Hitachi Zaxis 160LC 180LC 180LCN Excavator Operational Principle+Troubleshooting+Workshop Manual
FILE DETAILS:
Hitachi Zaxis 160LC 180LC 180LCN Excavator Operational Principle+Troubleshooting+Workshop Manual
This Listing includes all of the manuals mentioned below:
- Hitachi Zaxis 160LC 180LC 180LCN Excavator Operational Principle Technical Manual
- Hitachi Zaxis 160LC 180LC 180LCN Excavator Troubleshooting Technical Manual
- Hitachi Zaxis 160LC 180LC 180LCN Excavator Workshop Manual
- Hitachi Zaxis 160LC 180LC 180LCN Excavator Electrical Circuit Diagram
DESCRIPTION:
Hitachi Zaxis 160LC 180LC 180LCN Excavator Operational Principle+Troubleshooting+Workshop Manual
INTRODUCTION:
TO THE READER:
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
ADDITIONAL REFERENCES:
• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION:
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.
TABLE OF CONTENTS:
Hitachi Zaxis 160LC 180LC 180LCN Excavator Operational Principle+Troubleshooting+Workshop Manual
- Hitachi Zaxis 160LC 180LC 180LCN Excavator Workshop Manual
SECTION 1
GENERAL
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
AssemblingW1-1-1
Maintenance Standard Terminology W1-1-7
Group 2 Tightening Torque
Tightening Torque Specification W1-2-1
Torque Chart W1-2-2
Piping Joint W1-2-5
Periodic Replacement of Parts W1-2-9
Group 3 Painting
Painting W1-3-1
Group 4 Bleeding Air from Hydraulic Oil
Tank
Bleed Air from Hydraulic Oil tank W1-4-1
SECTION 2
UPPERSTRUCTURE
Group 1 Cab
Remove and Install Cab W2-1-1
Dimensions of the Cab Glass W2-1-7
Group 2 Counterweight
Remove and Install CounterweightW2-2-1
Group 3 Main Frame
Remove and Install Main FrameW2-3-1
Group 4 Pump Device
Remove and Install Pump DeviceW2-4-1
Disassemble Pump DeviceW2-4-4
Assemble Pump DeviceW2-4-10
Disassemble Regulator CoverW2-4-18
Assemble Regulator CoverW2-4-22
Disassemble and Assemble
Control Housing W2-4-24
Disassemble and Assemble CoverW2-4-26
Disassemble and Assemble Gear PumpW2-4-28
Group 5 Control Valve
Remove and Install Control ValveW2-5-1
Disassemble 4-Spool Control Valve W2-5-4
Disassemble 5-Spool Control Valve W2-5-12
Separate and Combine
4-Spool and 5-Spool Control Valves W2-5-22
Assemble 4-Spool Control Valve W2-5-24
Assemble 5-Spool Control Valve W2-5-34
Group 6 Swing Device
Remove and Install Swing Device W2-6-1
Disassemble Swing Reduction Gear W2-6-6
Assemble Swing Reduction Gear W2-6-16
Disassemble Swing Motor W2-6-26
Assemble Swing Motor W2-6-30
Maintenance StandardW2-6-34
Group 7 Pilot Valve
Remove and Install Right Pilot Valve W2-7-1
Remove and Install Left Pilot Valve W2-7-5
Remove and Install Travel Pilot Valve W2-7-9
Disassembe Right and Left Pilot Valves W2-7-12
Assemble Right and Left Pilot Valves W2-7-16
Disassemble Travel Pilot Valve W2-7-20
Assemble Travel Pilot Valve W2-7-26
Group 8 Pilot Shut-Off Valve
Remove and Install Pilot Shut-Off
Valve W2-8-1
Disassemble Pilot Shut-Off Valve W2-8-4
Assemble Pilot Shut-Off Valve W2-8-6
