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Hitachi LX15-7 LX20-7 LX30-7 LX40-7 Wheel Loader Shop Manual – PDF DOWNLOAD
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Hitachi LX15-7 LX20-7 LX30-7 LX40-7 Wheel Loader Shop Manual
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Description
Hitachi LX15-7 LX20-7 LX30-7 LX40-7 Wheel Loader Shop Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:653
DOWNLOADABLE:YES
FILE TYPE:PDF
HITACHI LX15-7 LX20-7 LX30-7 LX40-7 WHEEL LOADER SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Hitachi LX15-7 LX20-7 LX30-7 LX40-7 Wheel Loader Shop Manual
To Readers of This Manual
This manual provides service staff who have completed basic training with technical information necessary for service activity. For obtaining satisfaction and trust from customers, you are expected to read through this manual and acquire correct product knowledge and service technique.
Reference Material
This manual does not, in principle, describe basic items and overlapped areas with other materials (below) to eliminate redundancy.
• For basic items, refer to training materials such as “Sales and Technical Material.”
• For handling and inspection procedures, refer to “Instruction Manual.”
• For structure and component parts, refer to “Parts Catalog.”
• For handling, maintenance procedure and parts of the engine, refer to materials issued by the engine manufacturer.
Organization
This manual is organized into four parts: 1. General Instructions 2. Construction and Function 3. Oveahaul 4. Troubleshooting
1. General Instructions
Safety during maintenance work and general cautionary instructions are compiled.
2. Construction and Function
An explanation of the construction and function and an explanation of operation (function) by illustrations, circuit diagrams and system diagrams are compiled.
3. Oveahaul
Methods of removing hydraulic equipment from a vehicle, its disassembly and reassembly, its adjusting method, standard values used for service work and service limits are compiled.
4. Troubleshooting
Probable causes and corrections for troubles are compiled
TABLE OF CONTENTS:
Hitachi LX15-7 LX20-7 LX30-7 LX40-7 Wheel Loader Shop Manual
TTLA0576................................................................. 1 INDEX................................................................ 1 OPERATIONAL PRINCIPLE................................................ 1 1. GENERAL INFOMATION................................................ 2 1-1. COMMON ITEMS................................................ 4 Scope of Description and Usage of This Manual................ 6 Precautions in Inspection and Service........................ 9 General Precautions for Inspection and Service............... 11 General Precautions for Safety Operation..................... 12 Disassembly and Assembly..................................... 19 1-2. SPECIFICATIONS.............................................. 28 Outline Drawings/Specifications.............................. 30 Fuel, Water and Oil Selection and Capacities................. 34 Weight of Main Components.................................... 38 Check and Service List....................................... 39 2. CONSTRUCTION AND FUNCTION......................................... 42 2-0. ENGINE...................................................... 44 Engine....................................................... 46 Engine Assembly, Engine Mount................................ 50 Air Cleaner.................................................. 51 Muffler...................................................... 52 Radiator..................................................... 55 Engine Control............................................... 57 Fuel System.................................................. 58 2-1. ELECTRIC SYSTEM............................................. 62 Meter Panel.................................................. 64 Electrical Components........................................ 65 Electrical Circuit........................................... 69 Monitor Lamp Circuit..................................... 69 Gauge Circuit............................................ 71 Charging Circuit......................................... 73 Pre-heating Circuit...................................... 74 Start and Stop Circuit................................... 76 Traveling System Circuit................................. 78 Light Circuit............................................ 84 Horn Circuit............................................. 86 Auto-leveler Circuit..................................... 87 2-2. POWER TRAIN I............................................... 88 Power Train.................................................. 90 HST.......................................................... 93 HST Pump..................................................... 94 HST Motor....................................................107 HST Piping...................................................113 HST Oil Filter...............................................114 Relief Valve.................................................115 HST Control..................................................116 HST Hydraulic Circuit........................................117 Reduction Gear Box...........................................119 2-3. POWER TRAIN II..............................................122 Propeller Shaft..............................................124 Axle.........................................................125 Differential.................................................128 Final Gear...................................................130 Wheel........................................................131 2-4. BRAKE SYSTEM................................................132 Brake System.................................................134 How to Toe...................................................140 Wet Brake Assembly in Reduction Gear Box.....................141 Master Cylinder..............................................142 2-5. STEERING SYSTEM.............................................144 Steering.....................................................146 Steering Hydraulic Circuit...................................147 Power Steering Assembly......................................148 Steering Cylinder............................................149 2-6. FRAME.......................................................150 Frame........................................................152 Center Pin...................................................153 Suspension...................................................154 2-7. HYDRAULIC SYSTEM............................................156 Main Piping..................................................158 Control Valve................................................160 Main Pump....................................................167 Oil Tank.....................................................168 Return Filter................................................169 Lift / Tilt Cylinder.........................................170 2-8. WORKING EQUIPMENT...........................................172 Shovel Linkage...............................................174 Auto-leveler.................................................179 Shovel Control...............................................180 KM-SM047E-00.............................................................182 INDEX_SM.............................................................182 1. GENERAL INFOMATION................................................184 1-1. Common Items................................................186 Scope of Description and Usage of This Manual................188 Precautions in Inspection and Service........................191 General Precautions for Inspection and Service...............193 General Precautions for Safety Operation.....................194 Disassembly and Assembly.....................................201 1-2. Specifications..............................................210 Outline Drawings/Specifications..............................212 Fuel, Water and Oil Selection and Capacities.................216 Weight of Main Components....................................220 Check and Service List.......................................221 2. CONSTRUCTION AND FUNCTION.........................................224 2-0. Engine......................................................226 Engine.......................................................228 Engine Assembly, Engine Mount................................232 Air Cleaner..................................................233 Muffler......................................................234 Radiator.....................................................237 Engine Control...............................................239 Fuel System..................................................240 2-1. Electronic System...........................................244 Meter Panel..................................................246 Electrical