All-Inclusive Factory Service Technical manual for Hitachi Wheel Loaders Models LX150-2

This manual will assist you in diagnosing, repairing, repairing engine, operating, maintaining, and finding spare parts for your wheel loader

Covered Models:
   LX150-2

The manual comprises 5 documents, including the Technical Manual, Workshop Manual, Engine Technical Manual, Operate and Maintenance manual, and Parts Catalog

1. Technical Manual (T482E-02)
Format: PDF, 872 pages
Language: English
Table of Contents:
   LX100-2 LX120-2 LX150-2 Wheel Loader
   Introduction
   General Information
      Safety Information
      General Specifications
      Torpue Values
      Fuels And Lubricants
      Oparational Checkout Procedure
      Operational Checkout Procedure
   Engine Operation And Tests
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub System Diagnostics
      References
   Pwer Train Operation And Tests
      Theory Of Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Tests
   Hydraulic System Operation And Tests
      Theory OF Operation
      System Operational Checks
      Diagnostic Information
      Adjustments
      Test
   Air Conditioning System
      Theory Of Operation
      System Oparational Checks
      Diagnostic Information
      Adjustments
      Tests
   Index

2. Workshop Manual (W482E-02)
Format: PDF, 603 pages
Language: English
Table of Contents:
   INTRODUCTION
      GENERAL INFORMATION
      WHEELS CONTENTS
      AXLES AND SUSPENSION SYSTEMS
      TRANSMISSION CONTENTS
      ENGINE CONTENTS
      ENGINE AUXILIARY SYSTEMS
      DAMPENER DRIVE
      STEERING SYSTEM
      SERVICE BRAKES
      PARK BRAKE CONTENTS
      EQUIPMENT ATTACHING CONTENTS
      ELECTRICAL SYSTEMS
      FRAME OR SUPPORTING STRUCTURE CONTENTS
      OPERATOR'S STATION
      LOADER CONTENTS
      DEALER FABRICATED TOOLS CONTENTS
   INDEX
   SERVICE MANUAL REVISION REQUES FORM

3. Engine Technical Manual (CTM42)
Format: PDF, 559 pages
Language: English
Table of Contents:
   Introduction
      Not a Real Standard Block
      About This Manual
   Safety
      Handle Fluids Safely-Avoid Fires
      Prevent Battery Explosions
      Prepare for Emergencies
      Prevent Acid Burns
      Avoid High-Pressure Fluids
      Wear Protective Clothing
      Service Machines Safely
      Work In Ventilated Area
      Work in Clean Area
      Remove Paint Before Welding or Heating
      Avoid Heating Near Pressurized Fluid Lines
      Illuminate Work Area Safely
      Use Proper Lifting Equipment
      Practice Safe Maintenance
      Use Proper Tools
      Decommissioning - Proper Recycling and Disposal of Fluids and Components
      Live With Safety
   General Information
      Unified Inch Bolt and Screw Torque Values
      Metric Bolt and Screw Torque Values
      Engine Model Designation
      Engine Serial Number Plate Information
      Engine Application Chart
      OEM Applications
   Fuels, Lubricants, and Coolant
      Diesel Fuel
      Lubricity of Diesel Fuels
      Diesel Engine Break-In Oil - Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III
      Diesel Engine Oil
      Oilscan™ and CoolScan™
      Grease
      Alternative and Synthetic Lubricants
      Engine Coolant Requirements
      Recommended Engine Coolant
      Engine Coolant Specifications
      Replenishing Supplemental Coolant Additives (SCA`s) Between Coolant Changes
      Operating in Tropical Conditions
      Flush and Service Cooling System
      Disposing of Coolant
   Engine Mounting
      Engine Repair Stand
      Safety Precautions
      Install 400 Series Adapters on Repair Stand
      Engine Lifting Procedure
      Clean Engine
      Disconnect Turbocharger Oil Inlet Line
      Mount Engine on Repair Stand
   Engine Rebuild Guide
      6076 Engine Disassembly Sequence
      Sealant Application Guidelines
      6076 Engine Assembly Sequence
   Cylinder Head and Valves
      Essential Tools
      Service Equipment and Tools
      Other Material
      Cylinder Head and Valves Specifications
      Check and Adjust Valve Clearance
