Part of the Hitachi Repair Manuals.
This is the factory set for the Zaxis ZX160LC, ZX180LC and ZX180LCN: the Workshop Manual (W1F1E-01) for teardown of the swing device, main pump, travel motors, undercarriage and front attachment, the Troubleshooting and Operational Principle technical volumes, the full Isuzu 4BG1 engine manual (AA-4BG1TCG-01, CC-4BG1TCG, BB-4BG1TRG), and fold-out hydraulic and electrical circuit sheets per model. What makes it worth the money is the wear judgement tables: every inspection item prints the new value next to the throw-away limit. Swing bearing play 0.2 to 1.25 mm new against a 2.0 to 3.05 mm limit. Compression 3.04 MPa nominal against 2.5 MPa repair limit. You measure, you compare, you know whether to buy parts.
What's Inside This Hitachi Zaxis ZX160LC, Zaxis ZX180LC, Zaxis ZX180LCN Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Workshop Manual: General | 1-58 | Precautions for Disassembling and Assembling, Maintenance Standard Terminology, Tightening Torque Specification, Painting |
| Workshop Manual: Upperstructure | 59-250 | Cab Removal and Cab Glass Dimensions, Swing Device, Swing Reduction Gear, Main Pump, Control Valve, Pilot Valve |
| Workshop Manual: Undercarriage | 251-380 | Swing Bearing, Travel Device, Track Adjuster, Idler, Track Roller, Sprocket, Track Chain |
| Workshop Manual: Front Attachment | 381-428 | Front Attachment Removal, Arm and Bucket Connection Dimensions, Cylinders, Bushings and Pins, Maintenance Standards |
| Engine and Accessory: General Information | 429-456 | General Repair Instructions, Manual Format Notes, Engine Identification, Service Data Conventions |
| Engine: Maintenance | 457-472 | Periodic Service Items, Adjustment Procedures, Inspection Intervals |
| Engine Assembly Disassembly | 473-540 | Cylinder Head, Pistons and Connecting Rods, Crankshaft, Camshaft, Timing Gear, Flywheel |
| Engine: Lubricating, Cooling, Fuel and Turbocharger | 541-572 | Oil Pump and Relief Valve, Water Pump and Thermostat, Injection Pump and Nozzles, Turbocharger Overhaul |
| Engine Electricals | 573-600 | Starter Motor, Alternator, Glow Plug System, Sensors and Switches |
| Engine Troubleshooting | 601-626 | Hard Starting, Low Power, Smoke, Overheating, Oil Consumption Diagnosis |
| Repair Standards and Conversion Table | 627-652 | Inspection Items with Assembly Standards and Limit Values for Aa-4BG1TCG-01, Cc-4BG1TCG and Bb-4BG1TRG, Unit Conversion |
| Technical Manual: Introduction and Safety | 653-687 | Manual Composition, Safety Precautions, How to Read the Volumes |
| Operational Performance Test | 688-791 | Preparation for Performance Tests, Engine Test, Excavator Test, Travel Speed, Track Revolution Speed, Component Test |
| Troubleshooting | 792-997 | Diagnosing Procedure, Fault Code List, Troubleshooting a and B Procedures, Electrical System Inspection |
| Operational Principle: General | 998-1023 | Specification, Working Range, Component Specifications, Engine and Accessories |
| Operational Principle: System | 1024-1101 | Control System Outline, Engine Control, Hydraulic System, Electrical System Main Circuit |
| Operational Principle: Component Operation | 1102-1217 | Pump Device and Main Pump, Pilot Valve, Control Valve, Swing Device, Travel Device, Signal Control Valve |
| Circuit Diagrams | 1218-1224 | Hydraulic Circuit Sheets per Model, Cab Harness, Connector Chart, Engine Harness, Monitor Harness, Standard Electrical Sheet |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Swing bearing play | 0.2 to 1.25 mm | p. 693 |
| Swing bearing play - allowable limit | 2.0 to 3.05 mm | p. 693 |
| Mistrack in fast and slow travel modes | 200 mm or less per 20 m | p. 693 |
| Travel motor leakage | 0 mm in 5 min | p. 693 |
| Swing motor leakage with the bucket loaded | 0 mm in 5 min | p. 693 |
| Travel speed - fast | 14.2 +/- 1.0 sec per 20 m | p. 693 |
| Track revolution speed - fast | 16.1 +/- 1.0 sec per 3 revolutions | p. 693 |
| Swing speed with an empty bucket | 13.3 +/- 1.0 sec per 3 revolutions | p. 693 |
| Swing function drift with an empty bucket | 1260 mm or less per 180 degrees | p. 693 |
| Boom raise cycle time, 2.58 m arm and 0.60 m3 bucket | 3.0 +/- 0.3 sec | p. 693 |
| Maximum swingable slant angle, bucket loaded | 22 degrees or more | p. 693 |
| Engine compression pressure after warm-up | 3.04 MPa (31 kgf/cm2, 440 psi) | p. 692 |
| Engine compression pressure - repair limit | 2.5 MPa (26 kgf/cm2, 370 psi) | p. 628 |
| Lubricating oil pressure - nominal | 290 to 390 kPa (3.0 to 4.0 kgf/cm2, 43 to 57 psi) | p. 638 |
| Lubricating oil pressure - repair limit | 196 kPa (2.0 kgf/cm2, 28 psi) | p. 638 |
| Nozzle injection pressure | 18.14 MPa (185 kgf/cm2, 2630 psi) | p. 692 |
| Valve clearance inlet and exhaust, engine cold | 0.4 mm | p. 692 |
| Slow idle speed | 950 +150 / -100 min-1 | p. 692 |
| Hydraulic oil temperature for measurement | 50 +/- 5 C (122 +/- 9 F) | p. 692 |
| Operating weight | 15600 kg (34400 lb) ZX160LC; 17800 kg (39200 lb) ZX180LC; 17500 kg (38300 lb) ZX180LCN | p. 1006 |
Hitachi Zaxis ZX160LC, Zaxis ZX180LC, Zaxis ZX180LCN Common Problems This Manual Covers
Machine pulls to one side when travelling and you cannot tell if it is a motor, a brake valve or just track tension.
