Hitachi Zaxis 160LC-6N Excavator Diagnosis and Tests Service Technical Manual (TM13999X19)
Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for Hitachi Zaxis 160LC-6N Excavator, with workshop information to maintain, diagnose, and rebuild like professional mechanics.
Hitachi Excavator ZX160LC-6N workshop Diagnosis & Tests technical manual includes:
* 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.
TM13999X19 - Hitachi Zaxis 160LC-6N Excavator Technical Manual.pdf
tm13999x63 - HitachiExcavadora Zaxis160LC-6N.pdf
tm13999x28 - Hitachi Excavatrice Zaxis160LC-6N.pdf
PRODUCT DETAILS:
Total Pages: 921 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English Spanish French
Models: John Deere HITACHI - Zaxis160LC-6N Excavator - 1FFDBP70__F240001
TABLE OF CONTENTS....1
Section 9000: General Information....25
Group 01: Safety....25
Recognize Safety Information....29
Understand Signal Words....30
Follow Safety Instructions....31
Prepare for Emergencies....33
Wear Protective Clothing....34
Protect Against Noise....35
Inspect Machine....36
General Precautions for Cab....37
Use Handholds and Steps....38
Adjust the Operator's Seat....39
Ensure Safety Before Rising from or Leaving Operator’s Seat....40
Fasten Your Seat Belt....41
Move and Operate Machine Safely....42
Operate Only from Operator's Seat....43
Jump Starting....44
Keep Riders off Machine....45
Precautions for Operations....46
Investigate Job Site Beforehand....47
Install OPG Guard....49
Restriction of Attachment Installation....50
Provide Signals for Jobs Involving Multiple Machines....51
Confirm Direction of Machine to be Driven....52
Drive Machine Safely....53
Avoid Injury from Rollaway Accidents....57
Avoid Injury from Back-Over and Swing Accidents....58
Keep Person Clear from Working Area....60
Never Position Bucket Over Anyone....61
Avoid Undercutting....62
Avoid Tipping....63
Never Undercut a High Bank....65
Dig with Caution....66
Operate with Caution....67
Avoid Power Lines....68
Precautions for Lightning....69
Object Handling....70
Protect Against Flying Debris....71
Park Machine Safely....72
Handle Fluids Safely−Avoid Fires....73
Transport Safely....74
Practice Safe Maintenance....75
Warn Others of Service Work....77
Support Machine Properly....78
Stay Clear of Moving Parts....79
Prevent Parts From Flying....80
Avoid Injury from Attachment Falling Accident....81
Prevent Burns....82
Replace Rubber Hoses Periodically....83
Avoid High-Pressure Fluids....84
Prevent Fires....86
Evacuating in Case of Fire....88
Beware of Exhaust Fumes....89
Precautions for Welding and Grinding....90
Avoid Heating Near Pressurized Fluid Lines....91
Avoid Applying Heat to Lines Containing Flammable Fluids....92
Precautions for Handling Accumulator and Gas Damper....93
Remove Paint Before Welding or Heating....94
Beware of Asbestos and Silicon Dust and Other Contamination....95
Prevent Battery Explosions....96
Service Air Conditioning System Safely....97
Handle Chemical Products Safely....98
Dispose of Waste Properly....99
Never Ride Attachment....100
Notes for Aftertreatment Device....101
Precautions for Communication Terminal....102
FCC Notifications to User....103
Notes on Protection of Operator’s Station when the Machine Rolls Over....104
Section 9001: Diagnostics....106
Group 10: Main Controller (MCZ) Diagnostic Trouble Codes....117
Main Controller (MCZ) Diagnostic Trouble Codes....117
Controller Area Network 0 (CAN 0) Circuit Diagnostics....118
Controller Area Network 1 (CAN 1) Circuit Diagnostics....119
Interface Controller Area Network (N-CAN) Diagnostics....120
Engine Controller Area Network (Engine CAN) Diagnostics....121
Aftertreatment Controller Area Network (DCU CAN) Diagnostics....122
011000.02 - Abnormal EEPROM....106
011001.02 - Abnormal RAM....106
011002.02 - Abnormal A/D Converter....106
011003.03 - Abnormal Sensor Voltage....106
011006.02 - Engine Controller Communication Error....106
011007.02 - (CAN 0) Data Converter Communication Error 1....106
011008.02 - (CAN 1) Data Converter Communication Error 2....106
011009.02 - (CAN 0) Monitor Controller Communication Error 1....106
011100.02 - Abnormal Engine Speed....106
011101.03 - Engine Speed Dial Sensor Circuit High Input....106
