Hitachi EX160WD Hydraulic Excavator Workshop Repair Service Manual

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This complete service repair workshop manual PDF download for the EX160WD Hitachi Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

TABLE OF CONTENTS :

SECTION 1 HOW TO USE
Group 1 SECTION & GROUP CONTENTS
Group 2 INTRODUCTION
Group 3 FEATURES OF THIS MANUAL
Group 4 SAFETY INFORMATIONS

SECTION 2 SPECIFICATIONS
Group 1 GENERAL SPECIFICATIONS
Group 2 COMPONENTS SPECIFICATIONS
Group 3 TORQUE REFERENCE
Group 4 OTHERS
Group 5 CONVERSION TABLE

SECTION 3 GENERAL
Group 1 INTRODUCTION
Group 2 CONSTRUCTION
Group 3 HYDRAULIC SYSTEM
Group 4 AIR SYSTEM
Group 5 ELECTRIC SYSTEM

SECTION 4 SUPERSTRUCTURE
Group 1 HYDRAULIC PUMP
Group 2 CONTROL VALVE
Group 3 SWING DEVICE
Group 4 PILOT VALVE
Group 5 CONTROL NEUTRALIZER VALVE
Group 6 SHOCKLESS VALVE
Group 7 ACCUMULATOR
Group 8 SOLENOID VALVE
Group 9 MODE SELECTION CYLINDER
Group 10 RESTRICTION VALVE

SECTION 5 UNDERCARRIAGE
Group 1 UNDERCARRIAGE
Group 2 TRAVEL DEVICE
Group 3 STEERING DEVICE
Group 4 CENTER JOINT

SECTION 6 FRONT-END ATTACHMENTS
Group 1 FRONT-END ATTACHMENT
Group 2 HYDRAULIC CYLINDER
Group 3 PIN & BUSHING
Group 4 POINT & SIDE CUTTER

SECTION 7 HYDRAULIC SYSTEM
Group 1 OUTLINE
Group 2 MAIN HYDRAULIC CIRCUIT
Group 3 PILOT CIRCIUT
Group 4 SINGLE OPERATION
Group 5 COMBBINED OPERATION
Group 6 STEERING CIRCUIT
Group 7 RAM LOCK CIRCUIT
Group 8 OUTRIGGER CONTROL CIRCUIT
Group 9 BLADE CONTROL CIRCUIT

SECTION 8 PNEUMATIC SYSTEM
Group 1 AIR CIRCUIT
Group 2 AIR DRYER
Group 3 BRAKE VALVE
Group 4 AIR MASTER
Group 5 SOLENOID VALVE
Group 6 SOLENOID VALVE

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Manual No. : KM-116-00
Total Pages : 782

It works to give you both the general background as a training text and technical details of shop service and field service. It covers specifications construction, theory of operation, trouble shooting, removal and installation, disassembly and assembly, maintenance and repair. Using the service manual as a guide will reduce error and costly delay. It will also assure you the best in finished service work.

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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EX160WD SERVICE MANUAL
INDEX

SECTION 1 HOW TO USE
CONTENTS
Group 1 SECTION & GROUP CONTENTS
Group 2 INTRODUCTION
1. INTRODUCTION
2. CARE OF THE HANDLING
3. SYMBOLS
Group 3 FEATURES OF THIS MANUAL
1. CONSTRUCTION
2. TAB
3. PAGE
4. CONTENTS
Group 4 SAFETY INFORMATIONS