Run the tests in the Operational Performance Test section at 50 C hydraulic oil: mistrack must be 200 mm or less per 20 m, fast travel 14.2 sec per 20 m, and the travel motor leakage check must show 0 mm movement in 5 minutes. The results point you at motor, valve or adjustment before you pull anything apart.
Manual Section: Operational Performance Test p. 688Hard starting, white or black smoke, and low power on the 4BG1 with no obvious cause.
The Engine Troubleshooting section walks hard starting, smoke and low power symptom by symptom. Start with a compression test: 3.04 MPa is nominal after warm-up, 2.5 MPa is the repair limit, and the injection pump and nozzle checks follow from there.
Manual Section: Engine Troubleshooting p. 601Upperstructure drifts on a slope or creeps after you release the swing lever.
The performance test gives hard pass/fail numbers: swing drift 1260 mm or less per 180 degrees, swing motor leakage 0 mm in 5 minutes with the bucket loaded, and the machine should hold on a 22 degree slant. Fail those and the Upperstructure section covers swing device and reduction gear teardown.
Manual Section: Workshop Manual: Upperstructure p. 693Low oil pressure warning and you need to know whether it is the sender, the relief valve or a worn bottom end.
Nominal pressure is 290 to 390 kPa with a 196 kPa repair limit. The lubricating system section covers oil pump and relief valve inspection, and the repair standards table gives the bearing clearance limits that tell you if the bottom end is the real problem.
Manual Section: Engine: Lubricating, Cooling, Fuel and Turbocharger p. 638Frequently Asked Questions
My swing bearing feels loose - does this manual tell me if it actually needs replacing?
Yes, and this is exactly where the book earns its keep. The Undercarriage section gives the measuring procedure for swing bearing axial play with a normal value of 0.2 to 1.25 mm and an allowable limit of 2.0 to 3.05 mm. If your dial indicator reads inside the limit, you keep running it. Bearing replacement and mounting bolt work are covered in the same section. p. 693
Does it cover the Isuzu engine rebuild, or just the excavator side?
The engine volumes are the complete Isuzu manual for the 4BG1 variants fitted to these machines: cylinder head, pistons and rods, crankshaft, injection pump, turbocharger overhaul, plus the repair standards table with assembly values and limits for each engine code. Key numbers are in there: compression 3.04 MPa after warm-up with a 2.5 MPa repair limit, valve clearance 0.4 mm cold on inlet and exhaust, nozzle opening pressure 18.14 MPa. p. 473
The monitor is showing a fault code - can I diagnose it with this manual?
Yes. The Troubleshooting volume has the fault code list plus the A and B diagnosing procedures that walk you from a code or a symptom to the failed component, with electrical system inspection steps. The circuit diagram sheets cover the cab harness, engine harness, monitor harness and a connector chart, so you can pin-test instead of guessing and swapping parts. p. 792
Which models exactly, and are the specs really split per model?
ZX160LC, ZX180LC and ZX180LCN. Where the machines differ, the book says so: operating weights are 15600 kg, 17800 kg and 17500 kg respectively, and arm length and travel figures differ between the ZX160LC and the two 180s. The hydraulic circuit sheets are printed per model, so you read the diagram for your serial machine, not a generic one. p. 1006
Is this a searchable PDF?
It is a scan of the printed factory book run through OCR, so there is a text layer and searching works most of the time, but on dense spec tables and the fold-out circuit sheets accuracy is not perfect. Treat search as a shortcut and the bookmarks and section structure as the reliable way in. All diagrams and photos are the original factory pages. p. 1
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