011101.04 - Engine Speed Dial Sensor Circuit Low Input....106
011200.03 - Pump 1 Delivery Pressure Sensor Circuit High Input....106
011200.04 - Pump 1 Delivery Pressure Sensor Circuit Low Input....106
011202.03 - Pump 2 Delivery Pressure Sensor Circuit High Input....106
011202.04 - Pump 2 Delivery Pressure Sensor Circuit Low Input....106
011206.03 - Pump 1 Flow Control Pressure Sensor Circuit High Input....106
011206.04 - Pump 1 Flow Control Pressure Sensor Circuit Low Input....106
011208.03 - Pump 2 Flow Control Pressure Sensor Circuit High Input....106
011208.04 - Pump 2 Flow Control Pressure Sensor Circuit Low Input....106
011301.03 - Swing Pilot Pressure Sensor Circuit High Input....106
011301.04 - Swing Pilot Pressure Sensor Circuit Low Input....106
011302.03 - Boom Up Pilot Pressure Sensor Circuit High Input....106
011302.04 - Boom Up Pilot Pressure Sensor Circuit Low Input....106
011303.03 - Arm Roll-in Pilot Pressure Sensor Circuit High Input....106
011303.04 - Arm Roll-in Pilot Pressure Sensor Circuit Low Input....106
011304.03 - Travel Pilot Pressure Sensor Circuit High Input....107
011304.04 - Travel Pilot Pressure Sensor Circuit Low Input....107
011307.03 - Front Attachment Pilot Pressure Sensor Circuit High Input....107
011307.04 - Front Attachment Pilot Pressure Sensor Circuit Low Input....107
011325.03 - Bucket Roll-In Pilot Pressure Sensor Circuit High Input....107
011325.04 - Bucket Roll-In Pilot Pressure Sensor Circuit Low Input....107
011400.02 - Pump 2 Flow Rate Limit Solenoid Valve Feedback Abnormal....107
011400.03 - Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current....107
011400.04 - Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current....107
011401.02 - Torque Control Solenoid Valve Abnormal Feedback....107
011401.03 - Torque Control Solenoid Valve Feedback High Current....107
011401.04 - Torque Control Solenoid Valve Feedback Low Current....107
011402.02 - Dig Regenerative Solenoid Valve Feedback Current Abnormal....107
011402.03 - Dig Regenerative Solenoid Valve Feedback Current High....107
011402.04 - Dig Regenerative Solenoid Valve Feedback Current Low....107
011403.02 - Arm Regenerative Solenoid Valve Feedback Current Abnormal....107
011403.03 - Arm Regenerative Solenoid Valve Feedback Current High....107
011403.04 - Arm Regenerative Solenoid Valve Feedback Current Low....107
011407.02 - Power Dig/Travel Speed Solenoid Valve Feedback Current Abnormal....107
011407.03 - Power Dig/Travel Speed Solenoid Valve Feedback Current High....107
011407.04 - Power Dig/Travel Speed Solenoid Valve Feedback Current Low....107
011408.02 - Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal....107
011408.03 - Exhaust Aftertreatment Solenoid Valve Feedback Current High....107
011408.04 - Exhaust Aftertreatment Solenoid Valve Feedback Current Low....107
011409.02 - Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal....107
011409.03 - Exhaust Aftertreatment Solenoid Valve Feedback Current High....107
011409.04 - Exhaust Aftertreatment Solenoid Valve Feedback Current Low....107
011410.02 - Pump 1 Flow Rate Limit Solenoid Valve Feedback Abnormal....107
011410.03 - Pump 1 Flow Rate Limit Solenoid Valve Feedback High Input....107
011410.04 - Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Input....107
011434.02 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback....107
011434.03 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current....107
011434.04 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current....107
011435.02 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback....108
011435.03 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current....108
011435.04 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current....108
011457.02 - 2-Speed Activation Solenoid Valve Disconnected....108
011458.02 - Selector Valve Solenoid Valve Disconnected....108
011459.02 - Idle Stop Relay Circuit Malfunction....108
011810.03 - Electric Lever Operating Pressure Sensor 1 High Voltage....108
011810.04 - Electric Lever Operating Pressure Sensor 1 Low Voltage....108
011812.02 - OPT Electric Lever 1 Neutral Abnormal....108
011813.02 - OPT Electric Lever 1 Abnormal Operation....1038
