Hitachi ZX160LC-3 180LC-3 180LCN-3 Hydraulic Excavator Technical Troubleshooting Manual – PDF DOWNLOAD

Description

Hitachi ZX160LC-3 180LC-3 180LCN-3 Hydraulic Excavator Technical Troubleshooting Manual

FILE DETAILS:

Hitachi ZX160LC-3 180LC-3 180LCN-3 Hydraulic Excavator Technical Troubleshooting Manual

Language : English
Pages : 622
Downloadable : YES
Format : PDF
Size : 9.36 MB
Part No : TT1T1-E-00

DESCRIPTION:

Hitachi ZX160LC-3 180LC-3 180LCN-3 Hydraulic Excavator Technical Troubleshooting Manual

INTRODUCTION:

TO THE READER:
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.

ADDITIONAL REFERENCES:

• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material

MANUAL COMPOSITION:
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.

TABLE OF CONTENTS:

Hitachi ZX160LC-3 180LC-3 180LCN-3 Hydraulic Excavator Technical Troubleshooting Manual

ZX160LC-3/180LC-3/180LCN-3_TT1T1-E-00 1
INTRODUCTION 3
SAFETY 5
SECTION AND GROUP CONTENTS 41
SECTION 4 OPERATIONAL PERFORMANCE TEST 43
Group 1 Introduction 45
Operational Performance Tests 45
Preparation for Performance Tests 46
Group 2 Standard 47
ZAXIS160LC-3 OperationalPerformance Standard Table 47
ZAXIS180LC-3 OperationalPerformance Standard Table 52
Main Pump P-Q Diagram 58
Sensor Activating Range 60
Adjiustment Data List 61
Attachment Adjiustment Data List 62
Group 3 Engine Test 79
Engine Speed 79
Engine Compression Pressure 81
Valve Clearance 82
Lubricant Consumption 85
Group 4 Excavator Test 87
Travel Speed 87
Track Revolution Speed 88
Mistrack Check 89
Travel Parking Leakage 90
Swing Speed 91
Swing Function Drift Check 92
Swing Motor Leakage 94
Maximum Swingable Slant Angle 96
Swing Bearing Play 98
Hydraulic Cylinder Cycle Time100
Dig Function Drift Check102
Control Lever Operating Force104
Control Lever Stroke106
Combined Operation of Boom Raise / Swing Function Check108
Combined Operation of Boom Raise / Arm Roll-In Function Check110
Group 5 Component Test111
Primary Pilot Pressure111
Secondary Pilot Pressure113
Solenoid Valve Set Pressure115
Main Pump Delivery Pressure118
Main Relief Valve Set Pressure119
Relief Pressure(When relieving Swing)123
Overload Relief Valve Set Pressure125
Main Pump Flow Rate Measurement128
Swing Motor Drainage136
Travel Motor Drainage139
Group 6 Adjustment141
Adjustment141
Attachment Setting160
SECTION 5 TROUBLESHOOTING169
Group 1 Diagnosing Procedure173
Introduction173
Diagnosing Procedure174
Group 2 Monitor Unit179
Outline179
How to Use Screens197
Primary Screen207
Screen DisplayWhen An Alarm is Issued208
Contents of Alarms210
Troubleshooting212
Controller Version214
Monitoring216
Displaying Operating Conditions219
Pump 2 Flow Rate Adjustment (Only Machines Equipped with Optional Parts)220
Attachment Selection (Only Machines Equipped with Optional Parts)222
Time Set226
Fuel Rate Display/No Display228
Back Monitor Settings232
Maintenance Settings234
Language Settings240
Mail (Optional)242
Keyless Hour Meter244
List of Monitor Unit Sitting Function245
Group 3 e-Shovel249
Outline249
List of Daily Report Data250
List of Frequency Distribution Data253
List of Total Operating Hours254
How to Download and Upload Data of ICF256
Various Setup of ICF and Satellite Communication Terminal by Using Dr ZX259
List of Fault Code271
Satellite Communication System272
Group 4 Component Layout275
Main Components275
Electrical System (Overview)277
