Factory Service Repair Manuals set For Hitachi Zaxis 160LC, 180LC, 180LCN Excavators. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.
Format: PDF
Language: English
Pages: 1224
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes
Model
Hitachi ZAXIS 160LC, 180LC, 180LCN
Contents
1.Workshop Manual
2.Technical Manual(Troubleshooting)
3.Technical Manual(Operational Principle
4.Wiring Diagram
1.Workshop Manual
-GENERAL
–PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
Precautions for Disassembling and Assembling
Maintenance Standard Terminology
–TIGHTENING TORQUE
Tightening Torque Specification
Torque Chart
Piping Joint
Periodic Replacement of Parts
–PAINTING
Painting
–BLEEDING AIR FROM HYDRAULIC OIL TANK
Bleed Air from Hydraulic Oil tank
-UPPERSTRUCTURE
–CAB
Remove and Install Cab
Dimensions of the Cab Glass
–COUNTERWEIGHT
Remove and Install Counterweight
–MAIN FRAME
Remove and Install Main Frame
–PUMP DEVICE
Remove and Install Pump Device
Disassemble Pump Device
Assemble Pump Device
Disassemble Regulator Cover
Assemble Regulator Cover
Disassemble and Assemble Control Housing
Disassemble and Assemble Cover
Disassemble and Assemble Gear Pump
–CONTROL VALVE
Remove and Install Control Valve
Disassemble 4-Spool Control Valve
Disassemble 5-Spool Control Valve
Separate and Combine 4-Spool and 5-Spool Control Valves
Assemble 4-Spool Control Valve
Assemble 5-Spool Control Valve
–SWING DEVICE
Remove and Install Swing Device
Disassemble Swing Reduction Gear Assemble Swing Reduction Gear
Disassemble Swing Motor
Assemble Swing Motor
Maintenance Standard
–PILOT VALVE
Remove and Install Right Pilot Valve
Remove and Install Left Pilot Valve
Remove and Install Travel Pilot Valve
Disassembe Right and Left Pilot Valves
Assemble Right and Left Pilot Valves
Disassemble Travel Pilot Valve
Assemble Travel Pilot Valve
–PILOT SHUT-OFF VALVE
Remove and Install Pilot Shut-Off Valve
Disassemble Pilot Shut-Off Valve Assemble Pilot Shut-Off Valve
–SIGNAL CONTROL VALVE
Remove and Install Signal Control Valve
–SOLENOID VALVE
Remove and Install Solenoid Valve Unit
Disassemble Proportional Solenoid Vatve
Assemble Proportional Solenoid Valve
–SWING DEVICE
Remove and Install Swing Device
Disassemble Swing Reduction Gear Assemble Swing Reduction Gear
Disassemble Swing Motor
Assemble Swing Motor
Maintenance Standard
–PILOT VALVE
Remove and Install Right Pilot Valve
Remove and Install Left Pilot Valve
Remove and Install Travel Pilot Valve
Disassembe Right and Left Pilot Valves
Assemble Right and Left Pilot Valves
Disassemble Travel Pilot Valve
Assemble Travel Pilot Valve
–PILOT SHUT-OFF VALVE
Remove and Install Pilot Shut-Off Valve
Disassemble Pilot Shut-Off Valve
Assemble Pilot Shut-Off Valve
–SIGNAL CONTROL VALVE
Remove and Install Signal Control Valve
–SOLENOID VALVE
Remove and Install Solenoid
Valve Unit
Disassemble Proportional Solenoid Valve
Assemble Proportional Solenoid Valve
-UNDERCARRIAGE
–SWING BEARING
Remove and Install Swing Bearing
Disassemble Swing Bearing
Assemble Swing Bearing
–TRAVEL DEVICE
Remove and Install Travel Device
Disassemble Travel Motor
Assemble Travel Motor
Disassemble Travel Reduction Gear
Assemble Travel Reduction Gear
Disassemble Base Plate
Assemble Base Plate
