOR……………………………… 90
GEARSHIFT SYSTEM………………………………………… 92
GEARSHIFT SYSTEM………………………………………… 96
FOURTH GEAR IDLER AND SHAFT……………………………….102
CLUTCH ASSEMBLY………………………………………….104
CLUTCH ASSEMBLY………………………………………….112
CLUTCH ASSEMBLY………………………………………….118
OUTPUT SHAFT…………………………………………….124
TRANSMISSION OIL COOLER…………………………………..128
TRANSMISSION OIL HYDRAULICS……………………………….130
THERMAL BY-PASS VALVE…………………………………….132
CLUTCH DISCONNECT CONTROL ………………………………..134
ENGINE………………………………………………….136
FAN BLADE, SPACER AND BELTS ………………………………138
RADIATOR , FAN SHROUD AND GUARD……………………………140
SPEED CONTROL CABLE AND PEDAL……………………………..144
AIR CLEANER …………………………………………….146
AIR CLEANER HOSE AND SENSOR……………………………….148
AIR STACK CAP …………………………………………150
MUFFLER AND TUBE ……………………………………….152
ENGINE MOUNTING BRACKETS …………………………………154
FUEL TANK AND FUEL TANK HOSES……………………………..156
FUEL TANK AND FUEL TANK HOSES……………………………..158
SECONDARY STEERING ………………………………………160
SECONDARY STEERING PUMP…………………………………..164
PRIORITY VALVE…………………………………………..166
STEERING VALVE…………………………………………..168
STEERING CYLINDER PINS……………………………………170
STEERING CYLINDER ……………………………………….172
STEERING CYLINDER (REPLACEMENT CYLINDER)……………………174
PRIORITY VALVE HYDRAULICS…………………………………176
STEERING WHEEL COLUMN AND LINKAGE………………………….180
STEERING CYLINDER HYDRAULICS………………………………184
BRAKES ……………………………………………….186
BRAKES………………………………………………….188
DUAL BRAKE OIL LINES …………………………………….190
BRAKE PEDALS…………………………………………….192
BRAKE VALVE……………………………………………..194
BRAKE VALVE HYDRAULICS……………………………………196
BRAKE VALVE HYDRAULICS……………………………………200
HYDRAULIC RELEASED PARKING BRAKE, HOSE AND BRACKETS………….204
PARK BRAKE CALIPER ASSEMBLY……………………………….206
PARK BRAKE REPAIR KIT …………………………………..208
LICENSE PLATE LIGHT AND BRACKET……………………………210
STEERING CYLINDER HEAD END LUBRICATION SYSTEM……………….212
GREASE GUN HOLDER………………………………………..214
MACHINE FILTERS …………………………………………216
BATTERY, HOLD-DOWNS AND CABLES…………………………….218
TRANSMISSION AND SECONDARY STEERING CONTROLLERS AND PLATE…….220
REAR LIGHT GUARD , MOUNT AND BRACKET……………………….222
FRONT LIGHT BRACKET………………………………………224
RIGHT CONSOLE PLATE………………………………………226
ELECTRIC PARTS (FRAME)……………………………………228
WORK LIGHT (FRONT)……………………………………….230
WORK LIGHT SWITCH………………………………………..232
CLUTCH CUT -OFF SWITCH……………………………………234
AIR HEATER RELAY ………………………………………..236
FLASHER SWITCH ………………………………………….238
HYDRAULIC FILTER LEAD ……………………………………240
LOAD CENTER PANEL ……………………………………….242
KEY SWITCH ……………………………………………..244
CIGAR LIGHTER ………………………………………….246
SHIFT SELECTOR , HIGU BEAM AND TURN SIGNAL SWITCH……………248
PARK BRAKE SWITCH ……………………………………….250
TRANSMISSION OIL TEMPERATURE SENDER………………………..252
RIDE CONTROL HARNESS …………………………………….254
RIDE CONTROL HARNESS …………………………………….256
ENGINE COOLANT TEMPERATURE SENDER …………………………258
TRANSMISSION OIL PRESSURE SWITCH …………………………260
CAB HARNESS …………………………………………..262
CAB GROUND STRAP ………………………………………264
RETURN – TO -DIG HARNESS………………………………….266