011816.02 - OPT Solenoid 1 Feedback Abnormal....108
011816.03 - OPT Solenoid 1 Feedback Current High....108
011816.04 - OPT Solenoid 1 Feedback Current Low....108
011817.02 - OPT Solenoid 2 Feedback Abnormal....108
011817.03 - OPT Solenoid 2 Feedback Current High....108
011817.04 - OPT Solenoid 2 Feedback Current Low....108
011901.03 - Hydraulic Oil Temperature Sensor Circuit High Input....108
011901.04 - Hydraulic Oil Temperature Sensor Circuit Low Input....108
011995.03 - Arm Roll-Out Pilot Pressure Sensor Circuit High Input....108
011995.04 - Arm Roll-Out Pilot Pressure Sensor Circuit Low Input....108
011997.03 - Bucket Roll-Out Pressure Sensor Circuit High....108
011997.04 - Bucket Roll-Out Pressure Sensor Circuit Low....108
015011.03 - Hydraulic Oil Temperature Sensor Circuit High Input (Pilot)....108
015011.04 - Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot)....108
015016.03 - Right Analog Stroke Sensor Circuit High Input....108
015016.04 - Right Analog Stroke Sensor Circuit Low Input....108
020010.02 - Abnormal Aftertreatment Device....108
020011.02 - Electric Lever Alarm....108
020012.02 - Line Filter Restriction Alarm....108
020303.02 - Electric Lever Pilot Cut Alarm....108
Group 20: Engine Control Module (ECM) Diagnostic Trouble Codes....361
Engine Control Module (ECM) Diagnostic Trouble Codes....361
000091.02 - Pedal Position Sensor 1 - 2 Voltage Correlation (P2138)....108
000091.03 - Pedal Position Sensor 1 Circuit High Input (P2123)....109
000091.03 - Pedal Position Sensor 2 Circuit High Input (P2128)....109
000091.04 - Pedal Position Sensor 1 Circuit Low Input (P2122)....109
000091.04 - Pedal Position Sensor 2 Circuit Low Input (P2127)....109
000100.03 - Engine Oil Pressure Sensor Circuit High (P0523)....109
000100.04 - Engine Oil Pressure Sensor Circuit Low (P0522)....109
000102.00 - Turbocharger Overboost Condition (P0234)....109
000102.01 - Declined Boost Pressure (P0299)....109
000102.03 - Turbocharger Boost Sensor Circuit High (P0238)....109
000102.04 - Turbocharger Boost Sensor Circuit Low (P0237)....109
000105.03 - Compressor Outlet Temperature Sensor Circuit High (P1098)....109
000105.04 - Compressor Outlet Temperature Sensor Circuit Low (P1097)....109
000108.03 - Barometric Pressure Sensor Circuit High (P2229)....109
000108.04 - Barometric Pressure Sensor Circuit Low (P2228)....109
000110.00 - Engine Coolant Over Temperature Condition (P0217)....109
000110.03 - Engine Coolant Temperature Sensor Circuit High (P0118)....109
000110.04 - Engine Coolant Temperature Sensor Circuit Low (P0117)....109
000132.03 - Mass Air Flow Sensor Circuit High Input (P0103)....109
000132.04 - Mass Air Flow Sensor Circuit Low Input (P0102)....109
000157.03 - Fuel Rail Pressure Sensor Circuit High (P0193)....109
000157.04 - Fuel Rail Pressure Sensor Circuit Low (P0192)....109
000157.15 - Fuel Pressure Regulator Performance (P0089)....109
000158.03 - System Voltage High (P0563)....109
000172.03 - Intake Air Temperature Sensor Circuit High (P0113)....109
000172.04 - Intake Air Temperature Sensor Circuit Low (P0112)....109
000173.03 - Catalyst Temperature Sensor Circuit High Sensor 1 (P0428)....109
000173.04 - Catalyst Temperature Sensor Circuit Low Sensor 1 (P0427)....109
000174.03 - Fuel Temperature Sensor Circuit High (P0183)....109
000174.04 - Fuel Temperature Sensor Circuit Low (P0182)....109
000190.00 - Engine Overspeed Condition (P0219)....109
000628.02 - Internal Control Module Memory Check Sum Error (P0601)....109
000633.07 - Fuel Rail/System Pressure - Too Low (P0087)....109
000636.02 - Camshaft Position Sensor Circuit (P0340)....109
000636.07 - Crankshaft Position - Camshaft Position Correlation (P0016)....110
000639.02 - Lost Communication With CAN (U0101)....110
000639.19 - Control Module Communication Bus Off (U0073)....110
000651.05 - Injector Circuit Open - Cylinder 1 (P0201)....110
000652.05 - Injector Circuit Open - Cylinder 2 (P0202)....110
000653.05 - Injector Circuit Open - Cylinder 3 (P0203)....110
000654.05 - Injector Circuit Open - Cylinder 4 (P0204)....110
000676.05 - Glow Relay Circuit Error (P0380)....110
000677.05 - Starter Relay Circuit Error (P0615)....110
000723.02 - Crankshaft Position Sensor Circuit (P0335)....110