Group 9 Signal Control Valve
Remove and Install Signal Control Valve W2-9-1
Group 10 Solenoid Valve
Remove and Install Solenoid
Valve UnitW2-10-1
Disassemble Proportional
Solenoid Valve W2-10-4
Assemble Proportional Solenoid Valve W2-10-6
SECTION 3
UNDERCARRIAGE
Group 1 Swing Bearing
Remove and Install Swing BearingW3-1-1
Disassemble Swing BearingW3-1-4
Assemble Swing BearingW3-1-6
Group 2 Travel Device
Remove and Install Travel Device W3-2-1
Disassemble Travel Motor W3-2-4
Assemble Travel Motor W3-2-8
Disassemble Travel Reduction Gear W3-2-12
Assemble Travel Reduction GearW3-2-16
Disassemble Base PlateW3-2-20
Assemble Base PlateW3-2-22
Disassemble Travel Reduction Gear
(ZAXIS180LC, 180LCN)W3-2-24
Assemble Travel Reduction Gear
(ZAXIS180LC, 180LCN)W3-2-32
Disassemble Travel Motor
(ZAXIS180LC, 180LCN)W3-2-42
Assemble Travel Motor
(ZAXIS180LC, 180LCN)W3-2-46
Disassemble Brake Valve
(ZAXIS180LC, 180LCN)W3-2-52
Assemble Brake Valve
(ZAXIS180LC, 180LCN)W3-2-54
Maintenance StandardW3-2-56
Group 3 Center Joint
Remove and Install Center JointW3-3-1
Disassemble Center JointW3-3-4
Assemble Center JointW3-3-6
Maintenance StandardW3-3-9
Group 4 Track Adjuster
Remove and Install Track Adjuster W3-4-1
Disassemble Track Adjuster W3-4-2
Assemble Track Adjuster W3-4-10
Group 5 Front Idler
Remove and Install Front Idler W3-5-1
Disassemble Front Idler W3-5-2
Assemble Front Idler W3-5-6
Maintenance Standard W3-5-8
Group 6 Upper and Lower Roller
Remove and Install Upper Roller W3-6-1
Remove and Install Lower Roller W3-6-5
Disassemble Lower Roller W3-6-8
Assemble Lower Roller W3-6-10
Maintenance Standard W3-6-12
Group 7 Track
Remove and Install Tracks W3-7-1
Maintenance Standard W3-7-8
SECTION 4
FRONT ATTACHMENT
Group 1 Front Attachment
Remove and Install Front Attachment W4-1-1
Maintenance StandardW4-1-8
Standard Dimensions for
Arm and Bucket Connection W4-1-11
Group 2 Cylinder
Remove and Install Cylinder W4-2-1
Hydraulic Circuit Pressure Release
Procedure W4-2-15
Disassemble Cylinder W4-2-16
Assemble Cylinder W4-2-24
Maintenance Standard W4-2-32
SECTION 5
ENGINE AND ACCESSORY
General Information
General Repair Instructions 1-2
Notes on the Format of This Manual 1-2
Main Data and Specifications 1-6
Performance Curve 1-8
External View1-11
Tightening Torque Specifications 1-14
Angular Nut and Bolt Tightening Method 1-16
Major Parts Fixing Nuts and Bolts 1-18
Identifications 1-26
Maintenance
Lubricating System 2-2
Fuel System 2-3
Cooling System 2-6
Valve Clearance Adjustment 2-6
Injection Timing 2-8
Compression Pressure Measurement 2-12
Turbocharger Inspection 2-13
Engine Repair Kit 2-14
Recommended Lubricants 2-15
Engine Oil Viscosity Chart 2-15
Engine Assembly 1 (Disassembly)
External Parts Disassembly Steps 3-2
Major Components 3-6
Rocker Arm and Rocker Arm Shaft
Disassembly Steps 3-10
Cylinder Head Disassembly Steps 3-11
Piston and Connecting Rod
Disassembly Steps 3-12
Engine Assembly 2
(Inspection and Repair)
Cylinder Head 4-2
