Technical Manual: 160LC 180LC 180LCN
Technical Manual: 160LC 180LC 180LCN
: KM-1F1E
Vol. No. : TO1F1E-02
160LC•180LC•180LCN
Technical Manual
(Operational Principle)
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this manual.
• Be sure to thoroughly read this manual for correct (Note: Do not tear off the form. Copy it for us-
product information and service procedures. age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
IN-01
Example : T 1-3-5
IN-02
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-03
IN-04
1F1T-1-1
1F1T-1-2
A C
G
B F
D
K K
J
I H
T1F1-01-01-001 M1F1-12-002
Std.
Model ZAXIS160LC Hydraulic Excavator ZAXIS180LC Hydraulic ZAXIS180LCN
Excavator Hydraulic Excavator
Type of Front-End Attachment 2.58 m (8 ft 6 in) Arm 2.70 m (8 ft 10 in) Arm
Bucket Capacity (Heaped) m3 (yd3) PCSA 0.60 m3 (0.80 yd3), CECE 0.55 m3 PCSA 0.70 m3 (0.92 yd3), CECE 0.60 m3
Operating Weight kg (lb) 15600 (34400) 17800 (39200) 17500 (38300)
Basic Machine Weight kg (lb) 12100 (26700) 13800 (30400) 13500 (29800)
Engine ISUZU AA-4BG1TC ISUZU AA-4BG1TC
74 kW (100 PS)/1950 min−1 (rpm) 87.4 kW (118.8 PS)/2000 min−1 (rpm)
Ò81 kW (110 PS)/2150 min-1 (rpm) 90.2 kW (123 PS)/2200 min-1 (rpm)
A : Overall Width
(Excluding Rearview Mirrors) mm (ftxin) 2500 (8′ 2″) 2590 (8′ 6″)
B : Cab Height mm (ftxin) 2880 (9′ 5″) 2880 (9′ 5″)
C : Rear End Swing Radius mm (ftxin) 2440 (8′ 0″) 2440 (8′ 0″)
D : Minimum Ground Clearance mm (ftxin) * 470 (1′ 7″) * 450 (1′ 6″)
E : Counterweight Clearance mm (ftxin) * 1000 (3′ 3″) * 1000 (3′ 3″)
F : Engine Cover Height mm (ftxin) * 2141 (7′ 0″) * 2141 (7′ 0″)
G : Overall Width of 2460 (8′ 1″) 2460 (8′ 1″)
Upperstructure mm (ftxin)
H : Undercarriage Length mm (ftxin) 3920 (12′ 10″) 4170 (13′ 8″)
I: Undercarriage Width mm (ftxin) 2490 (8′ 2″) 2800 (9′ 2″) 2490 (8′ 2″)
J : Sprocket Center to Idle Center mm (ftxin) 3100 (10′ 2″) 3370 (11′ 1″)
K : Track Shoe Width mm 500 (Grouser Shoe) 600 (Grouser Shoe) 500 (Grouser Shoe)
(ftxin) (20″) (24″) (20″)
Ground Pressure kPa (kgf/cm2) (psi) 45 (0.46) (6.5) 39 (0.40) (5.7) 47 (0.48) (6.8)
−1
Swing Speed min (rpm) 13.6 (13.6) 12.9 (12.9)
Travel Speed (fast/slow) km/h 5.3/3.1 5.0/3.0
(mph) (3.3/1.9) (3.1/1.9)
Gradeability degree (%) 35 (70) 35 (70)
T1-1-1
GENERAL / Specifications
WORKING RANGE
ZAXIS160LC,180LC,180LCN
G
G
C C
B D
D
E E
E
F
F A
A
B
B
M1F1-12-004
M1F1-12-003
Model ZX160LC
Category 2.58 m (8′ 6″)
3.10 m (10′ 2″) Arm 2.01 m (6′ 7″) Arm
Item Standard Arm
Backhoe Shovel Backhoe Shovel Backhoe Shovel
A : Maximum Digging Reach mm 8870 8980 9330 9440 8340 8460
(ftxin) (29′ 1″) (29′ 6″) (30′ 7″) (30′ 12″) (27′ 4″) (27′ 9″)
* B : Maximum Digging Depth mm 5980 6100 6490 6600 5410 5530
(ftxin) (19′ 7″) (20′ 0″) (21′ 4″) (21′ 8″) (17′ 9″) (18′ 2″)
* C : Maximum Cutting Height mm 8880 9130 9120 9370 8540 8840
(ftxin) (29′ 2″) (29′ 11″) (29′ 11″) (30′ 9″) (28′ 0″) (29′ 0″)
* D : Maximum Dumping Height mm 6170 6090 6400 6330 5870 5770
(ftxin) (20′ 3″) (19′ 12″) (20′ 12″) (20′ 9″) (19′ 3″) (18′ 11″)
E : Transport Height mm 2880 2860 3110 3110 3120 3120
(ftxin) (9′ 6″) (9′ 5″) (10′ 2″) (10′ 2″) (10′ 3″) (10′ 3″)
F : Overall Transport Length mm 8530 8530 8560 8560 8630 8630
(ftxin) (27′ 12″) (27′ 12″) (28′ 1″) (28′ 1″) (28′ 4″) (28′ 4″)
G : Minimum Swing Radius mm 2910 2910 2920 2920 3250 3250
(ftxin) (9′ 7″) (9′ 7″) (9′ 7″) (9′ 7″) (10′ 8″) (10′ 8″)
T1-1-2
GENERAL / Component Layout
MAIN COMPONENT LAYOUT
4
5
6
7
8
20
19
10
18
11
17 12
13
16 T1F1-01-02-001
15
14
T1-2-1
GENERAL / Component Layout
ELECTRICAL COMPONENT LAYOUT
(Overview)
View A
2
1
• Pressure Sensor
(Front Attachment)
Refer to the Swing
Device group.