LOAD CENTER HARNESS AND CLAMPING ………………………….268
BOOM – KICKOUT HARNESS ………………………………….270
RADIO <CAB>……………………………………………..272
AIR CONDITIONER <CAB>…………………………………….274
UNIT <AIRCONDITIONER ; MAIN>………………………………276
AIR CONDITIONING PANEL SWITCH , CLAMPS AND GROMMETS………….280
AIR CONDITIONING HARNESS , PLATE , CONTROLLER AND PLATE………282
LOADER FRAME HARNESS …………………………………..284
SECONDARY STEERING HARNESS ………………………………286
ENGINE HARNESS …………………………………………288
FRONT WINDSHIELD WIPER SWITCH AND RELAY…………………….290
REAR WINDSHIELD WIPER SWITCH AND RELAY……………………..292
ENGINE FRAME HARNESS……………………………………..294
TRANSMISSION HARNESS …………………………………….296
REAR FRAME HARNESS……………………………………….298
FUSES AND CIRCUIT BREAKERS………………………………..300
ROTARY BEACON SWITCH……………………………………..302
MONITOR ……………………………………………….304
MONITOR ALARM ………………………………………….306
SPEEDOMETER …………………………………………..308
WINDOW -WASHER <CAB>……………………………………..310
ENGINE FRAME …………………………………………..312
STEERING CUSHION ……………………………………….314
REAR BOTTOM GUARD ………………………………………316
AUXILIARY BOTTOM GUARD …………………………………318
COUNTERWEIGHT AND ATTACHING HARDWARE……………………….320
SECOND COUNTERWEIGHT AND ATTACHING HARD WARE………………..322
TRANSMISSION GUARD AND DOOR FOAM ……………………….324
SIDE SHIELD FOAM …………………………………….326
GRILLE FOAM ……………………………………………328
GRILLE ……………………………………………….330
CAB INTERIOR …………………………………………..332
STEEL CAB ASS’Y ………………………………………..334
STEEL CAB (1) …………………………………………336
STEEL CAB (2) …………………………………………338
STEEL CAB (3) …………………………………………340
DOOR CATCH (R)…………………………………………..342
DOOR CATCH (L)…………………………………………..344
STEEL CAB (4) <DOOR ; R>………………………………….346
STEEL CAB (5) <DOOR ; L>………………………………….348
ONE-SEATER STEEL CAB (46) <WINDOW WIPER>……………………352
OUTSIDE MIRROR <CAB>……………………………………..354
STEEL CAB PARTS …………………………………………356
CAB SHIELDS ……………………………………………358
CONSOLE ACCESS DOOR ……………………………………..360
RIGHT CONSOLE ………………………………………….362
FRONT AND REAR WINDOW WASHER …………………………….364
PLATFORM ………………………………………………366
SEAT SUPPORT ……………………………………………368
MONITOR HOUSING …………………………………………370
WRIST REST …………………………………………….372
ASHTRAY ……………………………………………….374
RETRACTABLE SEAT BELT …………………………………..376
SEAT ………………………………………………378
SEAT AND BACKREST CUSHION ……………………………….380
BACKREST EXTENSION ……………………………………..382
TETHER STRAP …………………………………………..384
ARMRESTS AND BACKREST BRACKETS …………………………..386
SEAT LOWER BACK ADJUSTER………………………………….388
SCISSORS SUSPENSION ARMS WITH SHAFTS ………………………390
SSEAT WEIGHT ADJUSTER ASSEMBLY…………………………….392
ENGINE COMPARTMENT STEP …………………………………394
ACCESS STEPS …………………………………………..396
HANDRAIL ……………………………………………..398
CONDENSER AND HOUSING ……………………………………400
RECEIVER DRIER AND SIGHT GLASS …………………………..402
DEFROSTER……………………………………………….404
DEFROSTER SWITCH…………………………………………406
BLOWER ASSEMBLY………………………………………….408
AIR CONDITIONER , HEATER ASSEMBLY AND BOX…………………..410
DUCT HOSES TO SEAT SUPPORT………………………………..412
COMPRESSOR BRACKET AND V-BELT……………………………..414
COMPRESSOR AND REFRIGERANT LINES ………………………….416