000723.08 - Crankshaft Position Sensor Circuit Range/Performance (P0336)....110
001077.02 - Internal Control Module CPU Error (P0606)....110
001079.02 - Sensor Reference Voltage 1 Circuit (P06A6)....110
001080.02 - Sensor Reference Voltage 2 Circuit (P06A7)....110
001131.03 - Intake Air Temperature (IAT) Sensor 2 Circuit High Voltage (P0098)....110
001131.04 - Intake Air Temperature (IAT) Sensor 2 Circuit Low Voltage (P0097)....110
001239.17 - Fuel Rail Pressure Too Low (P1093)....110
001239.31 - Fuel Rail Pressure Too Low (P3093)....110
001347.03 - Fuel Pressure Regulator Control Circuit High (P0092)....110
001347.04 - Fuel Pressure Regulator Control Circuit Low (P0091)....110
001485.05 - ECM Power Relay Control Circuit Open (P0685)....110
001485.06 - ECM Power Relay Control Circuit High (P0687)....110
002791.02 - EGR Flow Insufficient Detected (P0401)....110
004332.12 - Urea Fluid Concentration Too Low (P207F)....110
005285.01 - Charge Air Cooler Performance Failure (P1236)....110
010001.02 - EGR Sensor Circuit (P0409)....110
010001.13 - EGR Position Fault (P1404)....110
010002.02 - EGR Control Circuit Range/Performance (P0404)....110
010003.02 - Fuel Injector Group 1 Supply Voltage Circuit (P2146)....110
010004.02 - Fuel Injector Group 2 Supply Voltage Circuit (P2149)....110
010005.02 - Injector Positive Voltage Control Circuit Group 1 (P1261)....110
010006.02 - Injector Positive Voltage Control Circuit Group 2 (P1262)....110
010007.02 - Internal Control Module CPU IC Error (P060A)....110
010008.02 - Internal Control Module A/D Processing Performance (P060C)....111
010009.02 - Sensor Reference Voltage 3 Circuit (P06A8)....111
010010.02 - Sensor Reference Voltage 4 Circuit (P06A9)....111
010011.02 - Sensor Reference Voltage 5 Circuit (P06D5)....111
010012.02 - 12-Volt Circuit Error (P0560)....111
010013.02 - Control Module Long Term Memory Performance (P1621)....111
010014.03 - EGR Cooler Outlet 1 Temp Sensor Circuit High (P041D)....111
010014.04 - EGR Cooler Outlet 1 Temp Sensor Circuit Low (P041C)....111
010022.02 - Throttle Actuator Control Range/Performance (P0638)....111
010022.03 - Throttle Position Sensor Circuit High (P0123)....111
010022.04 - Throttle Position Sensor Circuit Low (P0122)....111
010024.03 - Catalyst Temperature Sensor Circuit High Sensor 2 (P042D)....111
010024.04 - Catalyst Temperature Sensor Circuit Low Sensor 2 (P042C)....111
010025.05 - DPD Lamp Control Circuit (P1669)....111
010029.00 - Purge Time Out Error (P2458)....111
010032.02 - Internal Control Module QR Code Error (P0602)....111
010033.02 - Internal Control Module RAM Error (P0604)....111
010040.19 - CAN Bus Error (ISO-CAN) (U0001)....111
010041.02 - Lost Communications With Dosing Control Module (U010E)....111
010042.12 - SCR System Error (Inducement, No Purge) (P2BAA)....111
010043.02 - SCR System Error (No Inducement) (P204F)....111
010044.01 - SCR System Error (P20C9)....111
010045.02 - AD-IC Failure Error (P160B)....111
010046.02 - SWIC-1 Failure (P1606)....111
010047.02 - SWIC-2 Failure (P1606)....111
010048.02 - SWIC-1 Communication Failure (P1606)....111
010049.02 - SWIC-2 Communication Failure (P1606)....111
010050.02 - INJ-IC Failure (P06AF)....111
010051.03 - Charge Air Cooler (CAC) Temperature Sensor 1 Circuit High Voltage (P1077)....111
010051.04 - Charge Air Cooler (CAC) Temperature Sensor 1 Circuit Low Voltage (P1076)....111
010053.03 - EGR Cooler Inlet 1 Temp Sensor Circuit High (P0546)....111
010053.04 - EGR Cooler Inlet 1 Temp Sensor Circuit Low (P0545)....111
010054.17 - Exhaust Gas Recirculation (EGR) Cooling System Performance (P2457)....111
010078.12 - AD-IC2 Failure Error (P160C)....112
010082.02 - INJ-IC Communication Failure (P06AF)....112
010083.02 - INJ-IC Checksum Failure (P06AF)....112
010500.12 - Urea Fluid Injector Circuit Abnormal (P2048) (P2049)....112
010501.12 - Urea Fluid Injector Stuck (P208E)....112
010502.12 - Exhaust Gas Temperature (EGT) Sensor 3 Circuit Abnormal (P242C) (P242D)....112
010503.12 - Exhaust Gas Temperature (EGT) Sensor 3 Performance (P242B)....112
010504.12 - NOx Sensor Heater Control Circuit Sensor 1 Abnormal (P2206) (P2207)....112
010505.12 - Upstream NOx Sensor Performance (P2201)....112