5 • Solenoid Valve
Unit (SC)
• Solenoid Valve
Unit (SI)
Refer to the Solenoid
Valve Unit group.
15 7
T1-2-2
GENERAL / Component Layout
ELECTRICAL SYSTEM
(Relays and Related Equipment) Rear Deck
5
4
3 6
2
T178-01-02-006
15
14
10
18 13
17 12
16 11
T178-01-02-007
T16J-05-01-001
1- Mail Switch (Satellite 6- Fuse Box 11- Load Damp Relay (R1) 16- Wiper Relay A (R6)
Terminal Equipped
Machines only)
2- QOS Controller 7- Learning Switch 12- Washer Relay (R2) 17- Wiper Relay B (R7)
3- ICX (Information Controller) 8- Dr. EX Connector to MC 13- Work Light Relay 2 (R3) 18- Wiper Relay C (R8)
4- MC (Main Controller) 9- Download Connector (Not connected on 14- Work Light Relay 1 (R4)
Satellite Terminal Equipped Machines)
5-Satellite Terminal (Optional) 10- Dr. EX Connector to ICX 15- Horn Relay (R5)
T1-2-3
GENERAL / Component Layout
ELECTRICAL SYSTEM
(Monitors and Switches)
1 2
20
19
21
18
3
17
22
16 4
15 23
5
24
14
6
13 7
12 8
25
11
9
10
T178-01-01-012
T178-01-01-013
T1-2-4
GENERAL / Component Layout
PUMP DEVICE CONTROL VALVE
6
7
5
1
4 T1F1-01-02-003
T176-01-02-003
11
10
12
T178-03-06-015
T178-03-02-001
1 - Pump 2 Control Pressure 4 - Pump 1 Delivery Pressure 7 - Main Relief Valve 10 - Pressure Sensor
Sensor Sensor (Front Attachment)
2 - Pump 1 Control Pressure 5 - N Sensor 8 - Pressure Sensor 11 - Pressure Sensor (Swing)
Sensor (Boom Raise)
3 - Pump 2 Delivery Pressure 6 - Pressure Sensor 9 - Swing Relief Valve 12 - Pressure Sensor (Travel)
Sensor (Arm Roll-In)
T1-2-5
GENERAL / Component Layout
TRAVEL DEVICE
ZAXIS160LC ZAXIS180LC,180LCN
1
1
2
T155-01-01-013
T1HD-01-02-001
3
4
5
6
T176-03-07-002
T1F1-01-02-004
1 - Counter Balance Valve 3 - Pump 2 Flow Rate Control 5 - Solenoid Valve Unit (SC) 6 - Solenoid Valve Unit (SI)
Solenoid Valve
2 - Travel Relief Valve 4 - Torque Control Solenoid
Valve
T1-2-6
GENERAL / Component Specifications
ENGINE
Manufacturer ..................................................ISUZU
Model..............................................................AA-4BG1TCG
Type................................................................Diesel, 4-Cycle, Water-cooled, Inline, Direct Injection
Cyl. No.- Bore × Stroke...................................4-105 mm×125 mm (4.13 in×4.92 in)
3 3
Piston Displacement.......................................4329 cm (264 in )
-1
Rated Output..................................................ZAXIS160LC: 74 kW/1950 min (100 PS/1950 rpm)
-1
HP Mode: 81 kW/2150 min (110 PS/2150 rpm)
-1
ZAXIS180LC,180LCN: 87.4 kW/2000 min
(118.8 PS/2000 rpm)
-1
HP Mode: 90.2 kW/2200 min (123 PS/2200 rpm)
Compression Ratio.........................................18:0
Dry Weight......................................................362 kg (798 lb)
Firing Order ....................................................1-3-4-2
Rotation Direction ...........................................Clockwise (Viewed from fan side)
COOLING SYSTEM
Cooling Fan....................................................Dia. 600 mm (21.7 in),
7 Blades (N-Type Blade, Unequal Pitch), Draw-in Type
Fan Pulley Ratio .............................................ZAXIS160LC: Engine rpm × 0.80
ZAXIS180LC,180LCN: Engine rpm × 0.84
Thermostat ..................................................... Cracking Temperature at Atmospheric Pressure:
82 °C (180 °F)
Full Open (Stroke: 10 mm or more) Temperature:
95 °C (203 °F)
Water Pump ...................................................Centrifugal Belt Driven Type
T1-3-1
GENERAL / Component Specifications
LUBRICATION SYSTEM
Lubrication Pump Type...................................Gear Pump
Oil Filter ..........................................................Full-Flow Paper Element Type with Bypass
Oil Cooler........................................................Water Cooled Integral Type
STARTING SYSTEM
