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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