      Check Valve Lift
      Remove Cylinder Head
      Disassemble and Inspect Rocker Arm Shaft Assembly
      Assemble Rocker Arm Shaft Assembly
      Measure Valve Recess
      Preliminary Cylinder Head and Valve Checks
      Remove Valve Assembly
      Inspect and Measure Valve Springs
      Inspect Valve Rotators and Wear Caps
      Clean Valves
      Inspect and Measure Valves
      Grind (Reface) Valves
      Inspect and Clean Cylinder Head
      Check Cylinder Head Combustion Face Flatness
      Measure Cylinder Head Thickness
      Clean Valve Guides
      Measure Valve Guides
      Knurl Valve Guides
      Clean and Inspect Valve Seats
      Measure Valve Seats
      Grind Valve Seats
      Remove Valve Seat Inserts and Measure Bores in Cylinder Head
      Install Valve Seat Inserts
      Inspect and Clean Cylinder Head Nozzle Bore
      Clean and Inspect Push Rods
      Inspect and Clean Ventilator Outlet Hose
      Clean and Inspect Top Deck of Cylinder Block
      Measure Cylinder Liner Standout (Height Above Block)
      Assemble Valve Assembly
      Install Cylinder Head
      Cylinder Head Cap Screw Types
      Clean, Inspect and Install Cylinder Head Cap Screws
      Torque-Turn Flanged-Head Cap Screws-Grade 180
      Torque-to-Yield Flanged-Head Cap Screws-Grade 180 Marked “Special”
      Install Rocker Arm Assembly
      Complete Final Assembly of Injection Pump Side
      Complete Final Assembly on Exhaust Manifold Side
      Perform Engine Break-In
   Cylinder Block, Liners, Pistons and Rods
      Essential Tools
      Service Equipment and Tools
      Other Material
      Cylinder Block, Liners, Pistons, and Rods Specifications
      Preliminary Liner, Piston and Rod Checks
      Remove Pistons and Connecting Rods
      Measure Cylinder Liner Standout (Height Above Block)
      Remove Cylinder Liners
      Deglaze Cylinder Liners
      Clean Cylinder Liners
      Disassemble Piston/Rod Assembly and Clean Piston
      Visually Inspect Pistons
      Check Piston Compression Ring Groove Wear
      Measure Oil Control Ring Groove
      Install Piston Pin In Piston Pin Bore
      Visually Inspect Cylinder Liners
      Cylinder Liner Manufacturing Date Code Explanation
      Measure Piston Skirt OD
      Measure Cylinder Liner ID
      Measure Cylinder Liner Flange Thickness
      Inspect and Measure Connecting Rod Bearings
      Inspect Connecting Rod and Cap
      Inspect Piston Pins and Bushings
      Remove Piston Pin Bushing
      Clean and Inspect Connecting Rod Pin Bore
      Install Piston Pin Bushing in Rod
      Complete Disassembly of Cylinder Block (If Required)
      Remove and Clean Piston Cooling Orifices
      Inspect and Clean Cylinder Block
      Clean Cylinder Liner O-Ring Bore
      Measure Cylinder Block
      Install Piston Cooling Orifices and Gallery Plugs
      Recheck Cylinder Liner Standout (Height Above Block)
      Install Liner Shims-If Required
      Install Cylinder Liner O-Rings and Packings
      Install Cylinder Liners
      Install Pistons and Connecting Rods
      Torque-Turn Connecting Rod Cap Screws
      Check Engine Rotation for Excessive Tightness
      Complete Final Assembly
   Crankshaft, Main Bearings and Flywheel
      Essential Tools
      Service Equipment and Tools
      Other Material
      Crankshaft, Main Bearings, and Flywheel Specifications
      Crankshaft and Main Bearing Failure Analysis
      Remove Crankshaft Rear Oil Seal and Wear Sleeve (With Oil Seal Housing Installed)
      Install Crankshaft Rear Oil Seal and Wear Sleeve (Without Engine Disassembly)
      Inspect Vibration Damper
      Check Crankshaft End Play
      Remove Damper Pulley
      Remove Crankshaft Front Oil Seal (With Timing Gear Cover Installed on Engine)
      Remove Crankshaft Front Wear Sleeve (With Timing Gear Cover Installed or Removed)
      Install Crankshaft Front Wear Sleeve
      Install Crankshaft Front Oil Seal (With Timing Gear Cover Installed on Engine)
      Replace Timing Gear Cover (6076HRW33, 34, and 35 Engines)-Engine Installed in Vehicle