010506.12 - Urea Fluid Tank Temperature Sensor Performance (P205B)....112
010507.12 - Urea Fluid Tank Heater Coolant Control Valve Circuit Abnormal (P20B1) (P20B3) (P20B4)....112
010508.12 - Urea Fluid Pump Control Circuit Abnormal (P208A) (P208C) (P208D)....112
010509.12 - Urea Fluid Pump Performance (P208B)....112
010510.12 - Urea Fluid Reverting Valve Circuit Abnormal (P20A0) (P20A3)....112
010511.12 - Urea Fluid Pressure Sensor Circuit Abnormal (P204C) (P204D)....112
010512.12 - Urea Fluid Pressure Sensor Performance (P204B)....112
010513.12 - Urea Fluid Pump Temperature Sensor Performance (P20AC)....112
010514.12 - Control Module Malfunction (P0607) (P060B) (P062F)....112
010515.12 - Actuator Supply Voltage Circuit Abnormal (P0641) (P0658) (P0659)....112
010516.12 - Urea Fluid Pump Module Temperature Sensor Performance (P20AD)....112
010517.12 - DCU High Temperature (P1468) (P1493)....112
010518.12 - Urea Fluid Over Pressure (P1491)....112
010519.12 - Urea Fluid Pressure Reduction Malfunction (P149C)....112
010520.12 - Urea Fluid Pressure Buildup Error (P20FE)....112
010521.12 - Urea Fluid Tank Overtemperature (P149D)....112
010522.12 - Urea Fluid Tank Level Sensor Stuck (P203B)....112
010523.12 - Urea Fluid Concentration Too Low (P207F)....112
010524.12 - Lost Communication With NOx Sensor 1 (U029D)....112
010525.12 - Lost Communication With Engine Control Module (ECM) (U0100)....112
010526.12 - Urea Fluid Quality Sensor Timeout Error (P1462)....112
010527.12 - CAN Bus Off (U0002)....112
010528.12 - Main Relay Performance (P1464)....112
010529.12 - Urea Fluid Quality Sensor Circuit Abnormal (P206A) (P206C) (P206D)....113
010530.12 - Urea Fluid Over Pressure (P20E9)....113
010531.12 - Urea Fluid Tank Level Sensor Abnormal (P203C) (P203D)....113
010532.12 - Urea Fluid Tank Temperature Sensor Abnormal (P205C) (P205D)....113
010533.12 - Urea Fluid Pressure Under Pressure (P20E8)....113
010534.12 - Urea Fluid Pressure Reduction Malfunction (P20EA)....113
010535.12 - Urea Sensor Overtemperature Condition (P206B)....113
010536.12 - Urea Fluid Reverting Valve Circuit Low Voltage (P20A2)....113
Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes....503
Monitor Controller (DSZ) Diagnostic Trouble Codes....503
013000.02 - Flash Memory Failure 1....113
013001.02 - Flash Memory Failure 2....113
013002.02 - ECM Communication Error....113
013003.02 - Main Controller (MCZ) Communication Error 1....113
013004.02 - Main Controller (MCZ) Communication Error 2....113
013005.02 - Monitor Controller (DSZ) Communication Error 1....113
013006.02 - Monitor Controller (DSZ) Communication Error 2....113
013007.02 - Machine Controller (BCZ) Communication Error....113
020113.02 - System Error Alarm....113
Group 40: Information Controller (ICZ) Diagnostic Trouble Codes....514
Information Controller (ICZ) Diagnostic Trouble Codes....514
013303.02 - Abnormal Monitor Internal Temperature Sensor....113
013304.02 - Alternator Alarm....113
013305.02 - Abnormal Manual Glow EXT Output....113
013310.03 - Coolant Temperature Sensor Short Circuit....113
013311.03 - Fuel Level Sensor Open Circuit....113
013311.04 - Fuel Level Sensor Shorted Circuit....113
013334.02 - Radiator Water Temp Receive Error....113
014000.02 - CAN Communication Error 1....113
014001.02 - Flash Memory Read/Write Error....113
014002.02 - External RAM Read/Write Error....113
014003.02 - Abnormal EEPROM....113
014006.02 - Communication Terminal:Communication Error....113
014008.02 - Abnormal Internal RAM....114
014009.02 - CAN Communication Error 2....114
014021.02 - Communication Terminal Security Error....114
014022.02 - SIM Card Error....114
014023.02 - Security Error....114
020100.02 - Overheat Alarm....114
020101.02 - Engine Warning Alarm....114
020102.02 - Engine Oil Pressure Alarm....114
020103.02 - Alternator Alarm....114
020105.02 - Hydraulic Oil Filter Restriction Alarm....114
020106.02 - Air Cleaner Restriction Alarm....114
020107.02 - Water Separator Alarm....114
020109.02 - Pilot Control Shut-Off Lever Alarm....114
020110.02 - Fuel Filter Restriction Alarm....114
020114.02 - Overheat Alarm (Immediately After the Key is Turned ON)....114
020149.02 - EGR Gas Temperature Alarm....114