Motor ..............................................................Magnetic Pinion Shift Reduction Type
Voltage / Output..............................................24 V / 4.5 kW
PREHEAT SYSTEM
Preheating Method .........................................Glow Plug (QOS 2 Type)
ALTERNATOR
Type................................................................Regulator Integrated AC Type
Voltage / Output..............................................24 V / 50 A (Brushless)
SUPERCHARGING SYSTEM
Type................................................................Exhaust-Turbocharger Type TD04HL
T1-3-2
GENERAL / Component Specifications
FUEL SYSTEM
Type................................................................BOSCH Type (AD Concave Cam)
Governor.........................................................Centrifugal All Speed Control RSV Type
Injection Nozzle ............................................Multi-Hole Type
T1-3-3
GENERAL / Component Specifications
Engine Performance Curve (AA-4BG1TCG)
Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for Construc-
tion Machinery) under standard atmospheric pressure.
2. Equipped with the fan and alternator.
Torque
ZAXIS160LC
N⋅m
HP Mode
P Mode
Output
kW
HP Mode
P Mode
Fuel
Consumption
Ratio
g/kW・h
T1F1-01-03-001
Engine Speed min-1 (rpm) ×100
T1-3-4
GENERAL / Component Specifications
ZAXIS180LC,180LCN
Torque
N・m
HP Mode
P Mode
Output
kW
HP Mode
P Mode
Fuel
Consumption
Ratio
g/kW・h
T1-3-5
GENERAL / Component Specifications
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
Type......................................................Radiator/Oil Cooler/Intercooler Tandem Type Assembly
Weight ..................................................73 kg (160 lb)
Intercooler
Capacity................................................7.2 L (1.9 US gal.)
2
Air-Tight Test Pressure .........................250 kPa (2.6 kgf/cm , 36.3 psi)
Cap Opening Pressure......................... −
BATTERY
Capacity................................................55 Ah (5-Hour Rate)
Voltage..................................................12 V
Weight ..................................................17.7 kg (39 lb) × 2
T1-3-6
GENERAL / Component Specifications
HYDRAULIC COMPONENT
MAIN PUMP
Model..............................................................A8V080LA1KH2/63R1
Type................................................................Variable Displacement Double Pump
Maximum Flow (Theoretical Value)................ZAXIS160LC: 138 L/min (36.5 US gpm) × 2
HP Mode: 152.1 L/min (40.2 US gpm) ×2
ZAXIS180LC,180LCN: 150 L/min (39.6 US gpm) × 2
HP Mode: 165 L/min (43.6 US gpm) ×2
REGULATOR
Type................................................................Hydraulic Pressure Operated Type
PILOT PUMP
Type................................................................Fixed Displacement Type Gear Pump
Maximum Flow (Theoretical Value)................ZAXIS160LC: 24.2 L/min (6.39 US gpm)
HP Mode: 26.7 L/min (7.05 US gpm)
ZAXIS180LC,180LCN: 24.8 L/min (6.55 US gpm)
HP Mode: 27.3 L/min (7.21 US gpm)
CONTROL VALVE
Model..............................................................X34
Type................................................................Pilot Pressure Operated Type (4-Spools + 5-Spools)
Main Relief Set-Pressure ...............................Normal:
2
ZAXIS160LC: 34.3 MPa (350 kgf/cm , 4980 psi)
at 90 L/min (23.8 US gpm)
2
ZAXIS180LC,180LCN: 34.3 MPa (350 kgf/cm , 4980 psi)
at 100 L/min (26.4 US gpm)
2
Overload Relief Set-Pressure.........................37.3 MPa (380 kgf/cm , 5400 psi) at 50 L/min (13.2 US gpm)
(Boom, Arm Roll-In, Bucket Roll-In)
2
39.2 MPa (400 kgf/cm , 5690 psi) at 50 L/min (13.2 US gpm)
(Arm Roll-Out, Bucket Roll-Out)
T1-3-7
GENERAL / Component Specifications
SWING DEVICE