      Remove Timing Gear Cover
      Inspect and Measure Flywheel
      Check Flywheel Housing Face Runout
      Check Flywheel Face Flatness
      Check Pilot Bearing Bore Concentricity
      Remove Flywheel
      Remove SAE 1 and SAE 2 Flywheel Housing
      Remove SAE 3 Flywheel Housing
      Replace Flywheel Ring Gear
      Replace Rear Oil Seal Housing (6076HRW33, 34, and 35 Engines)-Engine Installed In Vehicle
      Remove Rear Oil Seal Housing and Wear Sleeve (With Engine Disassembled)
      Remove Crankshaft Main Bearings
      Check Main Bearing Clearance
      Remove Crankshaft
      Inspect Crankshaft
      Measure Assembled ID of Bearings and OD of Crankshaft Journals
      Main Bearing Cap Line Bore Specification
      Crankshaft Grinding Guidelines
      Thrust Bearing New Part Specifications
      Crankshaft Grinding Specifications
      Replace (Crankshaft) Oil Pump Drive Gear
      Replace Crankshaft Gear
      Inspect Thrust Bearings
      Remove and Clean Piston Cooling Orifices
      Install Main Bearings and Crankshaft
      Install Crankshaft
      Install Crankshaft Rear Oil Seal Housing
      Check Oil Seal Housing Runout
      Crankshaft Rear Oil Seal and Wear Sleeve Handling Precautions
      Install Crankshaft Rear Oil Seal and Wear Sleeve Assembly
      Install Timing Gear Cover
      Install Front Wear Sleeve
      Install Crankshaft Front Oil Seal (With Timing Gear Cover Installed on Engine)
      Install Damper Pulley Assembly
      Install SAE 3 Flywheel Housing
      Install Flywheel
      Install SAE 1 and SAE 2 Flywheel Housing
      Complete Final Assembly
   Camshaft and Timing Gear Train
      Essential Tools
      Service Equipment and Tools
      Other Material
      Camshaft and Timing Gear Train Specifications
      Check Valve Lift
      Check Camshaft End Play
      Remove Damper Pulley and Timing Gear Cover
      Measure Camshaft Drive Gear-to-Crankshaft Gear Backlash
      Remove Camshaft
      Remove Camshaft Gears
      Measure Thrust Washer Thickness
      Inspect and Measure Camshaft Followers
      Visually Inspect Camshaft
      Measure Camshaft Journal OD and Bushing ID
      Measure Camshaft Lobe Lift
      Install Camshaft Gears
      Service Camshaft Bushings Using JDG602 Adapter Set
      Service Camshaft Bushings Using JDG606 Adapter Set
      Install Camshaft
      Install Thrust Washer and Timing Gear Cover
      Install Crankshaft Front Oil Seal (With Timing Gear Cover Installed on Engine)
      Complete Final Assembly
   Lubrication System
      Other Material
      Lubrication System Specifications
      Drain Engine Oil and Remove Oil Pan
      Oil Filter and Oil Conditioning Housing Assembly
      Remove Oil Filter and Oil Conditioning Housing
      Inspect and Replace Oil Filter Adapter
      Remove, Inspect, and Install Oil Pressure Regulating Valve, Oil Filter Bypass Valve, and Oil Cooler Bypass Valve
      Install Oil Filter and Oil Conditioning Housing
      Remove Engine Oil Cooler
      Clean, Inspect, and Install Engine Oil Cooler
      Check Crankshaft Gear-to-Oil Pump Drive Gear Backlash
      Remove Engine Oil Pump
      Inspect and Clean Oil Pump
      Check Drive Shaft End Play
      Check Drive Shaft Side Movement
      Check Pumping Gear Backlash
      Inspect Oil Pump Drive Gear
      Install Engine Oil Pump
      Install Oil Pan
      Tighten Cap Screws on Front Frame/Oil Sump
   Cooling System
      Essential Tools
      Other Material
      Cooling System Specifications
      Service Equipment and Tools
      Replace Bearings in Standard Duty, Adjustable Fan Drive Assembly
      Replace Bearings in Heavy Duty, Adjustable Fan Drive Assembly
      Replace Bearings in Water Manifold Mounted, Fixed Fan Drive Assembly
      Replace Bearing in Injection Pump Drive Gear Cover Mounted, Fan Drive
      Inspect and Check Belt Tensioner Spring Tension
      Replace Belt Tensioner Assembly
      Remove Water Pump
      Disassemble Engine Water Pump
      Inspect Water Pump Parts
      Assemble Engine Water Pump
      Install Engine Water Pump