SECTION 2 SPECIFICATIONS
CONTENTS
Group 1 GENERAL SPECIFICATIONS
1. DIMENSIONS
2. WEIGHTS & GROUND PRESSURE
3. FRONT-END ATTACHMENTS
4. WORKING RANGES
5. LIFTING CAPACITIES
Group 2 COMPONENTS SPECIFICATIONS
1. ENGINE
2. MAIN PUMP
3. STEERING PUMP
4. CONTROL VALVE
5. SWING MOTOR
6. TRAVEL MOTOR
7. STEERING VALVE
8. RELIEF VALVE (for Steering Circuit)
9. PILOT VALVE (for Travel & Outrigger)
10. PILOT VALVE (for Swing, Boom, Arm, Bucket)
11. CONTROL NEUTRALIZER VALVE
12. SHOCKLESS VALVE
13. ACCUMULATOR
14. SUCTION FILTER
15. FULL-FLOW FILTER
16. AIR BREEZER
17. BYPASS CHECK VALVE
18. PILOT FILTER
19. OIL COOLER
20. RESTRICTION VALVE
21. SOLENOID VALVE (for E, L-Mode & Ram Lock)
22. SOLENOID VALVE (for P-Mode)
23. MODE SELECTION CYLINDER
24. CENTER JOINT
25. STEERING CYLINDER
26. RAM CYLINDER
27. OPERATE CHECK VALVE (for Ram Cylinder)
28. OUTRIGGER CYLINDER
29. DOUBLE OPERATE CHECK VALVE (for Outrigger Cylinder)
30. BLADE CYLINDER
31. HOLDING VALVE (for Blade Circuit)
32. BOOM CYLINDER
33. ARM CYLINDER
34. BUCKET CYLINDER
PNEUMATIC SYSTEM
35. AIR COMPRESSOR
36. AIR DRYER
37. AIR TANK
38. GOVERNOR
39. SAFETY VALVE (for Air Tank)
40. PRESSURE PROTECTION VALVE
41. LOW PRESSURE SWITCH
42. BRAKE VALVE
43. PRESSURE SWITCH (for Stop Light Switch)
44. SPEED CONTROLLER (Throttle Valve)
45. CHECK VALVE
46. MAGNETIC VALVE
47. AIR HORN
48. AIR MASTER
49. SOLENOID VALVE (Working Brake Valve)
50. SOLENOID VALVE (Parking Brake & Transmission Sift Valve)
POWER TRAIN
1. TRANSMISSION
2. FRONT DRIVE AXLE
3. REAR DRIVE AXLE
4. PROPELLER SHAFT (Front)
5. PROPELLER SHAFT (Rear)
6. TIRE (Wheel)
Group 3 TORQUE REFERENCE
Group 4 OTHERS
1. MAINTENANCE INTERVALS
Group 5 CONVERSION TABLE

SECTION 3 GENERAL
CONTENTS
Group 1 INTRODUCTION
Group 2 CONSTRUCTION
Group 3 HYDRAULIC SYSTEM
1. HYDRAULIC SYSTEM
2. MAIN HYDRAULIC CIRCUIT
3. PILOT HYDRAULIC CIRCUIT
4. STEERING HYDRAULIC CIRCUIT
Group 4 AIR SYSTEM
Group 5 ELECTRIC SYSTEM
1. MAIN CIRCUIT
2. CONTROL SYSTEM
3. MONITOR SYSTEM

SECTION 4 SUPERSTRUCTURE
CONTENTS
Group 1 HYDRAULIC PUMP
O/P, HYDRAULIC PUMP
D/A, MAIN PUMP
Group 2 CONTROL VALVE
O/P, CONTROL VALVE
D/A, CONTROL VALVE
Group 3 SWING DEVICE
O/P, SWING MOTOR
D/A, SWING MOTOR
D/A, SWING REDUCTION DEVICE
Group 4 PILOT VALVE
O/P, PILOT VALVE
D/A, HV TYPE PILOT VALVE (Fornt-End Attachment)
D/A, HV TYPE PILOT VALVE (Travel and Outrigger)
Group 5 CONTROL NEUTRALIZER VALVE
O/P, CONTROL NEUTRALIZER VALVE
D/A, CONTROL NEUTRALIZER VALVE
Group 6 SHOCKLESS VALVE
O/P, SHOCKLESS VALVE
D/A, SHOCKLESS VALVE
Group 7 ACCUMULATOR
O/P, ACCUMULATOR
Group 8 SOLENOID VALVE
O/P, SOLENOID VALVE (Three Spools)
D/A, SOLENOID VALVE (Three Spools)
O/P, SOLENOID VALVE (One Spool)
D/A, SOLENOID VALVE (One Spool)
Group 9 MODE SELECTION CYLINDER
D/A, MODE SELECTION CYLINDER
Group 10 RESTRICTION VALVE
O/P, RESTRICTION VALVE

SECTION 5 UNDERCARRIAGE
CONTENTS
Group 1 UNDERCARRIAGE
1. OUTLINE
2. POWER TRAIN SYSTEM
3. FRONT AND REAR PROPEL SHAFT
4. TRANSMISSION
5. REAR AXLE
6. FRONT AXLE
7. BRAKE
8. STEERING
9. OUTRIGGER SYSTEM AND EQUALIZER SYSTEM
Group 2 TRAVEL DEVICE
D/A, UNDERCARRIAGE (AXLE)
D/A, TRANSMISSION
O/P, TRAVEL MOTOR
D/A, TRAVEL MOTOR
O/P, BRAKE VALVE
D/A, BRAKE VALVE
Group 3 STEERING DEVICE
O/P, STEERING VALVE
D/A, STEERING VALVE
D/A, STEERING PUMP
D/A, STEERING CYLINDER
Group 4 CENTER JOINT
O/P, CENTER JOINT

