Hitachi Zaxis160LC-5G (ZX160LC-5G) Excavator Workshop Repair Technical Manual TM12644 - Diagnosis & Tests PDF - MHITTM12644.zip
A complete technical manual covering diagnosis and testing, complete with electrical wiring schematics, for the Hitachi Zaxis160LC-5G Excavator — packed with service data so you can service, troubleshoot, and overhaul the machine the way professional technicians do.
This Diagnosis & Tests workshop manual for the Hitachi Zaxis160LC-5G (ZX160LC-5G) Excavator contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
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PRODUCT DETAILS:
Total Pages: 1,153 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English Spanish French Portuguese
Models: John Deere / HITACHI - Excavator - 1FFDBGH0__C230001
TABLE OF CONTENTS...1
Section 9000: General Information...18
Group 01: Safety...18
Recognize Safety Information...21
Understand Signal Words...22
Follow Safety Instructions...23
Prepare for Emergencies...24
Wear Protective Clothing...25
Protect Against Noise...26
Inspect Machine...27
General Precautions for Cab...28
Use Handholds and Steps...29
Adjust the Operator's Seat...30
Ensure Safety Before Rising From or Leaving Operator’s Seat...31
Fasten Your Seat Belt...32
Move and Operate Machine Safely...33
Operate Only From Operator's Seat...34
Jump Starting...35
Keep Riders Off Machine...36
Precautions for Operations...37
Investigate Job Site Beforehand...38
Install OPG Guard...40
Restriction of Attachment Installation...41
Provide Signals for Jobs Involving Multiple Machines...42
Confirm Direction of Machine to be Driven...43
Drive Machine Safely...44
Avoid Injury From Rollaway Accidents...48
Avoid Injury From Back-Over and Swing Accidents...49
Keep Person Clear From Working Area...51
Never Position Bucket Over Anyone...52
Avoid Undercutting...53
Avoid Tipping...54
Never Undercut a High Bank...56
Dig With Caution...57
Operate With Caution...58
Avoid Power Lines...59
Precautions for Lightning...60
Object Handling...61
Protect Against Flying Debris...62
Park Machine Safely...63
Handle Fluids Safely−Avoid Fires...64
Transport Safely...65
Practice Safe Maintenance...66
Warn Others of Service Work...68
Support Machine Properly...69
Stay Clear of Moving Parts...70
Prevent Parts From Flying...71
Avoid Injury from Attachment Falling Accident...72
Prevent Burns...73
Replace Rubber Hoses Periodically...74
Avoid High-Pressure Fluids...75
Prevent Fires...77
Evacuating in Case of Fire...79
Beware of Exhaust Fumes...80
Precautions for Welding and Grinding...81
Avoid Heating Near Pressurized Fluid Lines...82
Remove Paint Before Welding or Heating...83
Beware of Asbestos and Silicon Dust and Other Contamination...84
Prevent Battery Explosions...85
Service Air Conditioning System Safely...86
Handle Chemical Products Safely...87
Dispose of Waste Properly...88
Never Ride Attachment...89
Precautions for Communication Terminal...90
FCC Notifications to User...91
Before Returning the Machine to the Customer...92
Notes on Protection of Operator’s Station When the Machine Rolls Over...93
Section 9001: Diagnostics...95
Group 10: Main Controller (MCZ) Diagnostic Trouble Codes...100
Main Controller (MCZ) Diagnostic Trouble Codes...100
Controller Area Network 0 (CAN 0) Circuit Diagnostics...101
Controller Area Network 1 (CAN 1) Circuit Diagnostics...102
Interface Controller Area Network (N-CAN) Diagnostics...103
011000.02 - Abnormal EEPROM...95
011001.02 - Abnormal RAM...95
011002.02 - Abnormal A/D Converter...95
011003.03 - Abnormal Sensor Voltage...95
011006.02 - Engine Controller Communication Error...95