Disassemble Travel Reduction Gear (ZAXIS180LC, 180LCN)
Assemble Travel Reduction Gear (ZAXIS180LC, 180LCN)
Disassemble Travel Motor (ZAXIS180LC, 180LCN)
Assemble Travel Motor (ZAXIS180LC, 180LCN)
Disassemble Brake Valve (ZAXIS180LC, 180LCN)
Assemble Brake Valve (ZAXIS180LC, 180LCN)
Maintenance Standard
–CENTER JOINT
Remove and Install Center Joint
Disassemble Center Joint
Assemble Center Joint
Maintenance Standard
–TRACK ADJUSTER
Remove and Install Track Adjuster
Disassemble Track Adjuster
Assemble Track Adjuster
–FRONT IDLER
Remove and Install Front Idler
Disassemble Front Idler
Assemble Front Idler
Maintenance Standard
–UPPER AND LOWER ROLLER
Remove and Install Upper Roller
Remove and Install Lower Roller
Disassemble Lower Roller
Assemble Lower Roller
Maintenance Standard
–TRACK
Remove and Install Tracks
Maintenance Standard
-FRONT ATTACHMENT
–FRONT ATTACHMENT
Remove and Install Front Attachment
Maintenance Standard
Standard Dimensions for Arm and Bucket Connection
–CYLINDER
Remove and Install Cylinder
Hydraulic Circuit Pressure Release Procedure
Disassemble Cylinder
Assemble Cylinder
Maintenance Standard
-ENGINE AND ACCESSORY
–GENERAL INFORMATION
General Repair Instructions
Notes on the Format of This Manual
Main Data and Specifications
Performance Curve
External View
Tightening Torque Specifications
Angular Nut and Bolt Tightening Method
Major Parts Fixing Nuts and Bolts
Identifications
–MAINTENANCE
Lubricating System
Fuel System
Cooling System
Valve Clearance Adjustment
Injection Timing
Compression Pressure Measurement
Turbocharger Inspection
Engine Repair Kit
Recommended Lubricants
Engine Oil Viscosity Chart
–ENGINE ASSEMBLY 1 (DISASSEMBLY)
Fxternal Parts Disassembly Steps Major Components
Rocker Arm and Rocker Arm Stiaft Disassembly Steps
Cylinder Head Disassembly Steps
Piston and Connecting Rod Disassembly Steps
–ENGINE ASSEMBLY 2 (INSPECTION AND REPAIR)
Cylinder Head
Valve Guide
Valve Spring
Tappet
Push Rod
Rocker Arm Shaft and Rocker Arm
Idler Gear and Idler Gear Shaft
Camshaft
Cylinder Body and Liner
Piston and Piston Ring
Piston Pin
Connecting Rod
Crankshaft
Flywheel
Timing Gear Case Cover
–ENGINE ASSEMBLY 3 (REASSEMBLY)
Piston and Connecting Rod
Reassembly Steps
Cylinder Head Reassembly Steps
Rocker Arm and Rocker Arm Shaft
Reassembly Steps
Major Component Reassembly Steps 1
Major Component Reassembly Steps 2
External Parts Reassembly Steps (Left-Hand Side)
External Parts Reassembly Steps (Right-Hand Side)
Engine Tuning Operation
–LUBRICATING SYSTEM
General Description
Oil Pump
Oil Cooler
–COOLING SYSTEM
General Description
Thermostat
–FUEL SYSTEM
General Description
Injection Nozzle
Injection Pump Calibration Data
–TURBOCHARGER
General Description
Turbocharger Identification
Troubleshooting
Inspection and Repair
–ENGINE ELECTRICALS
Starter Identification
Starter Main Data and Specifications
Starter Sectional View
Performance
Disassembly
Inspection and Repair
Reassembly
Adjustment
Performance Test
Alternator Identification
Main Data and Specifications
Alternator Sectional View
Charging Circuit
Structure
Disassembly
Inspections
Reassembly
Bench Test
Current Output Test
Fault Finding
Specifications
–TROUBLESHOOTING
HARD STARTING
STARTER INOPERATIVE