SECTION 6 FRONT-END ATTACHMENTS
CONTENTS
Group 1 FRONT-END ATTACHMENT
1. BOOM ASSEMBLY
2. ARM ASSEMBLY
3. BUCKET ASSEMBLY
4. FRONT PIPINGS
Group 2 HYDRAULIC CYLINDER
OPERATIONAL PRINCIPLE
DISASSEMBLY & ASSEMBLY
Group 3 PIN & BUSHING
1. SPECIFICATIONS
Group 4 POINT & SIDE CUTTER
1. MAINTENANCE

SECTION 7 HYDRAULIC SYSTEM
CONTENTS
Group 1 OUTLINE
Group 2 MAIN HYDRAULIC CIRCUIT
1. SUCTION CIRCUIT & DELIVERY CIRCUIT
2. RETURN CIRCUIT
3. DRAIN CIRCUIT
Group 3 PILOT CIRCIUT
1. SUCTION, DELIVERY & RETURN CIRCUIT
2. ACCUMULATOR
3. CONTROL NEUTRALIZER VALVE
4. PUMP DISPLACEMENT CONTROL CIRCUIT
5. RELIEF PRESSURE CHANGE CIRCUIT
6. HEAT-RUN CIRCUIT
7. SWING PARKING BRAKE
8. PILOT CIRCUIT DIAGRAM
Group 4 SINGLE OPERATION
1. BOOM RAISE CIRCUIT OPERATION
2. BOOM LOWER CIRCUIT OPERATION
3. ARM ROLL-IN CIRCUIT OPERATION
4. ARM ROLL-IN CIRCUIT OPERATION
5. BUCKET CIRCUIT OPERATION
6. SWING CIRCUIT OPERATION
7. SWING OPERATION
8. TRAVEL CIRCUIT OPERATION
9. TRAVEL FOWARD & REVERSE OPERATION
Group 5 COMBBINED OPERATION
1. OUTLINE
2. COMBINED SWING & BOOM OPERATION
3. COMBINED SWING & ARM OPERATION
4. COMBINED SWING, BOOM & ARM OPERATION
5. COMBINED SWING, BOOM & ARM & BUCKET OPERATION
6. COMBINED BOOM & TRAVEL OPERATION
7. COMBINED ARM & TRAVEL OPERATION
8. COMBINED BUCKET & TRAVEL OPERATION
Group 6 STEERING CIRCUIT
Group 7 RAM LOCK CIRCUIT
1. OUTLINE
2. RAM LOCK OPERATION
3. RAM LOCK CIRCUIT
Group 8 OUTRIGGER CONTROL CIRCUIT
1. OUTLINE
2. OUTRIGGER CIRCUIT OPERATION
3. DOUBLE OPERATE CHECK VALVE
4. OUTRIGGER CIRCUIT
Group 9 BLADE CONTROL CIRCUIT
1. OUTLINE
2. BLADE CIRCUIT OPERATION
3. HOLDING VALVE
4. BLADE CIRCUIT

SECTION 8 PNEUMATIC SYSTEM
CONTENTS
Group 1 AIR CIRCUIT
1. OUTLINE
2. ACCUMULATE THE AIR
3. TRAVEL BRAKE CIRCUIT
4. TRANSMISSION SHIFT CIRCUIT
5. AIR COMPRESSOR
6. GOVERNOR
7. PRESSURE PROTECTION VALVE
8. AIR HORN
9. CHECK VALVE
10. AIR BRAKE CIRCUIT
11. AIR CIRCUIT
Group 2 AIR DRYER
O/P, AIR DRYER
D/A, AIR DRYER
Group 3 BRAKE VALVE
O/P, BRAKE VALVE
D/A, BRAKE VALVE
Group 4 AIR MASTER
O/P, AIR MASTER
D/A, AIR MASTER
Group 5 SOLENOID VALVE
O/P, SOLENOID VALVE (P/B, T/M)
Group 6 SOLENOID VALVE
O/P, SOLENOID VALVE (W/B)

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