      Remove and Test Thermostats
      Install Thermostats
      Remove Water Manifold
      Install Water Manifold
      Remove Coolant Heater-If Equipped
      Install Coolant Heater-If Equipped
      Complete Final Assembly
      Fan Belt Tension Specifications
   Air Intake and Exhaust System
      Essential Tools
      Other Material
      Air Intake and Exhaust System Specifications
      Extending Turbocharger Life
      Remove Turbocharger
      Diagnose Engine Malfunction
      Turbocharger Seven-Step Inspection
      Perform Radial Bearing Clearance Test
      Perform Axial Bearing End Play Test
      Repair Turbocharger
      Disassemble Turbocharger
      Clean and Inspect Turbine and Compressor Housings
      Replace Center Housing Assembly and Assemble Turbocharger
      Prelube Turbocharger
      Install Turbocharger
      Remove, Inspect, and Install Intake Manifold (6076T and 6076H Engines)
      Remove Vertically-Mounted Aftercooler and Intake Manifold (6076A Engines)
      Remove and Disassemble Horizontally-Mounted Aftercooler Assembly (6076A Engines)
      Inspect and Repair Aftercooler (6076A Engines)
      Inspect and Repair Intake Manifold and Air Intake Cover (6076A Engines)
      Install Intake Manifold and Vertically-Mounted Aftercooler (6076A Engines)
      Assemble and Install Horizontally-Mounted Aftercooler Assembly (6076A Engines)
      Remove, Inspect, and Install Exhaust Manifold
   Fuel System
      Essential Tools
      Other Material
      Diesel Fuel System Specifications
      Relieve Fuel System Pressure
      Replace Rectangular Fuel Filter Element
      Replace Fuel Check Valve
      Replace Round Fuel Filter Element
      Identification of Mechanical Fuel Supply Pumps
      Remove Mechanical Fuel Supply Pump
      Test Mechanical Fuel Supply Pump for Leaks
      Disassemble Mechanical (Roller Tappet) Fuel Supply Pump-Nippondenso
      Inspect and Repair Mechanical (Roller Tappet) Fuel Supply Pump Components-Nippondenso
      Assemble Mechanical (Roller Tappet) Fuel Supply Pump-Nippondenso
      Disassemble Mechanical (Flat Plunger) Fuel Supply Pump-Robert Bosch
      Inspect and Repair Mechanical (Flat Plunger) Fuel Supply Pump-Robert Bosch
      Assemble Mechanical (Flat Plunger) Fuel Supply Pump-Robert Bosch
      Install Mechanical Fuel Supply Pump
      Remove and Install Electric Fuel Supply Pump-6076TRW31 Engines
      Clean or Replace Electric Fuel Supply Pump Filter Screen-6076TRW31 Engines
      Repair Aneroid-If Equipped
      Remove Hydraulic Aneroid Activator-If Equipped
      Disassemble and Clean Hydraulic Aneroid Activator Parts-If Equipped
      Assemble and Install Hydraulic Aneroid Activator-If Equipped
      Service Injection Pump Overflow Valve
      Remove and Install Fuel Shutoff Solenoid
      Identification of In-Line Fuel Injection Pumps
      Remove In-Line Fuel Injection Pump
      Install In-Line Fuel Injection Pump
      Remove Rotary Fuel Injection Pump-Stanadyne DB4
      Install Rotary Fuel Injection Pump-Stanadyne DB4
      Remove Fuel Injection Nozzles
      Diagnose Engine Malfunction
      Test Fuel Injection Nozzles
      Perform Opening Pressure Test
      Injection Nozzle Specifications
      Perform Nozzle Leakage Test
      Perform Chatter and Spray Pattern Test
      Disassemble Fuel Injection Nozzle
      Clean and Inspect Fuel Injection Nozzle Assembly
      Perform Nozzle Slide Test
      Clean Spray Orifices
      Inspect Nozzle Holder
      Inspect Gland Nut
      Assemble Fuel Injection Nozzle
      Adjust Fuel Injection Nozzles
      Inspect and Clean Cylinder Head Nozzle Bore
      Inspect and Clean Nozzle Seating Surface
      Install Fuel Injection Nozzles
   Engine Tune-Up and Break-In
      Effects of Altitude and Temperature on Engine Performance
      Preliminary Engine Testing
      General Tune-Up Recommendations
      Dynamometer Test
      Engine Break-In Guidelines
      Perform Engine Break-In
      Check Crankcase Ventilation System
      Check Air Intake System
      Check Exhaust System