Group 50: Air Conditioner Controller (ACF) Diagnostic Trouble Codes....568
Air Conditioner Controller (ACF) Diagnostic Trouble Codes....568
11 - Open Circuit in Air Recirculation Sensor....114
12 - Short-Circuited Air Recirculation Sensor....114
13 - Open Circuit in Ambient Air Temperature Sensor....114
14 - Short-Circuited Ambient Air Temperature Sensor....114
18 - Short-Circuited Solar Radiation Sensor....114
21 - Open Circuit in Air Conditioner Freeze Control Switch....114
22 - Short-Circuited Air Conditioner Freeze Control Switch....114
43 - Abnormal Air Conditioner and Heater Blower Port Change Servo Motor....114
44 - Abnormal Air Conditioner and Heater Mixer Servo Motor....114
51 - Abnormal High/Low Refrigerant Pressure....114
91 - Communication Error....114
92 - CAN Bus Off Error....114
Group 60: Premium Seat Controller (PSC) Diagnostic Trouble Codes....604
Premium Seat Controller (PSC) Diagnostic Trouble Codes....604
0 - Cushion Blower Minimum Voltage....114
1 - Back Blower Minimum Voltage....115
2 - Cushion Blower Short to Power....115
3 - Back Blower Short to Power....115
4 - Cushion Fan Power Transistor Short to Ground....115
5 - Back Fan Power Transistor Short to Ground....115
6 - Cushion Fan Power Transistor Open Circuit....115
7 - Back Fan Power Transistor Open Circuit....115
8 - Lower Thermal Duct Module Temperature Sensor Short to Ground....115
9 - Upper Thermal Duct Module Temperature Sensor Short to Ground....115
10 - Lower Thermal Duct Module Temperature Sensor Open Circuit....115
11 - Upper Thermal Duct Module Temperature Sensor Open Circuit....115
12 - Lower Thermal Duct Module Short to Ground....115
13 - Upper Thermal Duct Module Short to Ground....115
14 - Lower Thermal Duct Module Open Circuit....115
15 - Upper Thermal Duct Module Open Circuit....115
16 - Lower Thermal Duct Module Over Temperature....115
17 - Upper Thermal Duct Module Over Temperature....115
21 - Thermal Duct Module Short to Power....115
Section 9005: Operational Checkout Procedure....627
Group 10: Operational Checkout Procedure....627
Operational Checkout....691
Section 9010: Engine....754
Group 05: Theory of Operation....1038
Isuzu Engine....772
Engine Fuel System Component Location (S.N. —XXXXXX)....757
Engine Fuel System Component Location (S.N. XXXXXX— )....758
Engine Cooling System Component Location....759
Diesel Exhaust Fluid (DEF) System Component Location....760
Cold Weather Starting Aid....761
Engine Speed Control System Operation....1038
Group 15: Diagnostic Information....754
Isuzu Engine....772
Group 20: Adjustments....754
Isuzu Engine....772
Group 25: Tests....754
Isuzu Engine....772
Section 9015: Electrical System....773
Group 05: System Information....773
Electrical Diagram Information....786
Group 10: System Diagrams....773
Explanation of Wire Markings....795
Fuse and Relay Specifications....796
System Functional Schematic, Component Location, and Wiring Diagram Master Legend....801
System Functional Schematic....811
Cab Harness (W1) Component Location....826
Cab Harness (W1) Wiring Diagram....834
Machine Harness (W2) Component Location....849
Machine Harness (W2) Wiring Diagram....852
Monitor Harness (W3) Component Location....863
Monitor Harness (W3) Wiring Diagram....864
Engine Harness (W4) Component Location....866
Engine Harness (W4) Wiring Diagram....870
Pump Harness (W8) Component Location....872
Pump Harness (W8) Wiring Diagram....874
Aftertreatment Device Regeneration Switch Harness (W9) Component Location....875
Aftertreatment Device Regeneration Switch Harness (W9) Wiring Diagram....876
Pilot Shutoff Switch Harness (W11) Component Location....877
Pilot Shutoff Switch Harness (W11) Wiring Diagram....878
Heated Air Seat Harness (W14) Component Location....879
Heated Air Seat Harness (W14) Wiring Diagram....880
Multi-Function Pilot Control Lever Harness (W15) Component Location....881
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram....883
Travel Alarm Cancel Switch Harness (W16) Component Location....884
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram....885
Attachment Harness (W17) Component Location....886
Attachment Harness (W17) Wiring Diagram....888
Rear Camera Harness (W19) Component Location....889
Rear Camera Harness (W19) Wiring Diagram....890
