Hitachi Zaxis 160LC-5G (ZX 160LC-5G) Excavator Diagnostic & Test Service Manual PDF (TM13198X19) - MHITTM13198X19.zip
Full-service technical manual offering complete diagnostics and testing procedures, complete with electrical wiring schematics for the Hitachi Zaxis 160LC-5G Excavator — packed with workshop guidance so you can service, troubleshoot, and rebuild it just like a seasoned technician.
This workshop diagnosis & tests manual for the Hitachi ZX 160LC-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: 1,173 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English Portuguese Spanish
Model: John Deere / HITACHI - Zaxis160LC-5G Excavator - 1F9DBGG0__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....25
Wear Protective Clothing....26
Protect Against Noise....27
Inspect Machine....28
General Precautions for Cab....29
Use Handholds and Steps....30
Adjust the Operator's Seat....31
Ensure Safety Before Rising From or Leaving Operator’s Seat....32
Fasten Your Seat Belt....33
Move and Operate Machine Safely....34
Operate Only From Operator's Seat....35
Jump Starting....36
Keep Riders Off Machine....37
Precautions for Operations....38
Investigate Job Site Beforehand....39
Install OPG Guard....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
Store Attachments Safely....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
Notes on Protection of Operator’s Station When the Machine Rolls Over....92
Section 9001: Diagnostics....94
Group 10: Main Controller (MCZ) Diagnostic Trouble Codes....99
Main Controller (MCZ) Diagnostic Trouble Codes....99
Controller Area Network 0 (CAN 0) Circuit Diagnostics....100
Controller Area Network 1 (CAN 1) Circuit Diagnostics....101
Interface Controller Area Network (N-CAN) Diagnostics....102
011000.02 - Abnormal EEPROM....94
011001.02 - Abnormal RAM....94
011002.02 - Abnormal A/D Converter....94
011003.03 - Abnormal Sensor Voltage....94
011006.02 - Engine Controller Communication Error....94
011007.02 - (CAN 0) Data Converter Communication Error 1....94
011008.02 - (CAN 1) Data Converter Communication Error 2....94
011009.02 - (CAN 0) Monitor Controller Communication Error 1....94
011010.02 - (CAN 1) Monitor Controller Communication Error 2....94
011100.02 - Abnormal Engine Speed....94
011101.03 - Engine Control Dial Sensor Circuit High Input....94
011101.04 - Engine Control Dial Sensor Circuit Low Input....94
011200.03 - Pump 1 Delivery Pressure Sensor Circuit High Input....94
011200.04 - Pump 1 Delivery Pressure Sensor Circuit Low Input....94
011202.03 - Pump 2 Delivery Pressure Sensor Circuit High Input....94
011202.04 - Pump 2 Delivery Pressure Sensor Circuit Low Input....94
011206.03 - Pump 1 Flow Control Pressure Sensor Circuit High Input....94
011206.04 - Pump 1 Flow Control Pressure Sensor Circuit Low Input....94
011208.03 - Pump 2 Flow Control Pressure Sensor Circuit High Input....94
011208.04 - Pump 2 Flow Control Pressure Sensor Circuit Low Input....94
011301.03 - Swing Pilot Pressure Sensor Circuit High Input....94
011301.04 - Swing Pilot Pressure Sensor Circuit Low Input....94
011302.03 - Boom Up Pilot Pressure Sensor Circuit High Input....94
011302.04 - Boom Up Pilot Pressure Sensor Circuit Low Input....94
011303.03 - Arm In Pilot Pressure Sensor Circuit High Input....94
011303.04 - Arm In Pilot Pressure Sensor Circuit Low Input....94
011304.03 - Travel Pilot Pressure Sensor Circuit High Input....94
011304.04 - Travel Pilot Pressure Sensor Circuit Low Input....95
011307.03 - Front Attachment Pilot Pressure Sensor Circuit High Input....95
011307.04 - Front Attachment Pilot Pressure Sensor Circuit Low Input....95
011400.02 - Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback....95
011400.03 - Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current....95
011400.04 - Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current....95
011401.02 - Torque Control Solenoid Valve Abnormal Feedback....95
011401.03 - Torque Control Solenoid Valve Feedback High Current....95
011401.04 - Torque Control Solenoid Valve Feedback Low Current....95
011402.02 - 3-Spool Solenoid Valve Unit (SF) Abnormal Feedback....95
011402.03 - 3-Spool Solenoid Valve Unit (SF) Feedback High Input....95
011402.04 - 3-Spool Solenoid Valve Unit (SF) Feedback Low Input....95