      Check and Service Cooling System
      Check Electrical System
   Engine System Operation and Test
      Essential Tools
      Engine Test Specifications
      Engine-Sectional View
      General Engine Description
      How the Lubrication System Works
      How the Cooling System Works
      Head Gasket Joint Construction and Operation
      Diagnosing Head Gasket Joint Failures
      Head Gasket Inspection and Repair Sequence
      Diagnosing Engine Malfunctions
      Test Engine Compression Pressure
      Check Engine Oil Pressure
      Pressure Test Cooling System and Radiator Cap
      Inspect Thermostat and Test Opening Temperature
   Air Intake System Operation and Test
      Essential Tools
      Air Intake and Exhaust System Test Specifications
      Diagnosing Air Intake Malfunctions
      How the Air Intake and Exhaust System Works
      Air Cleaner Operation
      Air Filter Restriction Indicator Switch Test
      Diagnosing Turbocharger Malfunctions
      How the Turbocharger Works
      How the Turbocharger is Lubricated
      How the Aftercooler Works-6076A Engines
      Check Intake Manifold Pressure (Turbocharger Boost)
   Fuel System Operation and Test
      Essential Tools
      Fuel System Test Specifications
      Check and Adjust Rotary Fuel Injection Pump Dynamic Timing Using JT07158 TIME TRAC Kit
      Fuel System Operation-In-Line Fuel Injection Pump
      Fuel System Operation-Rotary Fuel Injection Pump
      Diagnose Fuel System Malfunctions
      Mechanical Fuel Supply Pump Operation
      Diagnosing Mechanical Fuel Supply Pump Malfunctions
      Test Mechanical Fuel Supply Pump for Leaks
      Check Mechancial Fuel Supply Pump Operation
      Service Mechanical Fuel Supply Pump
      Electric Fuel Supply Pump Operation
      Diagnose Electric Fuel Supply Pump Malfunction
      Test Electric Fuel Supply Pump for Output Pressure and Flow
      Fuel Shut-Off Solenoid Operational Check
      Fuel Shut-Off Solenoid Resistance Test
      Fuel Shut-Off Solenoid Linkage Adjustment
      Rectangular Fuel Filter Operation
      Round (Final) Fuel Filter Operation
      Bleed the Fuel System
      Diagnose In-Line Fuel Injection Pump Malfunctions
      Line Fuel Injection Pump Operation
      Check Fast Idle Speed-In-Line Fuel Injection Pump
      Check and Adjust Slow Idle Speed-In-Line Fuel Injection Pump
      Rotary Fuel Injection Pump Operation-Stanadyne DB4
      Diagnose Engine Malfunction
      Check and Adjust Engine Speeds on Rotary Pump-Stanadyne DB4
      How the Aneroid Works (If Equipped)-In-Line Injection Pumps
      Diagnose Aneroid Malfunction
      How the Hydraulic Aneroid Activator Works (If Equipped)
      Diagnose Malfunctions-Hydraulic Aneroid Activator
      Fuel Injection Nozzles-General Information
      Fuel Injection Nozzle Operation
      Diagnose Malfunctions-Fuel Injection Nozzle
      Test Fuel Injection Nozzles (Engine Running)
      Fuel Drain Back Test Procedure
      Instructions for Changing 6076 Gen Set Engine Rated Speed from 1800 RPM (60 Hz) to 1500 RPM (50 Hz)-Mechanical Governor
      Change Engine Rated Speed from 1800 RPM to 1500 RPM and Adjust Droop
   Dealer Fabricated Tools
      How to Make Tools
      Cylinder Liner Holding Fixture

4. Operate and Maintenance manual (EM42D-1-1)
Format: PDF, 208 pages
Language: English
Table of Contents:
   INTRODUCTION
   INDEX
      SAFETY
      SAFETY SIGNS
      OPERATOR'S STATION
      BREAK-IN
      PRE-START INSPECTION
      OPERATING THE ENGINE
      DRIVING THE MACHINE
      OPERATING THE MACHINE
      TRANSPORTING
      MAINTENANCE
      MAINTENANCE - EVERY 10 HOURS OR DAILY
      MAINTENANCE - EVERY 100 HOURS
      MAINTENANCE - EVERY 250 HOURS
      MAINTENANCE - EVERY 500 HOURS
      MAINTENANCE - EVERY 1000 HOURS
      MAINTENANCE - EVERY 2000 HOURS
      MAINTENANCE - EVERY 3000 HOURS
      MAINTENANCE - AS REQUIRED
      MAINTENANCE
      STORAGE
      TROUBLESHOOTING
      SPECIFICATIONS
      MACHINE NUMBERS

5. Parts Catalog (LX150-2+P42D-1-2)
Format: PDF, 602 pages
Language: English