2STARTER OPERATES BUT
ENGINE DOES NOT TURN OVER
3ENGINE TURNS OVER BUT DOES NOT START
FUEL IS BEING DELIVERED TO THE INJECTION PUMP
ENGINE TURNS OVER BUT DOES NOT START
Unstable Low Idling
Insufficient Power
Excessive Fuel Consumption
Excessive Oil Consumption
Overheating
Whity Exhaust Smoke
Dark Exhaust Smoke
Oil Pressure does not Rise
Abnormal Engine Noise
–SPECIAL TOOL LIST
Special Tool List
–REPAIR STANDARDS
Repair Standards
–CONVERSION TABLE
Length
Area
Volume
Mass
Pressure
Torque
Temperature
2.Technical Manual(Troubleshooting)
INTRODUCTION
SAFETY
-OPERATIONAL PERFORMANCE TEST
–INTRODUCTION
Operational Performance Tests
Preparation for Performance Tests
–STANDARD
ZAXIS160LC Operational Performance Standard Table
ZAXIS180LC, 180LCN Operational Performance Standard Table
ZAXIS160LC Main Pump P-Q Dagram
ZAXIS180LC 180LCN Main Pump
P-Q Diagram
Injection Pump
ZAXIS160LC DrEX Monitor Indicating Values
ZAXIS180LC 180LCN DrEX Monitor Inchoating Values
Sensor Activating Range
–ENGINE TEST
Engine Speed
Engine Compression Pressure
Valve Clearance Adjustment
Nozzle Check
Injection Timing
–EXCAVATOR TEST
Travel Speed
Track Revolution Speed
Mistrack Check
Travel Parking Leakage
Swing Speed
Swing Function Drift Check Swing Motor Leakage
Maximum Swingable Slant Angle Swing Bearing Play
Hydraulic Cylinder Cycle Time Dig Function Drift Check
Control Lever Operating Force Control Lever Stroke
Combined Boom Raise/Swing Function Check
Boom Raise/Arm Roll-In Combined Operation
–COMPONENT TEST
Primary Pilot Pressure
Secondary Pilot Pressure
Solenoid Valve Set Pressure
Main Pump Delivery Pressure
Main Relief Valve Set Pressure
Relief Pressure (When relieving Swing)
Relief Pressure (When relieving Travel)
Overload Relief Valve Set Pressure
Main Pump Flow Rate Measurement
Swing Motor Drainage
Travel Motor Drainage (ZAXIS1S0LC)
Travel Motor Drainage (ZAXIS180LC, 180LCN)
–ADJUSTMENT
Engine Speed Adjustment and Engine Learning
Governor Lever and Fuel Cut Lever Position
-TROUBLESHOOTING
–GENERAL
Introduction
Diagnosing Procedure
Built-In Diagnosing System Operation
Built-In Diagnosing Function Display List
Dr EX Operation
Dr EX Fault Code List
Dr EX Monitoring Item List
Dr EX Special Function
Dr EX Service Mode
Adjustment Data List’
–COMPONENT LAYOUT
Main Component Layout
Electrical Component Layout (Overview)
Electrical System (Relays and Related Equipment)
Electrical System (Monitors and Switches)
Hump Device
Swing Device
Control Valve
Signal Control Valve
Travel Device Pilot Relief Valve
Solenoid Valve Unit
Components in Control Valve
Signal Control Valve Port Location
–TROUBLESHOOTING A
Troubleshooting A Procedure
Fault Code List
Fault Code 01, 02, 03
Fault Code 04
Fault Code 06
Fault Code 07
Fault Code 10 11
Fault Code 12, 13
Fault Code 14, 15, 16, 18
Fault Code 19
–TROUBLESHOOTING B
Troubleshooting B Procedure
Relationship between Machine Trouble Symptoms and Related Parts
Correlation between Trouble Symptoms and Part Failures
Engine System Troubleshooting
All Actuator System Troubleshooting
Front Attachment System T roubleshooting
Swing System Troubleshooting
Travel System Troubleshooting
Other System Troubleshooting
Exchange Inspection
Emergency Boom Lowering Procedure
–TROUBLESHOOTING C