011403.02 - 3-Spool Solenoid Valve Unit (SC) Abnormal Feedback....95
011403.03 - 3-Spool Solenoid Valve Unit (SC) Feedback High Input....95
011403.04 - 3-Spool Solenoid Valve Unit (SC) Feedback Low Input....95
011407.02 - 3-Spool Solenoid Valve Unit (SG) Abnormal Feedback....95
011407.03 - 3-Spool Solenoid Valve Unit (SG) Feedback High Input....95
011407.04 - 3-Spool Solenoid Valve Unit (SG) Feedback Low Input....95
011410.02 - Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback....95
011410.03 - Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current....95
011410.04 - Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current....95
011457.02 - 2-Speed Activation Solenoid Disconnected or Not Present....95
011458.02 - (Auxiliary) Discontinuity of Selector Valve....95
011901.03 - Hydraulic Oil Temperature Sensor Circuit High Input....95
011901.04 - Hydraulic Oil Temperature Sensor Circuit Low Input....95
Group 20: Engine Controller (ECF) Diagnostic Trouble Codes....249
Engine Controller (ECF) Diagnostic Trouble Codes....249
011600.02 - Abnormal EEPROM....95
011601.02 - Abnormal RAM....95
011602.02 - Abnormal A/D Conversion....95
011603.03 - Abnormal Sensor Voltage....95
011604.02 - Abnormal CAN Communication....95
016605.02 - Abnormal Engine Speed....95
016606.03 - Abnormal EC Angle Sensor High Voltage....96
016606.04 - Abnormal EC Angle Sensor Low Voltage....96
016607.02 - Target Engine Speed Sent From Main Controller....96
Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes....265
Monitor Controller (DSZ) Diagnostic Trouble Codes....265
013000.02 - Flash Memory Error 1....96
013001.02 - Flash Memory Error 2....96
013002.02 - Engine Controller (ECF) Communication Error....96
013003.02 - Main Controller (MCZ) Communication Error 1....96
013004.02 - Main Controller (MCZ) Communication Error 2....96
013005.02 - Monitor Controller (DSZ) Communication Error 1....96
013006.02 - Monitor Controller (DSZ) Communication Error 2....96
013007.02 - Machine Controller (BCZ) Communication Error....96
020113.02 - System Error Alarm....96
Group 40: Information Controller (ICZ) Diagnostic Trouble Codes....276
Information Controller (ICZ) Diagnostic Trouble Codes....276
013303.02 - Abnormal Monitor Internal Temperature Sensor....96
013304.02 - Alternator Alarm....96
013310.03 - Shorted Circuit in Coolant Temperature Sensor....96
013311.03 - Fuel Level Sensor Open Circuit....96
013311.04 - Fuel Level Sensor Shorted Circuit....96
014001.02 - Flash Memory Read/Write Error....96
014002.02 - External RAM Read/Write Error....96
014003.02 - Abnormal EEPROM....96
014006.02 - Communication Terminal: Communication Error....96
014008.02 - Abnormal Internal RAM....96
014021.02 - Communication Terminal Security Error....96
014022.02 - SIM Card Error....96
014023.02 - Security Error....96
020100.02 - Overheat Alarm....96
020101.02 - Engine Warning Alarm....96
020102.02 - Engine Oil Pressure Alarm....96
020105.02 - Hydraulic Oil Filter Restriction Alarm....96
020106.02 - Air Cleaner Restriction Alarm....97
020109.02 - Pilot Control Shutoff Lever Alarm....97
020114.02 - Overheat Alarm....97
Group 50: Air Conditioner Controller (ACF) Diagnostic Trouble Codes....312
Air Conditioner Controller (ACF) Diagnostic Trouble Codes....312
11 - Open Circuit in Air Recirculation Sensor....97
12 - Short-Circuited Air Recirculation Sensor....97
13 - Open Circuit in Ambient Air Temperature Sensor....97
14 - Short-Circuited Ambient Air Temperature Sensor....97
18 - Short-Circuited Solar Radiation Sensor....97
21 - Open Circuit in Air Conditioner Freeze Control Switch....97
22 - Short-Circuited Air Conditioner Freeze Control Switch....97
43 - Abnormal Air Conditioner and Heater Blower Port Change Servomotor....97
44 - Abnormal Air Conditioner and Heater Mixer Servomotor....97
91 - Communication Error....97
92 - CAN Bus Off Error....97
Section 9005: Operational Checkout Procedure....342
Group 10: Operational Checkout Procedure....342
Operational Checkout....406
Section 9010: Engine....469
Group 05: Theory of Operation....656
Isuzu Engine....488
Engine Fuel System Component Location....472
Engine Cooling System Component Location....473
Engine Speed Control System Operation....656
Group 15: Diagnostic Information....469
Isuzu Engine....488
Group 20: Adjustments....469
Isuzu Engine....488
