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Part of the Hitachi Repair Manuals.
All 878 pages of this Hitachi EX150LC-5, EX160LC-5 Technical Manual PDF focus on one job: putting your hydraulic excavator back to factory spec. You get complete electrical circuit diagrams with cab, engine, and relay harness layouts, hydraulic schematics for the main and pilot circuits, and Dr.EX fault code tables that turn a blinking monitor into an actual diagnosis. Inside: a full troubleshooting section that walks engine, swing, travel, and front attachment problems from symptom to failed part, plus torque charts and step-by-step teardown procedures for every major component. Set the main relief valve to 34.3 MPa and confirm main pump flow at 126 L/min before you condemn the pump. No more chasing wiring faults with a multimeter and a prayer. Bookmarked with a live text layer; search any spec, jump straight to your system, and get back on the sticks.
What's Inside This Hitachi EX150LC-5 / EX160LC-5 Manual
| System | Pages | Key Topics |
|---|---|---|
| Electrical Circuit Diagrams | 1-10 | Electrical Circuit Diagram, Connectors, Cab Harness, Engine Harness, Relay Harness, A/C Harness, Hydraulic Circuit Diagram |
| Safety | 11-36 | Recognize Safety Information, Understand Signal Words, Follow Safety Instructions, Prepare for Emergencies, Wear Protective Clothing, Protect Against Noise, Inspect Machine |
| General | 37-52 | Specification |
| System | 53-88 | Control System, Hydraulic System |
| Component Operation | 89-160 | Pump Device, Swing Device, Control Valve, Pilot Valve, Travel Device, Others |
| Operational Performance Test | 161-214 | Introduction, Engine Test, Excavator Test, Component Test |
| Troubleshooting | 215-383 | Diagnosing Procedure, Component Layout, Troubleshooting a, Troubleshooting B, Troubleshooting C, Electrical System Inspection |
| General Information | 384-397 | Tightening Torque (Bleeding Air From Hydraulic System, Floating Seal Precautions, Maintenance Standard Terminology, Specifications, Torque Chart, Service Recommendations for Split Flange, Nut and Bolt Lockings, Piping Joint, O-Ring Seal Joint, Screwed-In Connection, Seal Tape Application, Low-Pressure-Hose Clamp Tightening Torque, Connecting Hose) |
| Upperstructure | 398-549 | Cab, Counterweight, Main Frame, Pump Device, Control Valve, Swing Device, Pilot Valve, Pilot Shut-Off Valve |
| Undercarriage | 550-641 | Swing Bearing, Travel Device, Center Joint, Track Adjuster, Front Idler, Upper and Lower Roller |
| Front Attachment | 642-671 | Cylinder, Maintenance Standard, Standard Dimensions for Arm and Bucket Connection |
| Engine and Accessory | 672-878 | Maintenance, Engine Assembly 1, Engine Assembly 2, Engine Assembly 3, Lubricating System, Cooling System, Fuel System, Turbocharger |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Main pump max. flow | 126 L/min | p. 44 |
| Pilot pump max. flow | 23.0 L/min | p. 44 |
| Main relief pressure | 34.3 MPa | p. 44 |
| Overload relief pressure (Boom raise/lower, Arm roll-in, Bucket roll-in) | 37.3 MPa | p. 44 |
| Injection pressure | 18.1 MPa | p. 42 |
| Nozzle opening pressure | 17.2 MPa (175 kgf/cm2) | p. 213 |
| Engine oil level indicator troubleshooting | Lower than 8 mm below LOW level | p. 320 |
| Operating Weight | 15000 kg | p. 39 |
| Engine Rated Output | 74 kW | p. 39 |
| Overload Relief Pressure (Arm roll-out, Bucket roll-out) | 39.2 MPa | p. 44 |
| Swing Relief Pressure | 31.9 MPa | p. 45 |
| Travel Relief Pressure | 35.3 MPa | p. 45 |
Hitachi EX150LC-5 / EX160LC-5 Common Problems This Manual Covers
Hitachi EX150LC-5 all hydraulic functions weak and slow, bucket digs without power
Connect a pressure gauge and stall the boom against relief. Main relief pressure should read 34.3 MPa, listed on page 44. If low, adjust the main relief valve and retest. If pressure checks good but functions stay weak, run the pump flow test in the performance test section starting on page 161; main pump max flow is 126 L/min.
Manual Section: Actuator Control System TroubleshootingEngine lacks power, will not reach full RPM, black smoke under heavy digging load
Check the fuel filter and air intake restriction first, then pop-test the injectors. Nozzle opening pressure should be 17.2 MPa (175 kgf/cm2) per the test spec on page 213. Replace any weak or dribbling nozzles and torque the nozzle connectors to 6.0 - 8.0 kg-m (43.4 - 57.8 lb.ft) as listed on page 811.
Manual Section: Engine TroubleshootingUpper structure swings slow in both directions, drifts past the stop point on slopes
Test swing relief pressure using the excavator performance test procedure starting on page 161. Spec is 31.9 MPa, listed on page 45. If pressure is low, adjust the swing relief valve and retest. If pressure checks good, inspect the swing motor seals for internal leakage and verify swing brake release pilot pressure.
Manual Section: Swing System TroubleshootingMachine pulls to one side during straight travel, one track noticeably slower
Swap the travel crossover lines at the center joint to confirm whether the fault follows the motor or stays with the circuit. Measure travel relief pressure; spec is 35.3 MPa on page 45. If pressure is correct but the track still lags, inspect the center joint seals and travel motor per the undercarriage section starting on page 550.
Manual Section: Travel System TroubleshootingEngine oil level indicator stays lit at startup even after topping off oil
Park on level ground, shut the engine down, and wait several minutes before checking the dipstick. The indicator trips when oil sits lower than 8 mm below the LOW mark, per the troubleshooting chart on page 320. Top off to the full mark, and if the light stays on, test the level switch circuit against the wiring diagram on page 1.
Manual Section: Monitor and Indicator Troubleshooting p. 320Frequently Asked Questions
How do I reset the error codes on the Hitachi EX150LC-5?
The controller automatically diagnoses and memorizes malfunctions. To clear these, you must perform a 'RETRIAL' using the Dr.EX diagnostic tool to erase the accumulated fault codes from the controller memory and confirm if any fault codes are indicated after the retrial. p. 219
What is the torque specification for the main pump delivery pressure sensor?
The tightening torque for the pressure sensor on the main pump is 118 N·m (12 kgf·m, 88 lbf·ft) using a 27 mm wrench. p. 419
What is the standard valve clearance for the 4BG1 and 6BG1 engines?
The standard valve clearance for both intake and exhaust valves on the 4BG1 and 6BG1 engines is 0.40 mm (0.0157 in) when the engine is cold. p. 743
What is the tightening torque for the main bearing cap bolts?
The main bearing cap bolts should be tightened to a torque of 23–25 kg·m (166–181 lb·ft). p. 777
What is the standard injection timing for the 4BG1T engine?
The standard injection timing for the 4BG1T engine is 12 degrees before Top Dead Center (TDC). p. 716
What do I get after purchasing this Hitachi EX150LC-5, EX160LC-5 manual?
Immediate download of the complete 878-page searchable Technical Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Is this Hitachi EX150LC-5, EX160LC-5 Technical Manual printable?
Zero restrictions. The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
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