Type................................................................Two-Stage Reduction Planetary Gear
Reduction Gear Ratio .....................................ZAXIS160LC: 14.9
ZAXIS180LC,180LCN: 16.563
SWING MOTOR
Type................................................................Swash-Plate Type, Fixed Displacement Axial Plunger Motor
VALVE UNIT
Type................................................................Non Counterbalance Valve Type
2
Relief Set-Pressure........................................ZAXIS160LC: 30.4 MPa (310 kgf/cm , 4408 psi)
2
ZAXIS180LC,180LCN: 33.3 MPa (340 kgf/cm , 4835 psi)
TRAVEL DEVICE
ZAXIS160LC
Type............................................................... Two-Stage Reduction Planetary Gear
Reduction Gear Ratio .................................... 62.5
ZAXIS180LC
Type............................................................... Three-Stage Reduction Planetary Gear
Reduction Gear Ratio .................................... 53.289
ZAXIS180LCN
Type............................................................... Three-Stage Reduction Planetary Gear
Reduction Gear Ratio .................................... 53.234
TRAVEL MOTOR
Type................................................................Swash-Plate Type Variable Displacement Axial Plunger Motor
T1-3-8
GENERAL / Component Specifications
CYLINDER
ZAXIS160LC
Boom Arm Bucket
Rod Diameter .................................................80 mm (3.15’’) 90 mm (3.54’’) 75 mm (2.95’’)
Cylinder Bore .................................................110 mm (4.33’’) 120 mm (4.72’’) 105 mm (4.13’’)
Stroke.............................................................1110 mm (3’ 7.7’’) 1365 mm (4’ 5.7’’) 935 mm (3’ 0.8’’)
Fully Retracted Length ...................................1655 mm (5’ 5.2’’) 1905 mm (6’ 3’’) 1460 mm (4’ 9.5’’)
Plating Thickness ...........................................30 µm (1.18 µin) 30 µm (1.18 µin) 30 µm (1.18 µin)
ZAXIS180LC,180LCN
Boom Arm Bucket
Rod Diameter .................................................85 mm (3.35’’) 90 mm (3.54’’) 75 mm (2.95’’)
Cylinder Bore .................................................120 mm (4.72’’) 125 mm (4.92’’) 105 mm (4.13’’)
Stroke.............................................................1123 mm (3’ 8.2’’) 1371 mm (4’ 6.0’’) 1060 mm (3’ 5.7’’)
Fully Retracted Length ...................................1723 mm (5’ 7.8’’) 1901 mm (6’ 2.8’’) 1565 mm (5’ 1.6’’)
Plating Thickness ...........................................30 µm (1.18 µin) 30 µm (1.18 µin) 30 µm (1.18 µin)
T1-3-9
GENERAL / Component Specifications
ELECTRICAL COMPONENT
BATTERY RELAY
Voltage / Current.............................................24 V / 100 A
GLOW RELAY
Voltage............................................................24 V
HORN
Voltage / Current.............................................24 V⋅1.5±0.5 A
Sound Pressure..............................................113±5 dB (A)
ILLUMINATION
Specifications .................................................Work Light : Halogen 24V, 70 W
Cab Light : 24 V, 10 W
AIR CONDITIONER
Refrigerant ....................................................134 a
Cooling Ability .................................................19.3 MJ/h (4600 kcal/h)
3
Cool Air Volume ..............................................550 m /h or More
Heating Ability.................................................21.0 MJ/h (5000 kcal/h) or More
3
Warm Air Volume............................................400 m /h or More
Temperature Adjusting System.......................Electronic Type
Refrigerant Quantity .......................................950±50 g
3
Compressor Oil Quantity ................................180 cm
T1-3-10
MEMO
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