Hitachi ZX160LC-3 / ZX180LC-3 / ZX180LCN-3 Crawler Excavator Technical Repair Service Manual

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Information included in this Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures for the ZX160LC-3 / ZX180LC-3 / ZX180LCN-3 Hitachi Crawler Hydraulic Excavator.


APPLICABLE MODELS :

Hitachi Excavator ZAXIS 160LC-3
Hitachi Excavator ZAXIS 180LC-3
Hitachi Excavator ZAXIS 180LCN-3


TABLE OF CONTENTS :

(Operational Principle) - TO1T1-E-00

SECTION 1 GENERAL
    Group 1 Specifications
    Group 2 Component Layout
    Group 3 Component Specifications
    
SECTION 2 SYSTEM
    Group 1 Controller
    Group 2 Control System
    Group 3 ECM System
    Group 4 Hydraulic System
    Group 5 Electrical System
    
SECTION 3 COMPONENT OPERATION
    Group 1 Pump Device
    Group 2 Swing Device
    Group 3 Control Valve
    Group 4 Pilot Valve
    Group 5 Travel Device
    Group 6 Signal Control Valve
    Group 7 Others (Upperstructure)
    Group 8 Others (Undercarriage)
        
(Troubleshooting) - TT1T1-E-00

SECTION 4 OPERATIONAL PERFORMANCE TEST
    Group 1 Introduction
    Group 2 Standard
    Group 3 Engine Test
    Group 4 Excavator Test
    Group 5 Component Test
    Group 6 Adjustment

SECTION 5 TROUBLESHOOTING
    Group 1 Diagnosing Procedure
    Group 2 Monitor Unit
    Group 3 e-Shovel
    Group 4 Component Layout
    Group 5 Troubleshooting A
    Group 6 Troubleshooting B
    Group 7 Electrical System Inspection
        
SERVICE MANUAL REVISION REQUEST FORM
THE ATTACHED DIAGRAM LIST

ZAXIS160-3 CLASS/180-3 CLASS ELECTRICAL DIAGRAM
ZAXIS160-3 CLASS/180-3 CLASS CONNECTORS
ZAXIS160-3 CLASS/180-3 CLASS ENGINE HARNESS
ZAXIS160-3 CLASS/180-3 CLASS CAB HARNESS
ZAXIS160-3 CLASS/180-3 CLASS MONITOR UNIT HARNESS
ZAXIS160-3 CLASS HYDRAULIC CIRCUIT DIAGRAM
ZAXIS160-3 CLASS HYDRAULIC CIRCUIT DIAGRAM
ZAXIS160-3 CLASS HYDRAULIC CIRCUIT DIAGRAM
ZAXIS180-3 CLASS HYDRAULIC CIRCUIT DIAGRAM
ZAXIS180-3 CLASS HYDRAULIC CIRCUIT DIAGRAM
ZAXIS180-3 CLASS HYDRAULIC CIRCUIT DIAGRAM


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 1030


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ZX160LC-3/180LC-3/180LCN-3_TO1T1-E-00
INTRODUCTION

SECTION AND GROUP CONTENTS

SECTION 1 GENERAL
    Group 1 Specifications
        Specifications
        Working Ranges
    Group 2 Component Layout
        Main Components
        Electrical System (Overview)
        Electrical System (IN CAB)
        Electrical System (Rear Tray)
        Electrical System (Switch Panel)
        Electrical System (Around Air Cleaner)
        Electrical System (Relays)
        Engine
        Pump Device
        Around Pump Device
        Swing Device
        Control Valve
        Signal Control Valve
        Solenoid Valve Unit
        Travel Device
        Layout of Attachmet Spec. Parts
    Group 3 Component Specifications
        Engine
        Engine Accessories
        Hydraulic Component
        Electrical Component
        
SECTION 2 SYSTEM
    Group 1 Controller
        Outline
        Can (Network Provided for Machine)
        MC: Main Controller
        ECM: Engine Control Module
        ICF: Information Controller
        Monitor Unit
    Group 2 Control System
        Outline
        Engine Control
        Pump Control
        Valve Control
        Other Controls
    Group 3 ECM System
        Outline
        Fuel Injection Control
        Engine Start Control
        EGR (Exhaust Gas Recirculation) Control
        Fuel Injection Amount Correction
        Engine Stop Control
    Group 4 Hydraulic System
        Outline
        Pilot Circuit
        Main Circuit
        Boom Lower Meter-In Cut Control
    Group 5 Electrical System
        Outline
        Main Circuit
        Electric Power Circuit (Key Switch: OFF)
        Accessory Circuit
        Starting Circuit (Key Switch: START)
        Charging Circuit (Key Switch: ON)
        Serge Voltage Prevention Circuit
        Pilot Shut-Off Circuit (Key Switch: ON)
        Security Lock Circuit
        Engine Stop Circuit (Key Switch: OFF)
        Security Horn Circuit
        Working Light Circuit
        Wiper Circuit
        
