Part of the Hitachi Repair Manuals.
Engine, swing, travel, front attachment and electrical systems are traced end to end in this 362-page Hitachi Zaxis 160LC, 180LC and 180LCN technical manual PDF (OEM ID TT1F1E-02), the troubleshooting and performance-test volume for these excavators. Roughly half the book is diagnosis, split three ways: fault codes read through Dr. EX, operational status symptoms, and monitor faults, with sensor voltages and adjustment data to check your readings against. Hydraulic circuit schematics and electrical wiring diagrams close out the volume, showing pilot and main circuit routing plus harness layouts. On the 160LC, main relief for boom, arm and bucket sets at 34.3 MPa (4980 psi), and neutral pump delivery should sit at 1.4 MPa (200 psi) before you condemn a pump. One wrong guess on a travel motor means two teardowns. Bookmarked, text-searchable and bought once, this copy stays yours for as long as you run the machine.
What's Inside This Hitachi ZAXIS 160LC, ZAXIS 180LC, ZAXIS 180LCN Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Manual | 1-2 | Operational Performance Test, Troubleshooting, Operational Principle, Workshop Manual |
| Introduction | 3-6 | Manual Composition, Additional References, Page Numbering, Safety Alert Symbols, Units of Measurement |
| Safety | 7-38 | Emergency Procedures, Protective Clothing, Machine Inspection, Safe Maintenance, Fire Prevention, High-Pressure Fluid Safety |
| Operational Performance Test | 39-144 | Operational Performance Test Introduction, Operational Performance Test Standard, Engine Test, Excavator Test, Component Test, Adjustment |
| General Troubleshooting | 145-172 | Diagnosing Procedure, Dr. EX Operation, Fault Code List, Adjustment Data List |
| Component Layout | 173-190 | Main Component Layout, Electrical Component Layout, Control Valve Components, Signal Control Valve Port Location |
| Troubleshooting a (Fault Code Diagnosis) | 191-200 | Troubleshooting Procedure, Fault Code List, Sensor Voltage, EC Sensor, Engine Control Dial |
| Troubleshooting B (Operational Status Diagnosis) | 201-257 | Engine System Troubleshooting, Actuator System Troubleshooting, Front Attachment System, Swing System, Travel System |
| Troubleshooting C (Monitor Diagnosis) | 258-316 | Front Attachment System, Swing System, Air Conditioner Malfunction, Coolant Temperature Gauge, Fuel Gauge, Hour Meter |
| Electrical System Inspection | 317-334 | Inspection Precautions, Fuse Inspection, Fusible Link Inspection, Battery Voltage Check, Continuity Check, Test Harness |
| ICX (Information Controller) | 335-353 | Daily Report Data, Frequency Distribution, Cumulative Operation Hours, Alarm List, Satellite Communication System |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Main Relief Valve Set Pressure (Boom, Arm, and Bucket) | 34.3 +2.0/-0 MPa (350 +20/-0 kgf/cm², 4980 +284/-0 psi) | p. 46 |
| Main Pump Delivery Pressure (In neutral) | 1.4 ±0.5 MPa (14 ±5 kgf/cm², 200 ±71 psi) | p. 45 |
| Main pump delivery pressure | 50 ± 5 °C (122 ± 9 °F) | p. 111 |
| Rocker arm adjusting screw lock nut torque | 25.5±4.9 N⋅m (2.6±0.5 kgf⋅m, 18.8±3.6 lbf⋅ft) | p. 73 |
| Delivery valve holder torque | 39 to 44 N⋅m (4 to 4.5 kgf⋅m, 28.9 to 32.6 lbf⋅ft) | p. 76 |
| Main relief valve set pressure adjustment torque | 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) | p. 114 |
| Main pump casing air bleed plug torque | 19 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft) | p. 122 |
| Main relief valve set pressure adjustment lock nut torque | 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) | p. 114 |
| Maximum flow rate adjustment screw torque | 40 N⋅m (4 kgf⋅m, 29.5 lbf⋅ft) | p. 127 |
| Pilot pressure characteristics adjustment screw torque | 10 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft) | p. 127 |
| Engine Compression Pressure | 3.04 MPa (31 kgf/cm², 440 psi) | p. 43 |
| Valve Clearance (IN, EX) | 0.4 mm | p. 73 |
Hitachi ZAXIS 160LC, ZAXIS 180LC, ZAXIS 180LCN Common Problems This Manual Covers
Hitachi Zaxis 160LC boom, arm, and bucket cylinders slow with weak actuator power under load
Measure main relief valve set pressure for boom, arm, and bucket against 34.3 +2.0/-0 MPa (4980 +284/-0 psi) on the ZAXIS160LC, per page 46. If it reads low, adjust the main relief valve following page 114 and torque the adjusting lock nut to 19.5 N·m (14.5 lbf·ft). Recheck pressure before pulling any cylinders.
