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 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 |