Troubleshooting C Procedure
Malfunction of Coolant Temperature Gauge
Malfunction of Fuel Gauge
Malfunction of Indicator Light Check System
Malfunction of Preheat Indicator
Malfunction of Engine Oil Level Indicator
Malfunction of Coolant Level Indicator
Malfunction of Alternator Indicator
Malfunction of Engine Oil Pressure Indicator
Malfunction of Overheat Indicator
Malfunction of Air Filter Restriction Indicator
Malfunction of Buzzer
Malfunction of LCD
Malfunction of Hour Meter
Malfunction of Hydraulic Oil Filter Indicator (Optional)
–ELECTRICAL SYSTEM INSPECTION
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fusible Link Inspection
Battery Voltage Check
How to Troubleshoot Alternator Malfunctions
Continuity Check
Voltage and Current Measurement
Check by False Signal
Test Harness
–ICX
Outline
ICX Fault Code List
Satellite Terminal Fault Code List
Fault Code 1 to 6
Fault Code 7 to 10
Some Parts of Data in Daily Report, Frequency Distribution, Cumulative Operation Hours are not Recorded
Troubleshooting and Setting of ICX and Satellite Terminal Using Dr EX
Satellite Communication System
3.Technical Manual(Operational Principle)
INTRODUCTION
-GENERAL
–SPECIFICATIONS
Specification
Working Range
–COMPONENT LAYOUT
Mam Component Layout
Electrical Component Layout
(Overview) Elecrical System
(Relays and Related Equipment) Electrical System
(Monitors and Switches)
Pump Device
Swing Device
Control Valve
Signal Control Valve
Travel Device
Pilot Relief valve
Solenoid Valve Unit
–COMPONENT SPECIFICATIONS
Engine
Engine Accessories
Hydraulic Component
Electrical Component
-SYSTEM
–CONTROL SYSTEM
Outline
Engine Control
Pump Control
Valve Control
Other Controls
–GROUP 2 HYDRAULIC SYSTEM
Outline
Pilot Circuit
Main Circuit
–ELECTRICAL SYSTEM OUTLINE
Main Circuit
Electric Power Circuit
Indicator Light Check Circuit
Accessory Circuit
Preheat Circuit
Starting Circuit
Charging Circuit
Serge Voltage Prevention Circuit
Engine Stop Circuit
-COMPONENT OPERATION
–PUMP DEVICE
Outline
Main Pump
Regulator
Pilot Pump
N Sensor (Engine Speed Sensor)
Pump Delivery Pressure Sensor
Pump Control Pressure Sensor
–SWING DEVICE
Outline
Swing Reduction Gear
Swing Motor
Swing Parking Brake
Valve Unit
–CONTROL VALVE
Outline
Hydraulic Circuit
Flow Combiner Valve
Main Relief Valve
Overload Relief Valve
Regenerative Valve
Anti-Drift Valve
Flow Rate Control Valve
Auxiliary Flow Combining Valve and Bypass Shut-Out Valve
–PILOT VALVE
Outline
Operation
–TRAVEL DEVICE
Outline
Travel Reduction Gears
Travel Motor
Parking Brake
Travel Mode Change
Travel Brake Valve
–SIGNAL CONTROL VALVE
Outline
Pilot Port
Shuttle Valve
Shockless Valve
Pump 1 and Pump 2 Flow Rate Control Valves
Bucket Flow Rate Control Valve, Control Spool, Flow Combiner Valve, Control Spool Swing Parking Brake
Release Spool
–OTHERS (UPPERSTRUCTURE)
Pilot Shut-Off Valve
Solenoid Valve Unit
Torque Control Solenoid Valve Pump 2 Flow Rate Control Solenoid Valve, Pilot Relief Valve
EC Motor
–OTHERS (UNDERCARRIAGE)
Swing Bearing
Center Joint
Track Adjuster
4.Wiring Diagrams
Zx160Lc_Hyd(E)
Zx180Lc,180Lcn_Hyd(E)
Zx160Lc-180Lcn_Cab(E)
Zx160Lc-180Lcn_Con(E)
Zx160Lc-180Lcn_Eng(E)
Zx160Lc-180Lcn_Mon(E)
Zx-Std_Ele(E)
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