Manual Section: Front Attachment System Troubleshooting p. 46All actuator speeds slow across boom, arm, bucket, swing, and travel functions
Measure main pump delivery pressure with the controls in neutral; on the ZAXIS160LC it should read 1.4 ±0.5 MPa (200 ±71 psi) per page 45. If pressure checks out, inspect the pump maximum flow rate adjustment screw following page 127 and torque it to 40 N·m (29.5 lbf·ft).
Manual Section: All Actuator System Troubleshooting p. 45Excavator swing speed slow or swing not moving at all during normal operation
Check the swing relief valve first. When reinstalling it, torque the valve to 176 N·m (130 lbf·ft) and the piston plug to 118 N·m (88 lbf·ft), as shown on page 115. Inspect the swing motor drain hose plug and torque it to 39 N·m (29 lbf·ft) following page 129.
Manual Section: Swing/Travel/Other System Troubleshooting p. 115Machine mistracks during straight travel or one track not rotating at all
Check the travel relief valve on the ZAXIS180LC and 180LCN and torque it to 450 N·m (330 lbf·ft) on reinstall, per page 117. Inspect the travel motor drain hose plug and torque it to 78 N·m (58 lbf·ft) following page 134. On the ZAXIS160LC, use the travel relief values on page 116 instead.
Manual Section: Swing/Travel/Other System Troubleshooting p. 117Diesel engine does not start, stalls after starting, or hunts at steady engine speed
Test compression on each cylinder against 3.04 MPa (440 psi), following page 43. Check nozzle injection pressure against 18.14 MPa (2630 psi) and confirm injection timing at 9° before TDC. Then set valve clearance to 0.4 mm (IN, EX) on page 73 and torque the rocker arm lock nuts to 25.5 ± 4.9 N·m.
Manual Section: Engine System Troubleshooting p. 43Coolant temperature gauge pointer does not move, swings over scale, or moves unstably
Inspect the fuses and fusible links first, then check battery voltage. Run continuity checks on the gauge circuit using the test harness, following the Electrical System Inspection procedures starting on page 317. Confirm the gauge reads correctly before chasing a cooling problem that may not exist.
Manual Section: Coolant Temperature Gauge MalfunctionFrequently Asked Questions
How do I clear Hitachi Zaxis error codes?
To clear fault codes, connect the Dr. EX tool to the machine. If a fault code is displayed, delete it once and retry the self-diagnosis. If the code appears again, refer to the Troubleshooting A section. After the machine trouble has been corrected, the fault code will be automatically deleted by the built-in diagnosing function. p. 150
Why is the excavator losing hydraulic power or moving slowly?
Slow actuator speeds can be caused by a reduction in pump 1 and 2 flow rates or a faulty pilot system. First, check the primary pilot pressure. If it is normal, monitor the actual engine speed and pump control pressure. If the pressure is 0 MPa when control levers are in neutral, it may indicate a faulty torque control solenoid valve or a bound control valve spool. p. 252
What is the standard valve clearance for the engine on the Hitachi ZAXIS 160LC, 180LC, 180LCN excavator?
The standard valve clearance for both intake (IN) and exhaust (EX) valves is 0.4 mm. This measurement should be performed with the engine cold. p. 43
How do I adjust the main relief valve set pressure on a Hitachi ZAXIS 160LC, 180LC, 180LCN excavator?
To adjust the main relief valve set pressure, loosen the lock nut (1) using a 17 mm wrench. Turn the adjusting screw (2) to adjust the pressure, then retighten the lock nut to 19.5 N·m (2 kgf·m, 14.5 lbf·ft). Recheck the set pressures after adjustment. p. 114
What is the standard injection timing for the engine?
The standard injection timing for the engine is 9 degrees before Top Dead Center (TDC). p. 43
Do I get instant access to this Hitachi 160LC Technical Manual?
A single searchable PDF file of 362 pages, downloadable right after payment. Nothing ships, nothing waits in the mail.
Does this Hitachi 160LC manual allow printing?
You can. Print the sections you want for your own use and keep the file as your backup.
Reviews
There are no reviews yet.