Pilot Shutoff Valve Harness (W21) Component Location....891
Pilot Shutoff Valve Harness (W21) Wiring Diagram....892
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location....893
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram....894
Seat Heater Switch Harness (W24) Component Location....895
Seat Heater Switch Harness (W24) Wiring Diagram....896
Attachment Interface Harness (W25) Component Location—If Equipped....897
Attachment Interface Harness (W25) Wiring Diagram—If Equipped....898
Travel Alarm Harness (W26) Component Location....899
Travel Alarm Harness (W26) Wiring Diagram....900
Starter Switch Harness (W29) Component Location....901
Starter Switch Harness (W29) Wiring Diagram....902
Data Converter Harness (W30) Component Location....903
Data Converter Harness (W30) Wiring Diagram....904
2-Speed Harness (W32) Component Location....905
2-Speed Harness (W32) Wiring Diagram....906
Heater and Air Conditioner Harness (W41) Component Location....907
Heater and Air Conditioner Harness (W41) Wiring Diagram....908
Cab Roof Light Harness (W44) Component Location....909
Cab Roof Light Harness (W44) Wiring Diagram....910
Cab Roof Light Jumper Harness (W45) Component Location....911
Cab Roof Light Jumper Harness (W45) Wiring Diagram....912
Cab Roof Light 1 Relay Harness (W46) Component Location....913
Cab Roof Light 1 Relay Harness (W46) Wiring Diagram....914
Cab Roof Light 2 Relay Harness (W47) Component Location....915
Cab Roof Light 2 Relay Harness (W47) Wiring Diagram....916
Travel Alarm Cancel Switch Jumper Harness (W48) Component Location....917
Travel Alarm Cancel Switch Jumper Harness (W48) Wiring Diagram....918
Heater and Air Conditioner Relay Harness (W51) Component Location....919
Heater and Air Conditioner Relay Harness (W51) Wiring Diagram....920
Exhaust Aftertreatment Harness (W53) Component Location (S.N. —240115)....922
Exhaust Aftertreatment Harness (W53) Wiring Diagram (S.N. —240115)....924
Exhaust Aftertreatment Harness (W53) Component Location (S.N. 240116— )....926
Exhaust Aftertreatment Harness (W53) Wiring Diagram (S.N. 240116— )....927
Diesel Exhaust Fluid (DEF) Supply Harness (W54) Component Location....929
Diesel Exhaust Fluid (DEF) Supply Harness (W54) Wiring Diagram....930
12-Volt Power Harness (W55) Component Location....931
12-Volt Power Harness (W55) Wiring Diagram....932
Auxiliary Solenoid Harness (W61) Component Location....933
Auxiliary Solenoid Harness (W61) Wiring Diagram....935
Auxiliary Function Lever (AFL) Harness (W75) Component Location....937
Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram....939
Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location....940
Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram....942
USB Harness (W82) Component Location....944
USB Harness (W82) Wiring Diagram....945
USB Jumper Harness (W83) Component Location....946
USB Jumper Harness (W83) Wiring Diagram....947
Rear Cab Light Switch Harness (W84) Component Location....948
Rear Cab Light Switch Harness (W84) Wiring Diagram....949
Rear Cab Light Relay Harness (W85) Component Location....950
Rear Cab Light Relay Harness (W85) Wiring Diagram....951
Rear Cab Light Harness (W86) Component Location....952
Rear Cab Light Harness (W86) Wiring Diagram....953
Premium Seat Harness (W87) Component Location....954
Premium Seat Harness (W87) Wiring Diagram....956
Premium Seat Power Harness (W88) Component Location....957
Premium Seat Power Harness (W88) Wiring Diagram....958
Satellite (SAT) Harness (W6003) Component Location....959
Satellite (SAT) Harness (W6003) Wiring Diagram....960
JDLink™ Harness (W6004) Component Location....961
JDLink™ Harness (W6004) Wiring Diagram....963
Group 15: Sub-System Diagnostics....775
Controller Area Network (CAN) Theory of Operation....1038
Starting and Charging Circuit Theory of Operation....1038
Monitor Controller (DSZ) Circuit Theory of Operation....1038
Engine Control Module (ECM) Circuit Theory of Operation....1038
Exhaust Aftertreatment Circuit Theory of Operation....1038
Main Controller (MCZ) Circuit Theory of Operation....1038
Machine Controller (BCZ) Circuit Theory of Operation....1038
Windshield Wiper and Washer Circuit Theory of Operation....1038