SECTION 3 COMPONENT OPERATION
    Group 1 Pump Device
        Outline
        Main Pump
        Regulator
        Solenoid Valve
        Pilot Pump
        Pump Delivery Pressure Sensor
        Pump Control Pressure Sensor
    Group 2 Swing Device
        Outline
        Swing Reduction Gear
        Swing Motor
        Swing Parking Brake
        Valve Unit
        Swing Dampener Valve
    Group 3 Control Valve
        Outline
        Hydraulic Circuit
        Flow Combiner Valve
        Main Relief Valve
        Overload Relief Valve
        Regenerative Valve
        Anti-Drift Valve
        Flow Rate Control Valve
        Digging Regenerative Valve
        Boom Lower Meter-In Cut Valve
        Auxiliary Flow Ccmbiner Valve and Bypass Shut-Out Valve
    Group 4 Pilot Valve
        Outline
        Operation
        Shockless Function(Only for Travel Pilot Valve)
    Group 5 Travel Device
        Outline
        Travel Reduction Gear
        Travel Motor
        Parking Brake
        Travel Mode Change
        Travel Brake Valve
    Group 6 Signal Control Valve
        Outline
        Pilot Port
        Shuttle Valve
        Shockless Valve
        Pump 1 and Pump 2 Flow Rate Control Valves
        Bucket Flow Rate Control Valve Control Spool,Flow Combiner Valve Control Spool, SwingParking Brake Release Spool, Arm 1 Flow Rate Control Valve Control Spool
    Group 7 Others (Upperstructure)
        Pilot Shut-Off Valve
        Solenoid Valve
        Hose Rupture Valve
        Pilot Relief Valve
    Group 8 Others (Undercarriage)
        Swing Bearing
        Center Joint
        Track Adjuster
        
        ZX160LC-3/180LC-3/180LCN-3_TT1T1-E-00
        
INTRODUCTION
SAFETY
SECTION AND GROUP CONTENTS

SECTION 4 OPERATIONAL PERFORMANCE TEST
    Group 1 Introduction
        Operational Performance Tests
        Preparation for Performance Tests
    Group 2 Standard
        ZAXIS160LC-3 OperationalPerformance Standard Table
        ZAXIS180LC-3 OperationalPerformance Standard Table
        Main Pump P-Q Diagram
        Sensor Activating Range
        Adjiustment Data List
        Attachment Adjiustment Data List
    Group 3 Engine Test
        Engine Speed
        Engine Compression Pressure
        Valve Clearance
        Lubricant Consumption
    Group 4 Excavator Test
        Travel Speed
        Track Revolution Speed
        Mistrack Check
        Travel Parking Leakage
        Swing Speed
        Swing Function Drift Check
        Swing Motor Leakage
        Maximum Swingable Slant Angle
        Swing Bearing Play
        Hydraulic Cylinder Cycle Time
        Dig Function Drift Check
        Control Lever Operating Force
        Control Lever Stroke
        Combined Operation of Boom Raise / Swing Function Check
        Combined Operation of Boom Raise / Arm Roll-In Function Check
    Group 5 Component Test
        Primary Pilot Pressure
        Secondary Pilot Pressure
        Solenoid Valve Set Pressure
        Main Pump Delivery Pressure
        Main Relief Valve Set Pressure
        Relief Pressure(When relieving Swing)
        Overload Relief Valve Set Pressure
        Main Pump Flow Rate Measurement
        Swing Motor Drainage
        Travel Motor Drainage
    Group 6 Adjustment
        Adjustment
        Attachment Setting
        