HEATER HOSES…………………………………………….418
FOOT DUMPER MOTOR AND DOOR………………………………..420
OUTLET DUMPER MOTOR AND DOOR………………………………422
ROOM AIR FILTER (AIR-CON)…………………………………424
HOOD …………………………………………………426
ENGINE SIDE SHIELDS …………………………………….428
TRANSMISSION SHIELDS …………………………………..430
BATTERY BOX COVERS ……………………………………..432
GRILLE AND GRILLE HOUSING ………………………………434
REAR FENDER ………………………………………….436
FRONT FENDERS …………………………………………438
BACK – UP ALARM ………………………………………..440
DUAL HORN …………………………………………….442
TOOL BOX …………………………………………….444
LOADER FRAME ………………………………………….446
LOADER FRAME ………………………………………….448
LOADER BOOM AND PINS ……………………………………450
LOADER LINKAGE ………………………………………..452
BUCKET AND CUTTING EDGE ………………………………..454
TOOTH ……………………………………………….456
LOADER CONTROL VALVE …………………………………..458
INLET SECTION VALVE WITCH RELIEF VALVE ……………………462
BOOM SECTION VALVE……………………………………….464
ANTI-CAVITY VALVE BOOM SECTION …………………………..466
BUCKET SECTION VALVE ……………………………………468
UNIVERSAL RELIEF VALVE BUCKET AND AUXILIARY SECTION ………..470
AUXILARY SECTION VALVE …………………………………472
SINGLE AUXILIARY CONTROLLER ……………………………..474
TWO -LEVER REMOTE CONTROLLER………………………………476
THREE -LEVER REMOTE CONTROLLER …………………………..478
FOUR -LEVER REMOTE CONTROLLER …………………………..480
BUCKET , BOOM AND AUXILIARY SECTION………………………..482
HYDRAULIC REMOTE CONTROLLER ………………………………490
SINGLE LEVER , TWO-LEVER AND THREE-LEVER HYDRAULICS………….496
SINGLE LEVER , TWO-LEVER AND THREE-LEVER HYDRAULICS………….500
THIRD FUNCTION REMOTE HYDRAULICS ………………………….504
THIRD FUNCTION REMOTE HYDRAULICS ………………………….508
FOURTH FUNCTION REMOTE HYDRAULICS …………………………512
BUCKET CYLINDER ………………………………………..516
BOOM CYLINDER…………………………………………..520
LOADER CONTROL VALVE TO BUCKET CYLINDER HYDRAULICS …………522
LOADER CONTROL VALVE TO BOOM CYLINDER HYDRAULICS …………..524
THIRD FUNCTION AUXILIARY HYDRAULICS ……………………….528
FOURTH FUNCTION AUXILIARY HYDRAULICS ………………………530
HYDRAULIC PUMP ………………………………………….532
HYDRAULIC PUMP KIT……………………………………….534
BRAKE PUMP ……………………………………………..536
HYDRAULIC PUMP HOSES AND FITTINGS………………………….540
HYDRAULIC RESERVOIR………………………………………542
HYDRAULIC RESERVOIR FITTINGS………………………………544
HYDRAULIC RESERVOIR AND RETURN FILTER HOSES TO OIL COOLER…….546
HYDRAULIC FILTER AND HOSES ……………………………….548
PRESSURE REDUCING VALVE MANIFOLD HOSES AND FITTINGES ………..550
PRESSURE REDUCING VALVE MANIFOLD ………………………….552
PRESSURE REDUCING VALVE ………………………………….554
SOLENOID VALVE…………………………………………..556
LOADER CONTROL VALVE AND STEERING VALVE RETURN HOSES ………..558
RETURN-TO-DIG BRACKET , SUPPORT AND SWITCH………………….560
BOOM KICKOUT BRACKETS AND SWITCH ………………………….562
RIDE CONTROL ……………………………………………564
RIDE CONTROL VALVE……………………………………….568
RIDE CONTROL ACCUMULATOR………………………………….570
TOOLS …………………………………………………572
NAME-PLATE (1) (JAPANESE)…………………………………576
NAME-PLATE (2) (JAPANESE)…………………………………580
PARTS INDEX…………………………………………………583
PARTS INDEX……………………………………………..584

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