Part of the Hitachi Repair Manuals.
All 718 pages of this Hitachi Zaxis 160W, Zaxis 210W workshop manual PDF focus on one job: complete teardown and repair of your wheeled hydraulic excavator, from cab to counterweight. You get full electrical circuit diagrams tracing the battery, starter, glow relay, main controller, and fuse box, plus hydraulic schematics mapping the main pump, control valve, swing motor, and every cylinder on the front attachment. Inside: step-by-step procedures for the travel motor, swing bearing, center joint, transmission, axles, and brake valve, and a full engine section running from assembly through turbocharger, fuel system, and troubleshooting. Torque the control valve mounting bolts to 210 N-m (152 lbf-ft), and swap the pump suction hose every 2 years per the maintenance chart. No more chasing wiring faults with a multimeter and a prayer. Bookmarked and keyword-searchable; jump straight to the spec and get your machine back on its wheels.
What's Inside This Hitachi ZAXIS 160W, ZAXIS 210W Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 3-34 | - |
| General | 35-60 | Precautions for Disassembling and Assembling, Tightening, Painting, Bleeding Air From Hydraulic Oiltank |
| Upperstructure | 61-262 | Cab, Counterweight, Main Frame, Pump Device |
| Undercarriage | 263-404 | Swing Bearing, Travel Motor, Center Joint, Transmission |
| Front Attachment | 405-472 | Cylinder, Hose-Rupture Safety Valve, Operate-Check Valve |
| Engine and Accessory | 473-700 | General Information, Maintenance, Engine Assembly 1, Engine Assembly 2 |
| Revision Request Form | 701-702 | Company Name, Model, Publication Number, Page Number, Comments |
| Circuito Elettrico (1) | 703-714 | Battery, Starter, Alternator, Glow Relay, Main Controller, Fuse Box |
| Circuito Elettrico (2) | 715 | Starter Switch, Wiper Motor, Horn, Combination Switch, Monitor, Pressure Switch |
| Circuito Idraulico Full Option | 716 | Main Pump, Control Valve, Swing Motor, Travel Motor, Boom Cylinder, Arm Cylinder |
| Hydraulic Circuit Diagram, Zaxis 210W (Standard) | 717 | Drawing Wcla-0567-Zx, Standard Machine Configuration, Main Pump and Control Valve Circuit, Swing and Travel Motors, Boom/Arm/Bucket Cylinders, Relief Valve Set Pressures (See Technical Manual Table) |
| Hydraulic Circuit Diagram, Zaxis 210W (Full Option) | 718 | Drawing Wcla-0568-Zx, Full Option Configuration, Main Pump and Control Valve Circuit, Swing and Travel Motors, Auxiliary/Attachment Lines, Relief Valve Set Pressures (See Technical Manual Table) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Fuel hose (Fuel tank to filter) replacement interval | Every 2 years | p. 53 |
| Fuel hose (Fuel tank to injection pump) replacement interval | Every 2 years | p. 53 |
| Pump suction hose replacement interval | Every 2 years | p. 53 |
| Control valve mounting bolts | 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft) | p. 117 |
| Fuel filter additional turn | 2/3 of a turn | p. 504 |
| Drain Plug Torque | 9-15 N·m (0.9-1.5 kgf·m/7-11 lb·ft) | p. 506 |
| Engine Oil Viscosity (Ambient -30°C to -15°C) | SAE 10W | p. 517 |
| Engine Oil Viscosity (Multi-grade -30°C to 30°C) | SAE 10W-30 | p. 517 |
| Engine Oil Viscosity (Multi-grade -15°C to 30°C) | SAE 15W-40, 20W-40, 20W-50 | p. 517 |
| Lubricating Oil Volume (Oil Pan) | 21.5 L | p. 45 |
Hitachi ZAXIS 160W, ZAXIS 210W Common Problems This Manual Covers
Hitachi Zaxis 160W hydraulics slow and weak after hose replacement, boom drops and cylinders creep
Bleed air from the hydraulic pump case and the travel and swing motors before loading the circuit. Cycle each cylinder slowly to full stroke several times at low idle. While you are in there, inspect the pump suction hose; the schedule on page 53 calls for replacing it every 2 years.
Manual Section: Bleeding Air from Hydraulic SystemEngine cranks but hard to start and runs rough after fuel filter change
Check the fuel filter seating first. Coat the new element gasket with clean fuel, spin it on until the gasket contacts, then tighten an additional 2/3 of a turn with the filter wrench per page 504. Bleed the lines, and torque the drain plug to 9-15 N·m (7-11 lb·ft) as listed on page 506.
Manual Section: Engine and Accessory p. 504Hydraulic oil leaking from hose fittings and O-rings again right after hose replacement
Release residual circuit pressure before cracking any fitting. Replace every O-ring you disturb; a reused or pinched O-ring will weep again within hours. Seat each ring square in its groove before tightening the fitting. If the leak is at the control valve body, torque the mounting bolts to 210 N·m (152 lbf·ft), listed on page 117.
Manual Section: Upperstructure p. 117Engine turns over slowly and will not start in cold weather below freezing
Check the engine oil grade first; heavy summer oil drags the starter in the cold. Fill with SAE 10W for -30°C to -15°C ambient, or run SAE 10W-30 multi-grade, good from -30°C to 30°C, per the chart on page 517. Load-test the battery and clean the ground connections before condemning the starter.
Manual Section: Engine and Accessory p. 517Engine burning oil between services, blue smoke on startup and under load
Verify the crankcase is not overfilled; the oil pan takes 21.5 L, and extra oil gets pushed past the rings and burned. Confirm viscosity matches the season, SAE 15W-40, 20W-40, or 20W-50 for -15°C to 30°C ambient per the chart on page 517. Check the turbocharger oil drain line for restriction before pulling the head.
Manual Section: Engine TroubleshootingFrequently Asked Questions
What are the torque specifications for the swing device mounting bolts on a Hitachi ZAXIS 160W/210W?
The torque specification for the swing device mounting bolts is 500 N·m (51 kgf·m, 370 lbf·ft). p. 45
How do I bleed air from the hydraulic system after replacing the hydraulic pump?
To bleed air from the hydraulic pump, remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. Temporarily tighten the plug, start the engine, and run at slow idle speed. Slightly loosen the plug to bleed air until hydraulic oil oozes out, then securely tighten the plug. p. 38
What is the standard valve clearance for the 6BG1T engine?
The standard valve clearance for both intake and exhaust valves on the 6BG1T engine is 0.40 mm (0.016 in) when the engine is cold. p. 508
What is the required gear oil capacity for the transmission?
The required gear oil capacity for the transmission is 2.9 L (0.8 US gal.). p. 308
What is the replacement interval for the brake hose on the undercarriage?
The brake hose on the undercarriage should be replaced every 1 year. p. 53
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