Engine Learning Procedure....482
Engine Speed Adjustment....484
Engine Fuel Shutoff Adjustment....486
Group 25: Tests....469
Isuzu Engine....488
Section 9015: Electrical System....489
Group 05: System Information....489
Electrical Diagram Information....500
Group 10: System Diagrams....489
Explanation of Wire Markings....509
Fuse and Relay Specifications....510
System Functional Schematic, Component Location, and Wiring Diagram Master Legend....515
System Functional Schematic....522
Cab Harness (W1) Component Location....532
Cab Harness (W1) Wiring Diagram....535
Machine Harness (W2) Component Location....539
Machine Harness (W2) Wiring Diagram....541
Monitor Harness (W3) Component Location....543
Monitor Harness (W3) Wiring Diagram....544
Pump Harness (W8) Component Location....546
Pump Harness (W8) Wiring Diagram....548
Pilot Shutoff Switch Harness (W11) Component Location....549
Pilot Shutoff Switch Harness (W11) Wiring Diagram....550
Auxiliary Fuse Box Harness (W13) Component Location....551
Auxiliary Fuse Box Harness (W13) Wiring Diagram....552
Multi-Function Pilot Control Lever Harness (W15) Component Location....554
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram....556
Travel Alarm Cancel Switch Harness (W16) Component Location....557
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram....558
Attachment Harness (W17) Component Location....559
Attachment Harness (W17) Wiring Diagram....561
Rear Camera Harness (W19) Component Location....562
Rear Camera Harness (W19) Wiring Diagram....563
Pilot Shutoff Valve Harness (W21) Component Location....564
Pilot Shutoff Valve Harness (W21) Wiring Diagram....565
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location....566
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram....567
Attachment Interface Harness (W25) Component Location....568
Attachment Interface Harness (W25) Wiring Diagram....569
Travel Alarm Harness (W26) Component Location....570
Travel Alarm Harness (W26) Wiring Diagram....571
Solenoid Harness (W28) Component Location....572
Solenoid Harness (W28) Wiring Diagram....573
Starter Switch Harness (W29) Component Location....574
Starter Switch Harness (W29) Wiring Diagram....575
Data Converter Harness (W30) Component Location....576
Data Converter Harness (W30) Wiring Diagram....578
Data Converter Interface Harness (W31) Component Location....580
Data Converter Interface Harness (W31) Wiring Diagram....581
2-Speed Harness (W32) Component Location....582
2-Speed Harness (W32) Wiring Diagram....583
Heater and Air Conditioner Harness (W41) Component Location....584
Heater and Air Conditioner Harness (W41) Wiring Diagram....585
Travel Alarm Cancel Switch Sub Harness (W50) Component Location....586
Travel Alarm Cancel Switch Sub Harness (W50) Wiring Diagram....587
Heater and Air Conditioner Relay Harness (W51) Component Location....588
Heater and Air Conditioner Relay Harness (W51) Wiring Diagram....589
Auxiliary Solenoid Harness (W61) Component Location....591
Auxiliary Solenoid Harness (W61) Wiring Diagram....593
Satellite (SAT) Harness (W6003) Component Location....595
Satellite (SAT) Harness (W6003) Wiring Diagram....596
JDLink™ Harness (W6004) Component Location....597
JDLink™ Harness (W6004) Wiring Diagram....599
Group 15: Sub-System Diagnostics....490
Controller Area Network (CAN) Theory of Operation....656
Starting and Charging Circuit Theory of Operation....656
Monitor Controller (DSZ) Circuit Theory of Operation....656
Engine Controller (ECF) Circuit Theory of Operation....656
Main Controller (MCZ) Circuit Theory of Operation....656
Travel Alarm Circuit Theory of Operation....656
Machine Controller (BCZ) Circuit Theory of Operation....656
Windshield Wiper and Washer Circuit Theory of Operation....656
Lighting Circuit Theory of Operation....656
Pilot Shutoff Circuit Theory of Operation....656
Attachment Control Circuit Theory of Operation....656
Group 16: Monitor Operation....656
Service Menu....647
Troubleshooting....648
Monitoring....649
Controller Version....654
Issued Warning Record....655
Operation....656
Machine Setting....657
Monitor Setting....662
Alarm Setting....665
Maintenance Mode....666
Rear View Camera Troubleshooting....667
Group 20: References....491
Reading Diagnostic Trouble Codes with Monitor Display....671