Valve Guide 4-3
Valve Spring 4-6
Tappet 4-7
Push Rod 4-8
Rocker Arm Shaft and Rocker Arm 4-8
Idler Gear and Idler Gear Shaft 4-9
Camshaft 4-10
Cylinder Body and Liner 4-11
Piston and Piston Ring 4-17
Piston Pin 4-18
Connecting Rod 4-19
Crankshaft 4-21
Flywheel 4-28
Timing Gear Case Cover 4-28
Engine Assembly 3 (Reassembly)
Piston and Connecting Rod
Reassembly Steps 5-2
Cylinder Head Reassembly Steps 5-4
Rocker Arm and Rocker Arm Shaft
Reassembly Steps 5-7
Major Component Reassembly Steps 1 5-8
Major Component Reassembly Steps 2 5-13
External Parts Reassembly Steps
(Left-Hand Side) 5-18
External Parts Reassembly Steps
(Right-Hand Side) 5-21
Engine Tuning Operation 5-25
- Hitachi Zaxis 160LC 180LC 180LCN Excavator Troubleshooting Technical Manual
SECTION 4
OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Operational Performance TestsT4-1-1
Preparation for Performance TestsT4-1-2
Group 2 Standard
ZAXIS160LC Operational Performance
Standard TableT4-2-1
ZAXIS180LC, 180LCN Operational
Performance Standard Table T4-2-5
ZAXIS160LC Main Pump P-Q Diagram T4-2-10
ZAXIS180LC, 180LCN Main Pump
P-Q DiagramT4-2-12
Injection PumpT4-2-14
ZAXIS160LC DrEX Monitor Indicating
Values T4-2-16
ZAXIS180LC, 180LCN DrEX Monitor
Indicating ValuesT4-2-20
Sensor Activating Range T4-2-24
Group 3 Engine Test
Engine Speed T4-3-1
Engine Compression PressureT4-3-4
Valve Clearance AdjustmentT4-3-6
Nozzle Check T4-3-8
Injection Timing T4-3-10
Group 4 Excavator Test
Travel Speed T4-4-1
Track Revolution Speed T4-4-2
Mistrack Check T4-4-3
Travel Parking Leakage T4-4-4
Swing Speed T4-4-5
Swing Function Drift Check T4-4-6
Swing Motor Leakage T4-4-8
Maximum Swingable Slant Angle T4-4-10
Swing Bearing Play T4-4-12
Hydraulic Cylinder Cycle Time T4-4-14
Dig Function Drift Check T4-4-16
Control Lever Operating Force T4-4-18
Control Lever Stroke T4-4-20
Combined Boom Raise/Swing
Function Check T4-4-22
Boom Raise / Arm Roll-In
Combined Operation T4-4-24
SECTION 5
TROUBLESHOOTING
Group 1 General
Introduction T5-1-1
Diagnosing Procedure T5-1-2
Built-In Diagnosing System Operation T5-1-6
Built-In Diagnosing Function Display List T5-1-7
Dr EX Operation T5-1-8
Dr EX Fault Code List T5-1-10
Dr EX Monitoring Item List T5-1-12
Dr EX Special Function T5-1-14
Dr EX Service Mode T5-1-16
Adjustment Data List T5-1-24
Group 2 Component Layout
Main Component Layout T5-2-1
Electrical Component Layout (Overview) T5-2-2
Electrical System
(Relays and Related Equipment) T5-2-3
Electrical System
(Monitors and Switches) T5-2-4
Pump Device T5-2-5
Swing Device T5-2-5
Control Valve T5-2-5
Signal Control Valve T5-2-5
Travel Device T5-2-6
Pilot Relief Valve T5-2-6
Solenoid Valve Unit T5-2-6
Components in Control Valve T5-2-8
Signal Control Valve
Port Location T5-2-16
Group 3 Troubleshooting A
Troubleshooting A Procedure T5-3-1
Fault Code List T5-3-2
Fault Code 01, 02, 03 T5-3-3
Fault Code 04 T5-3-3
Fault Code 06 T5-3-4
Fault Code 07 T5-3-5
Fault Code 10, 11 T5-3-6