Components........................................247 Electrical Circuit...........................................250 Main Circuit.............................................250 Monitor Lamp Circuit.....................................251 Gauge Circuit............................................253 Charging Circuit.........................................255 Pre-heating Circuit......................................256 Start and Stop Circuit...................................258 Traveling System Circuit.................................260 Light Circuit............................................266 Horn Circuit.............................................268 Auto-leveler Circuit.....................................269 2-2. Power Train I...............................................270 Power Train..................................................272 HST..........................................................275 HST Pump.....................................................276 HST Motor....................................................289 HST Piping...................................................295 Charging Pump................................................296 HST Oil Filter...............................................296 Relief Valve.................................................297 HST Control..................................................298 HST Hydraulic Circuit........................................299 Reduction Gear Box...........................................301 2-3. Power Train II..............................................304 Propeller Shaft..............................................306 Axle.........................................................307 Differential.................................................310 Final Gear...................................................312 Wheel........................................................313 2-4. Brake System................................................314 Brake System.................................................316 How to Toe...................................................322 Wet Brake Assembly in Reduction Gear Box.....................323 Master Cylinder..............................................324 2-5. Steering System.............................................326 Steering.....................................................328 Steering Hydraulic Circuit...................................329 Power Steering Assembly......................................330 Steering Cylinder............................................331 2-6. Frame.......................................................332 Frame........................................................334 Center Pin...................................................335 Suspension...................................................336 2-7. Hydraulic System............................................338 Main Piping..................................................340 Control Valve................................................342 Main Pump....................................................349 Oil Tank.....................................................350 Return Filter................................................351 Lift/Tilt Cylinder...........................................352 2-8. Working Equipment...........................................354 Shovel Linkage...............................................356 Auto-leveler.................................................361 Shovel Control...............................................362 3. OVERHAUL..........................................................364 3-0. Engine......................................................366 Removal of Engine LX15-7.....................................368 Installation of Engine LX15-7................................376 Removal of Engine LX20, 30, 40-7.............................385 Installation of Engine LX20, 30, 40-7........................393 Level Check and Addition of Oil in Engine Oil Pan............401 Adjustment of Engine Control.................................402 Removal of Radiator LX15-7...................................403 Installation of Radiator LX15-7..............................406 Removal of Radiator LX20, 30, 40-7...........................410 Installation of Radiator LX20, 30, 40-7......................413 Level Check and Addition of Coolant..........................417 Removal of Fuel Tank.........................................418 Installation of Fuel Tank....................................420 Level Check and Addition of Fuel.............................422 3-2. Powertrain 1................................................424 Removal of HST Pump LX15-7...................................426 Installation of HST Pump LX15-7..............................429 Removal of HST Pump LX20, 30, 40-7...........................432 Installation of HST Pump LX20, 30, 40-7......................435 Disassembly of HST Pump......................................438 Removal of HST Motor LX15-7..................................440 Installation of HST Motor LX15-7.............................442 Removal of HST Motor LX20, 30, 40-7..........................444 Installation of HST Motor LX20, 30, 40-7.....................446 Disassembly of HST Motor LX15-7..............................448 Disassembly of HST Motor LX20, 30, 40-7......................449 Removal of Reduction Gear....................................450 Installation of Reduction Gear...............................453 Reduction Gear Oil Change....................................456 Level Check and Addition of Fluid in Brake Fluid Tank........457 Bleeding Brake Fluid Tank....................................458 Disassembly of Reduction Gear................................459 Assembly of Reduction Gear...................................465 Service Standards of Reduction Gear..........................473 3-3. Powertrain 2................................................474 Removal of Front Axle........................................476 Installation of Front Axle...................................478 Removal of Rear Axle.........................................480 Installation of Rear Axle....................................482 Axle Oil Change..............................................485 Disassembly of Axle..........................................487 Assembly of Axle.............................................494 Service Standards of Differential............................506 Tooth Contact Adjustment of Ring Gear........................507 3-4. Brake System................................................510 Removal of Master Cylinder...................................512 Installation of Master Cylinder..............................514 Disassembly of Master Cylinder...............................517 Assembly of Master Cylinder..................................518 Installation Standards of Brake Control......................519 3-5. Steering....................................................522 Removal of Orbit-Roll........................................524 Installation of Orbit-Roll...................................526 Disassembly of Orbit-Roll....................................529 Assembly of Orbit-Roll.......................................534 Removal of Steering Cylinder.................................540 Installation of Steering Cylinder............................542 3-7. Hydraulic System............................................546 Removal of Control Valve.....................................548 Installation of Control Valve................................551 Disassembly of Control Valve.................................555 Assembly of Control Valve....................................561 Removal of Main Charging Pump................................569 Installation of Main Charging Pump...........................571 Removal of Hydraulic Fluid Tank..............................573 Installation of Hydraulic Fluid Tank.........................575 Level Check and Addition of Fluid in Hydraulic Fluid Tank....578 Disassembly of Cylinder......................................579 Assembly of Cylinder.........................................582 Service Standards of Cylinders...............................586 4. TROUBLESHOOTING / DIAGNOSIS.......................................588 4-0. Engine......................................................590 4-2. Powertrain 1................................................596 4-3. Powertrain 2................................................614 4-4. Brake System................................................620 4-5. Steering System.............................................626 4-7. Hydraulic System............................................630 SERVICE MANUAL REVISION REQUEST FORM.................................650 WCLA0532.................................................................652 WCLA0533.................................................................653
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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