011007.02 - (CAN 0) Data Converter Communication Error 1...95
011008.02 - (CAN 1) Data Converter Communication Error 2...95
011009.02 - (CAN 0) Monitor Controller Communication Error 1...95
011010.02 - (CAN 1) Monitor Controller Communication Error 2...95
011100.02 - Abnormal Engine Speed...95
011101.03 - Engine Control Dial Sensor Circuit High Input...95
011101.04 - Engine Control Dial Sensor Circuit Low Input...95
011200.03 - Pump 1 Delivery Pressure Sensor Circuit High Input...95
011200.04 - Pump 1 Delivery Pressure Sensor Circuit Low Input...95
011202.03 - Pump 2 Delivery Pressure Sensor Circuit High Input...95
011202.04 - Pump 2 Delivery Pressure Sensor Circuit Low Input...95
011206.03 - Pump 1 Flow Control Pressure Sensor Circuit High Input...95
011206.04 - Pump 1 Flow Control Pressure Sensor Circuit Low Input...95
011208.03 - Pump 2 Flow Control Pressure Sensor Circuit High Input...95
011208.04 - Pump 2 Flow Control Pressure Sensor Circuit Low Input...95
011301.03 - Swing Pilot Pressure Sensor Circuit High Input...95
011301.04 - Swing Pilot Pressure Sensor Circuit Low Input...95
011302.03 - Boom Up Pilot Pressure Sensor Circuit High Input...95
011302.04 - Boom Up Pilot Pressure Sensor Circuit Low Input...95
011303.03 - Arm In Pilot Pressure Sensor Circuit High Input...95
011303.04 - Arm In Pilot Pressure Sensor Circuit Low Input...95
011304.03 - Travel Pilot Pressure Sensor Circuit High Input...95
011304.04 - Travel Pilot Pressure Sensor Circuit Low Input...96
011307.03 - Front Attachment Pilot Pressure Sensor Circuit High Input...96
011307.04 - Front Attachment Pilot Pressure Sensor Circuit Low Input...96
011400.02 - Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback...96
011400.03 - Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current...96
011400.04 - Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current...96
011401.02 - Torque Control Solenoid Valve Abnormal Feedback...96
011401.03 - Torque Control Solenoid Valve Feedback High Current...96
011401.04 - Torque Control Solenoid Valve Feedback Low Current...96
011402.02 - 3-Spool Solenoid Valve Unit (SF) Abnormal Feedback...96
011402.03 - 3-Spool Solenoid Valve Unit (SF) Feedback High Input...96
011402.04 - 3-Spool Solenoid Valve Unit (SF) Feedback Low Input...96
011403.02 - 3-Spool Solenoid Valve Unit (SC) Abnormal Feedback...96
011403.03 - 3-Spool Solenoid Valve Unit (SC) Feedback High Input...96
011403.04 - 3-Spool Solenoid Valve Unit (SC) Feedback Low Input...96
011407.02 - 3-Spool Solenoid Valve Unit (SG) Abnormal Feedback...96
011407.03 - 3-Spool Solenoid Valve Unit (SG) Feedback High Input...96
011407.04 - 3-Spool Solenoid Valve Unit (SG) Feedback Low Input...96
011410.02 - Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback...96
011410.03 - Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current...96
011410.04 - Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current...96
011457.02 - 2-Speed Activation Solenoid Disconnected or Not Present...96
011458.02 - (Auxiliary) Discontinuity of Selector Valve...96
011901.03 - Hydraulic Oil Temperature Sensor Circuit High Input...96
011901.04 - Hydraulic Oil Temperature Sensor Circuit Low Input...96
Group 20: Engine Controller (ECF) Diagnostic Trouble Codes...250
Engine Controller (ECF) Diagnostic Trouble Codes...250
011600.02 - Abnormal EEPROM...96
011601.02 - Abnormal RAM...96
011602.02 - Abnormal A/D Conversion...96
011603.03 - Abnormal Sensor Voltage...96
011604.02 - Abnormal CAN Communication...96
016605.02 - Abnormal Engine Speed...96
016606.03 - Abnormal EC Angle Sensor High Voltage...97
