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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