SECTION 5 TROUBLESHOOTING
    Group 1 Diagnosing Procedure
        Introduction
        Diagnosing Procedure
    Group 2 Monitor Unit
        Outline
        How to Use Screens
        Primary Screen
        Screen DisplayWhen An Alarm is Issued
        Contents of Alarms
        Troubleshooting
        Controller Version
        Monitoring
        Displaying Operating Conditions
        Pump 2 Flow Rate Adjustment (Only Machines Equipped with Optional Parts)
        Attachment Selection (Only Machines Equipped with Optional Parts)
        Time Set
        Fuel Rate Display/No Display
        Back Monitor Settings
        Maintenance Settings
        Language Settings
        Mail (Optional)
        Keyless Hour Meter
        List of Monitor Unit Sitting Function
    Group 3 e-Shovel
        Outline
        List of Daily Report Data
        List of Frequency Distribution Data
        List of Total Operating Hours
        How to Download and Upload Data of ICF
        Various Setup of ICF and Satellite Communication Terminal by Using Dr. ZX
        List of Fault Code
        Satellite Communication System
    Group 4 Component Layout
        Main Components
        Electrical System (Overview)
        Electrical System (In Cab)
        Electrical System (Rear Tray)
        Electrical System (Switch Panel)
        Electrical System (Around Air Cleaner)
        Electrical System (Relays)
        Engine
        Pump Device
        Swing Device
        Control Valve
        Signal Control Valve
        Solenoid Valve Unit
        Travel Device
        Layout of Attachment Spec. Parts
        Layout of Control Valve
        Pilot Port (Signal Control Valve)
    Group 5 Troubleshooting A
        Troubleshooting A Procedure
        Fault Code List MC
        ECM
        ICF
        Controller Hardware Failure MC Fault Code 11000 to 11002
        MC Fault Code 11003
        MC Fault Code 11004
        CAN Harness Check
        Engine FailureMC Fault Code 11100
        MC Fault Code 11101
        Pump Failure MC Fault Code 11200
        MC Fault Code 11202
        MC Fault Code 11206
        MC Fault Code 11208
        Pilot Failure MC Fault Code 11301
        MC Fault Code 11302
        MC Fault Code 11303
        MC Fault Code 11304
        MC Fault Code 11307
        Proportional Solenoid Valve Failure MC Fault Code 11400
        MC Fault Code 11401
        MC Fault Code 11402
        MC Fault Code 11403
        MC Fault Code 11404
        MC Fault Code 11405
        MC Fault Code 11410(ZX160-3class Only)
        CAN Data Reception Failure MC Fault Code 11910, 11914, 11920
        CAN Harness Check MC Fault Code 11910, 11914, 11920
        MC Fault Code 11911, 11918
        CAN Harness Check MC Fault Code 11911, 11918
        Other Failures

MC Fault Code 11901
        ECM, Sensor System ECM Fault Codes 100, 102, 105, 108, 110, 157, 172
        ECM Fault Codes 174, 636, 723, 10001
        ECM, External Device System ECM Fault Codes 651, 652, 653, 654, 655, 656, 1347, 10002
        ECM, Fuel System ECM Fault Codes 157, 633, 1239, 1240
        ECM, Engine Protection ECM Fault Codes 110, 190
        ECM, Engine Protection ECM Fault Codes 987, 1485
        ECM, Internal Circuit System ECM Fault Codes 628, 1077, 1079, 1080, 10003, 10004, 10005
        ECM Fault Codes 10006, 10007, 10008, 10009, 10010, 10011, 10013
        ECM, Communication System ECM Fault Codes 639
        ICF, Satellite Terminal Fault Codes 14000 to 14003
        ICF, Satellite Terminal Fault Codes 14006, 14008, 14100 to 14106
        Monitor Unit Fault Code 13303
        Monitor Unit Fault Code 13304
        Monitor Unit Fault Code 13306, 13308
        Monitor Unit Fault Code 13310
        Monitor Unit Fault Code 13311
        Pilot Shut-Off Lever Alarm
    Group 6 Troubleshooting B
        Troubleshooting B Procedure
        Relationship between Machine Trouble Symptoms and Related Parts
        Correlation between Trouble Symptoms and Part Failures
        Engine System Troubleshooting
        All Actuator System Troubleshooting
        Front Attachment System Troubleshooting
        Swing System Troubleshooting
        Travel System Troubleshooting
        Other System Troubleshooting
        Exchange Inspection
        Emergency Boom LoweringProcedure
        Attachment Pilot Circuit Pressure Release Procedure
        One Part of Data, Daily Report Data, Distribution Data and Total Operating hours is not Recorded
    Group 7 Electrical System Inspection
        Precautions for Inspection and Maintenance
        Instructions for Disconnecting Connectors
        Fuse Inspection
        Fusible Link Inspection
        Battery Voltage Check
        Alternator Check
        Continuity Check
        Voltage and Current Measurement
        Check by False Signal
        Test Harness
        
SERVICE MANUAL REVISION REQUEST FORM
THE ATTACHED DIAGRAM LIST


ZAXIS160-3 CLASS/180-3 CLASS ELECTRICAL DIAGRAM
ZAXIS160-3 CLASS/180-3 CLASS CONNECTORS
ZAXIS160-3 CLASS/180-3 CLASS ENGINE HARNESS
ZAXIS160-3 CLASS/180-3 CLASS CAB HARNESS
ZAXIS160-3 CLASS/180-3 CLASS MONITOR UNIT HARNESS
ZAXIS160-3 CLASS HYDRAULIC CIRCUIT DIAGRAM
ZAXIS160-3 CLASS HYDRAULIC CIRCUIT DIAGRAM
ZAXIS160-3 CLASS HYDRAULIC CIRCUIT DIAGRAM
ZAXIS180-3 CLASS HYDRAULIC CIRCUIT DIAGRAM
ZAXIS180-3 CLASS HYDRAULIC CIRCUIT DIAGRAM
ZAXIS180-3 CLASS HYDRAULIC CIRCUIT DIAGRAM

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