016606.04 - Abnormal EC Angle Sensor Low Voltage...97
016607.02 - Target Engine Speed Sent From Main Controller...97
Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes...266
Monitor Controller (DSZ) Diagnostic Trouble Codes...266
013000.02 - Flash Memory Error 1...97
013001.02 - Flash Memory Error 2...97
013002.02 - Engine Controller (ECF) Communication Error...97
013003.02 - Main Controller (MCZ) Communication Error 1...97
013004.02 - Main Controller (MCZ) Communication Error 2...97
013005.02 - Monitor Controller (DSZ) Communication Error 1...97
013006.02 - Monitor Controller (DSZ) Communication Error 2...97
013007.02 - Machine Controller (BCZ) Communication Error...97
020113.02 - System Error Alarm...97
Group 40: Information Controller (ICZ) Diagnostic Trouble Codes...277
Information Controller (ICZ) Diagnostic Trouble Codes...277
013303.02 - Abnormal Monitor Internal Temperature Sensor...97
013304.02 - Alternator Alarm...97
013310.03 - Shorted Circuit in Coolant Temperature Sensor...97
013311.03 - Fuel Level Sensor Open Circuit...97
013311.04 - Fuel Level Sensor Shorted Circuit...97
014001.02 - Flash Memory Read/Write Error...97
014002.02 - External RAM Read/Write Error...97
014003.02 - Abnormal EEPROM...97
014006.02 - Communication Terminal: Communication Error...97
014008.02 - Abnormal Internal RAM...97
014021.02 - Communication Terminal Security Error...97
014022.02 - SIM Card Error...97
014023.02 - Security Error...97
020100.02 - Overheat Alarm...97
020101.02 - Engine Warning Alarm...97
020102.02 - Engine Oil Pressure Alarm...97
020105.02 - Hydraulic Oil Filter Restriction Alarm...97
020106.02 - Air Cleaner Restriction Alarm...98
020109.02 - Pilot Control Shutoff Lever Alarm...98
020114.02 - Overheat Alarm...98
Group 50: Air Conditioner Controller (ACF) Diagnostic Trouble Codes...313
Air Conditioner Controller (ACF) Diagnostic Trouble Codes...313
11 - Open Circuit in Air Recirculation Sensor...98
12 - Short-Circuited Air Recirculation Sensor...98
13 - Open Circuit in Ambient Air Temperature Sensor...98
14 - Short-Circuited Ambient Air Temperature Sensor...98
18 - Short-Circuited Solar Radiation Sensor...98
21 - Open Circuit in Air Conditioner Freeze Control Switch...98
22 - Short-Circuited Air Conditioner Freeze Control Switch...98
43 - Abnormal Air Conditioner and Heater Blower Port Change Servomotor...98
44 - Abnormal Air Conditioner and Heater Mixer Servomotor...98
91 - Communication Error...98
92 - CAN Bus Off Error...98
Section 9005: Operational Checkout Procedure...343
Group 10: Operational Checkout Procedure...343
Operational Checkout...408
Section 9010: Engine...472
Group 05: Theory of Operation...670
Isuzu Engine...492
Engine Fuel System Component Location...475
Engine Cooling System Component Location...476
Cold Weather Starting Aid...477
Engine Speed Control System Operation...670
Group 15: Diagnostic Information...472
Isuzu Engine...492
Group 20: Adjustments...472
Isuzu Engine...492
Engine Learning Procedure...486
Engine Speed Adjustment...488
Engine Fuel Shutoff Adjustment...490
Group 25: Tests...472
Isuzu Engine...492
Section 9015: Electrical System...493
Group 05: System Information...493
Electrical Diagram Information...505
Group 10: System Diagrams...493
Explanation of Wire Markings...514
Fuse and Relay Specifications...515
System Functional Schematic, Component Location, and Wiring Diagram Master Legend...520
System Functional Schematic...527
Cab Harness (W1) Component Location...537
Cab Harness (W1) Wiring Diagram...541
Machine Harness (W2) Component Location...545
Machine Harness (W2) Wiring Diagram...547