Fault Code 12, 13 T5-3-7
Fault Code 14, 15, 16, 18 T5-3-8
Fault Code 19 T5-3-9
Group 4 Troubleshooting B
Troubleshooting B Procedure T5-4-1
Relationship between Machine Trouble
Symptoms and Related Parts T5-4-2
Correlation between Trouble
Symptoms and Part Failures T5-4-20
Engine System Troubleshooting T5-4-31
All Actuator System Troubleshooting T5-4-52
Front Attachment System
Troubleshooting T5-4-58
Swing System Troubleshooting T5-4-66
Travel System Troubleshooting T5-4-67
Other System Troubleshooting T5-4-74
Exchange Inspection T5-4-90
Emergency Boom Lowering
Procedure T5-4-92
- Hitachi Zaxis 160LC 180LC 180LCN Excavator Operational Principle Technical Manual
SECTION 1
GENERAL
Group 1 Specifications
Specification T1-1-1
Working Range T1-1-2
Group 2 Component Layout
Main Component Layout T1-2-1
Electrical Component Layout T1-2-2
(Overview)
Elecrical System T1-2-3
(Relays and Related Equipment)
Electrical System T1-2-4
(Monitors and Switches)
Pump Device T1-2-5
Swing Device T1-2-5
Control Valve T1-2-5
Signal Control Valve T1-2-5
Travel Device T1-2-6
Pilot Relief valve T1-2-6
Solenoid Valve Unit T1-2-6
Group 3 Component Specifications
Engine T1-3-1
Engine Accessories T1-3-6
Hydraulic Component T1-3-7
Electrical Component T1-3-10
SECTION 2
SYSTEM
Group 1 Control System
Outline T2-1-1
Engine Control T2-1-2
Pump Control T2-1-21
Valve Control T2-1-28
Other Controls T2-1-36
Group 2 Hydraulic System
Outline T2-2-1
Pilot Circuit T2-2-2
Main Circuit T2-2-12
Group 3 Electrical System
Outline T2-3-1
Main Circuit T2-3-2
Electric Power Circuit T2-3-3
Indicator Light Check Circuit T2-3-4
Accessory Circuit T2-3-5
Preheat Circuit T2-3-6
Starting Circuit T2-3-8
Charging CircuitT2-3-11
Serge Voltage Prevention Circuit T2-3-14
Engine Stop Circuit T2-3-16
SECTION 3
COMPONENT OPERATION
Group 1 Pump Device
Outline T3-1-1
Main Pump T3-1-2
Regulator T3-1-5
Pilot Pump T3-1-20
N Sensor (Engine Speed Sensor) T3-1-20
Pump Delivery Pressure Sensor T3-1-21
Pump Control Pressure Sensor T3-1-21
Group 2 Swing Device
Outline T3-2-1
Swing Reduction Gear T3-2-2
Swing Motor T3-2-3
Swing Parking Brake T3-2-4
Valve Unit T3-2-6
Group 3 Control Valve
Outline T3-3-1
Hydraulic Circuit T3-3-10
Flow Combiner Valve T3-3-14
Main Relief Valve T3-3-16
Overload Relief Valve T3-3-18
Regenerative Valve T3-3-20
Anti-Drift Valve T3-3-22
Flow Rate Control Valve T3-3-24
Auxiliary Flow Combining Valve and
Bypass Shut-Out Valve T3-3-26
Group 4 Pilot Valve
Outline T3-4-1
Operation T3-4-2
Group 5 Travel Device
Outline T3-5-1
Travel Reduction Gears T3-5-4
Travel Motor T3-5-6
Parking Brake T3-5-8
Travel Mode Change T3-5-12
Travel Brake Valve T3-5-20
Group 6 Signal Control Valve
Outline T3-6-1
Pilot Port T3-6-2
Shuttle Valve T3-6-5
Shockless Valve T3-6-8
Pump 1 and Pump 2 Flow Rate
Control Valves T3-6-10
Bucket Flow Rate Control Valve
Control Spool, Flow Combiner Valve
Control Spool, Swing Parking Brake
Release Spool T3-6-12
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