Table of Contents
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Workshop Manual
Service Manual (Manual No. KM-1F1E) consists of the following three separate volumes;
Technical Manual (Operational Principle)
Technical Manual (Troubleshooting)
Workshop Manual
160LC
180LC
180LCN
Excavator
Manual No. : KM-1F1E
Vol. No.
: Vol. No. TO1F1E
: Vol. No. TT1F1E
: Vol. No. W1F1E
: W1F1E-01
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Table of Contents
Related Manuals for Hitachi Zaxis 160LC
Summary of Contents for Hitachi Zaxis 160LC
- Page 1 Manual No. : KM-1F1E Vol. No. : W1F1E-01 Workshop Manual 160LC 180LC 180LCN Excavator Service Manual (Manual No. KM-1F1E) consists of the following three separate volumes; Technical Manual (Operational Principle) : Vol. No. TO1F1E Technical Manual (Troubleshooting) : Vol. No. TT1F1E Workshop Manual : Vol.
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Page 3: Additional References
(Note: Do not tear off the form. Copy it for us- age.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-32-7173 FAX: 81-298-31-1162 ADDITIONAL REFERENCES • • Operation Manual of the Engine Please refer to the materials listed below in addition •... -
Page 4: Units Used
INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and • CAUTION: signal words are used to alert the reader to the Indicated potentially hazardous situation which potential for personal injury of machine damage. could, if not avoided, result in personal injury or death. -
Page 5: Recognize Safety Information
SAFETY RECOGNIZE SAFETY INFORMATION • This is the SAFETY ALERT SYMBOL. • When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices. 001-E01A-0688 SA-688 UNDERSTAND SIGNAL WORDS... -
Page 6: Follow Safety Instructions
SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual. • Safety signs should be installed, maintained and replaced when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your author- ized dealer in the same way you order other replacement parts (be sure to state machine... -
Page 7: Prepare For Emergencies
SAFETY PREPARE FOR EMERGENCIES • Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label at- tached on the fire extinguisher to use it properly. •... -
Page 8: Protect Against Noise
SAFETY PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. 006-E01A-0434 SA-434 INSPECT MACHINE •... -
Page 9: General Precautions For Cab
SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident. -
Page 10: Use Handholds And Steps
SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you mounting and dismounting the ma- chine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. -
Page 11: Fasten Your Seat Belt
SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine webbing, buckle... -
Page 12: Operate Only From Operator'sseat
SAFETY OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the track or on ground. -
Page 13: Keep Riders Off Machine
SAFETY KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner. -
Page 14: Drive Machine Safely
SAFETY DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive. • Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. -
Page 15: Avoid Injury From Rollaway Accidents
SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park machine. • Do not park the machine on a grade. •... -
Page 16: Avoid Injury From Back-Over And Swing Accidents
SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing swinging upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: •... -
Page 17: Avoid Tipping
SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE---SERIOUS FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT • The danger of tipping is always present when operating on a grade, possibly resulting in serious SA-012 injury or death. -
Page 18: Avoid Power Lines
SAFETY AVOID POWER LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. • When operating near an electric line, NEVER move any part of the machine or load closer than 3 m (10 ft) plus twice the line insulator length. -
Page 19: Protect Against Flying Debris
SAFETY PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object. -
Page 20: Handle Fluids Safely－Avoid Fires
SAFETY HANDLE FLUIDS SAFELY－AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks. -
Page 21: Safety Transporting
SAFETY SAFETY TRANSPORTING • danger tipping present when loading/unloading the machine onto/from a truck or trailer bed. • Be sure to observe local regulations when transporting the machine on public roads. • Provide an appropriate truck or trailer for transporting the machine. Take the following precautions when loading / unloading the machine: 1) Select firm level ground. -
Page 22: Practice Safe Maintenance
SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before doing work. • Keep work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving. - Page 23 SAFETY • If a maintenance procedure must be performed with the engine running, do not leave machine unattended. • If the machine must be raised, maintain a 90 to 110 angle between the boom and arm. Securely support any machine elements that must be raised for service work.
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Page 24: Warn Others Of Service Work
SAFETY WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury. • Before performing any work on the machine, at- tach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer. SS2045102 SUPPORT MACHINE PROPERLY •... -
Page 25: Prevent Parts From Flying
SAFETY PREVENT PARTS FROM FLYING • Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. • Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. •... -
Page 26: Prevent Burns
SAFETY PREVENT BURNS Hot spraying fluids: • After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. •... -
Page 27: Avoid High-Pressure Fluids
SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. •... -
Page 28: Prevent Fires
SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. - Page 29 SAFETY Check Key Switch: • If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. • Always check switch function before operating the machine every day: 1) Start the engine and run it at slow idle. 2) Turn the key switch to the OFF position to confirm that the engine stops.
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Page 30: Evacuating In Case Of Fire
SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. •... -
Page 31: Precautions For Welding And Grinding
SAFETY PRECAUTIONS WELDING GRINDING • Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. • Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. -
Page 32: Remove Paint Before Welding Or Heating
SAFETY REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. • Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. -
Page 33: Service Air Conditioning System Safely
SAFETY SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the freon container for proper use when servicing the air conditioning system. • Use a recovery and recycling system to avoid venting freon into the atmosphere. -
Page 34: Dispose Of Waste Properly
DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. - Page 35 SECTION 1 GENERAL — CONTENTS — Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling..........W1-1-1 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............
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- Page 37 GENERAL / Precautions for Disassembling and Assembling PRECAUTIONS DISASSEMBLING AND ASSEMBLING Precautions for Disassembling and Assembling • • Clean the Machine Precautions for Disassembling • To prevent dirt from entering, cap or plug the Thoroughly wash the machine before bringing it into the shop.
- Page 38 GENERAL / Precautions for Disassembling and Assembling • Precautions for Assembling Bleeding Air from Hydraulic System • Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the any damage. If any damage is found, repair or suction lines are replaced, or the removal and in- replace part.
- Page 39 GENERAL / Precautions for Disassembling and Assembling • Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each op- eration (never fully stroke the cylinders during ini- tial operation stage).
- Page 40 GENERAL / Precautions for Disassembling and Assembling Floating Seal Precautions 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together.
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