Monitor Harness (W3) Component Location...549
Monitor Harness (W3) Wiring Diagram...550
Pump Harness (W8) Component Location...552
Pump Harness (W8) Wiring Diagram...554
Pilot Shutoff Switch Harness (W11) Component Location...555
Pilot Shutoff Switch Harness (W11) Wiring Diagram...556
Auxiliary Fuse Box Harness (W13) Component Location...557
Auxiliary Fuse Box Harness (W13) Wiring Diagram...558
Heated Air Seat Harness (W14) Component Location...560
Heated Air Seat Harness (W14) Wiring Diagram...562
Multi-Function Pilot Control Lever Harness (W15) Component Location...563
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram...565
Travel Alarm Cancel Switch Harness (W16) Component Location...566
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram...567
Attachment Harness (W17) Component Location...568
Attachment Harness (W17) Wiring Diagram...570
Rear Camera Harness (W19) Component Location...571
Rear Camera Harness (W19) Wiring Diagram...572
Pilot Shutoff Valve Harness (W21) Component Location...573
Pilot Shutoff Valve Harness (W21) Wiring Diagram...574
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location...575
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram...576
Seat Heater Switch Harness (W24) Component Location...577
Seat Heater Switch Harness (W24) Wiring Diagram...578
Attachment Interface Harness (W25) Component Location...579
Attachment Interface Harness (W25) Wiring Diagram...580
Travel Alarm Harness (W26) Component Location...581
Travel Alarm Harness (W26) Wiring Diagram...582
Solenoid Harness (W28) Component Location...583
Solenoid Harness (W28) Wiring Diagram...584
Starter Switch Harness (W29) Component Location...585
Starter Switch Harness (W29) Wiring Diagram...586
Data Converter Harness (W30) Component Location...587
Data Converter Harness (W30) Wiring Diagram...589
Data Converter Interface Harness (W31) Component Location...591
Data Converter Interface Harness (W31) Wiring Diagram...592
2-Speed Harness (W32) Component Location...593
2-Speed Harness (W32) Wiring Diagram...594
Heater and Air Conditioner Harness (W41) Component Location...595
Heater and Air Conditioner Harness (W41) Wiring Diagram...596
Travel Alarm Cancel Switch Sub Harness (W50) Component Location...597
Travel Alarm Cancel Switch Sub Harness (W50) Wiring Diagram...598
Heater and Air Conditioner Relay Harness (W51) Component Location...599
Heater and Air Conditioner Relay Harness (W51) Wiring Diagram...600
12-Volt Power Harness (W55) Component Location...602
12-Volt Power Harness (W55) Wiring Diagram...603
Auxiliary Solenoid Harness (W61) Component Location...604
Auxiliary Solenoid Harness (W61) Wiring Diagram...606
Satellite (SAT) Harness (W6003) Component Location...608
Satellite (SAT) Harness (W6003) Wiring Diagram...609
JDLink™ Harness (W6004) Component Location...610
JDLink™ Harness (W6004) Wiring Diagram...612
Group 15: Sub-System Diagnostics...494
Controller Area Network (CAN) Theory of Operation...670
Starting and Charging Circuit Theory of Operation...670
Monitor Controller (DSZ) Circuit Theory of Operation...670
Engine Controller (ECF) Circuit Theory of Operation...670
Main Controller (MCZ) Circuit Theory of Operation...670
Travel Alarm Circuit Theory of Operation...670
Machine Controller (BCZ) Circuit Theory of Operation...670
Windshield Wiper and Washer Circuit Theory of Operation...670
Lighting Circuit Theory of Operation...670
Pilot Shutoff Circuit Theory of Operation...670
Attachment Control Circuit Theory of Operation...670
Group 16: Monitor Operation...670
Service Menu...661
Troubleshooting...662
Monitoring...663