Electrical System (In Cab)278
Electrical System (Rear Tray)279
Electrical System (Switch Panel)280
Electrical System (Around Air Cleaner)281
Electrical System (Relays)282
Engine283
Pump Device284
Swing Device285
Control Valve285
Signal Control Valve286
Solenoid Valve Unit286
Travel Device287
Layout of Attachment Spec Parts288
Layout of Control Valve292
Pilot Port (Signal Control Valve)308
Group 5 Troubleshooting A313
Troubleshooting A Procedure313
Fault Code List MC314
ECM332
ICF356
Controller Hardware Failure MC Fault Code 11000 to 11002362
MC Fault Code 11003363
MC Fault Code 11004364
CAN Harness Check366
Engine FailureMC Fault Code 11100385
MC Fault Code 11101386
Pump Failure MC Fault Code 11200387
MC Fault Code 11202388
MC Fault Code 11206389
MC Fault Code 11208390
Pilot Failure MC Fault Code 11301391
MC Fault Code 11302392
MC Fault Code 11303393
MC Fault Code 11304394
MC Fault Code 11307396
Proportional Solenoid Valve Failure MC Fault Code 11400397
MC Fault Code 11401398
MC Fault Code 11402399
MC Fault Code 11403400
MC Fault Code 11404401
MC Fault Code 11405402
MC Fault Code 11410(ZX160-3class Only)403
CAN Data Reception Failure MC Fault Code 11910, 11914, 11920404
CAN Harness Check MC Fault Code 11910, 11914, 11920406
MC Fault Code 11911, 11918409
CAN Harness Check MC Fault Code 11911, 11918410
Other Failures
MC Fault Code 11901413
ECM, Sensor System ECM Fault Codes 100, 102, 105, 108, 110, 157, 172414
ECM Fault Codes 174, 636, 723, 10001415
ECM, External Device System ECM Fault Codes 651, 652, 653, 654, 655, 656, 1347, 10002416
ECM, Fuel System ECM Fault Codes 157, 633, 1239, 1240417
ECM, Engine Protection ECM Fault Codes 110, 190418
ECM, Engine Protection ECM Fault Codes 987, 1485419
ECM, Internal Circuit System ECM Fault Codes 628, 1077, 1079, 1080, 10003, 10004, 10005420
ECM Fault Codes 10006, 10007, 10008, 10009, 10010, 10011, 10013421
ECM, Communication System ECM Fault Codes 639422
ICF, Satellite Terminal Fault Codes 14000 to 14003423
ICF, Satellite Terminal Fault Codes 14006, 14008, 14100 to 14106427
Monitor Unit Fault Code 13303429
Monitor Unit Fault Code 13304430
Monitor Unit Fault Code 13306, 13308431
Monitor Unit Fault Code 13310432
Monitor Unit Fault Code 13311433
Pilot Shut-Off Lever Alarm434
Group 6 Troubleshooting B435
Troubleshooting B Procedure435
Relationship between Machine Trouble Symptoms and Related Parts436
Correlation between Trouble Symptoms and Part Failures476
Engine System Troubleshooting492
All Actuator System Troubleshooting520
Front Attachment System Troubleshooting534
Swing System Troubleshooting554
Travel System Troubleshooting558
Other System Troubleshooting566
Exchange Inspection586
Emergency Boom LoweringProcedure589
Attachment Pilot Circuit Pressure Release Procedure590
One Part of Data, Daily Report Data, Distribution Data and Total Operating hours is not Recorded592
Group 7 Electrical System Inspection601
Precautions for Inspection and Maintenance601
Instructions for Disconnecting Connectors603
Fuse Inspection604
Fusible Link Inspection605
Battery Voltage Check606
Alternator Check607
Continuity Check608
Voltage and Current Measurement610
Check by False Signal617
Test Harness618
SERVICE MANUAL REVISION REQUEST FORM621
THE ATTACHED DIAGRAM LIST622

HITACHI ZX160LC-3 180LC-3 180LCN-3 HYDRAULIC EXCAVATOR TECHNICAL TROUBLESHOOTING MANUAL – PDF DOWNLOAD:

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