Lighting Circuit Theory of Operation....1038
Travel Alarm Circuit Theory of Operation....1038
Pilot Shutoff Circuit Theory of Operation....1038
Attachment Control Circuit Theory of Operation....1038
Group 16: Monitor Operation....1038
Service Menu....1027
Troubleshooting....1029
Monitoring....1030
Controller Version....1036
Issued Warning Record....1037
Operation....1038
Machine Setting....1039
Monitor Setting....1045
Alarm Setting....1048
Engine Setting....1049
Aftertreatment Device No...1050
Maintenance Mode....1051
Rear View Camera Troubleshooting....1052
Group 20: References....776
Reading Diagnostic Trouble Codes with Monitor Display....1056
Service ADVISOR™ Diagnostic Application....1057
Service ADVISOR™ Connection Procedure....1058
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application....1060
Clearing Engine Diagnostic Trouble Codes....1063
Clearing Dosing Control Unit (DCU) Diagnostic Trouble Codes....1069
MPDr Application....1070
MPDr Connection Procedure....1071
Coolant Bleeding With MPDr....1073
Diesel Exhaust Fluid (DEF) Leak Test With MPDr....1074
Controller Area Network (CAN) Circuit Test....1075
Electrical Component Specifications....1081
Alternator Test....1084
Electrical Component Checks....1086
Battery Remove and Install....1095
Rear Cover Remove and Install....1097
Main Controller (MCZ) Remove and Install....1099
Monitor Controller (DSZ) Remove and Install....1101
Heater Control Disable and Enable....1103
Section 9020: Power Train....1104
Group 05: Theory of Operation....1038
Track Adjuster and Recoil Spring Operation....1107
Travel Gear Case Operation....1109
Group 15: Diagnostic Information....1104
Noisy or Loose Track Chain....1104
Tight Track Chain....1104
Frequent Track Chain Sag Adjustment Required....1104
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers....1104
Bent Track Shoes....1104
“Popping” of Track....1104
Cracked Track Link....1104
Chipped Link Rails....1104
Individual Undercarriage Component Wear....1104
Measure Swing Bearing Wear....1127
Section 9025: Hydraulic System....1131
Group 05: Theory of Operation....1038
Hydraulic System Operation....1136
Pilot System Operation....1137
Pilot Pump, Pressure Regulating Valve and Filter Operation....1138
Pilot Shutoff Solenoid Valve Operation....1140
Pilot Control Valve Operation....1179
Travel Pilot Control Valve Operation....1179
Single Pedal Travel Operation—If Equipped....1151
Pilot Operation of Control Valve Operation....1179
Pilot Signal Manifold Operation....1157
Pump 1, Pump 2, and Drive Gear Case Operation....1166
Pump 1 and Pump 2 Regulator Operation....1169
Engine Speed Sensing Control Circuit Operation....1176
Control Valve Operation....1179
Control Valve Check Valves Identification and Operation....1194
Main Relief Valve Circuit Operation....1198
Circuit Relief and Anticavitation Valve Operation....1203
Travel Flow Combiner Valve Operation....1205
Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation....1208
Boom Lower Meter-In Cut Valve Operation....1213
Boom Regenerative Valve Circuit Operation....1217
Dig Regenerative Valve Circuit Operation....1220
Arm Regenerative Valve Circuit Operation....1224
Bucket Regenerative Valve Circuit Operation....1229
Boom and Arm Reduced Leakage Valves Operation....1232
Arm 1 Flow Rate Control Valve Circuit Operation....1234
Arm 2 Flow Rate Control Valve Circuit Operation....1238
Bucket Flow Rate Control Valve Circuit Operation....1242
Boom Flow Rate Control Valve Circuit Operation....1246
Auxiliary Flow Rate Control Valve Circuit Operation....1251
Swing Reduction Gear Case Operation....1256
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation....1257
Swing Motor Damper Valve....1261
Swing Motor Park Brake Release Circuit Operation....1272
Center Joint Operation....1273
Travel Motor and Park Brake Valve Operation....1274
Travel Motor Speed Circuit Operation....1282
Cylinder Operation....1286
Return Filter Operation....1288
Auxiliary System Operation....1289
Auxiliary Pilot Control Valve Operation....1290
Flow Rate Select Solenoid Valve Operation....1297
Flow Rate Pressure Reducing Valve Operation....1299
Secondary Auxiliary Relief Valve Solenoid Valve Operation....1301
Secondary Auxiliary Relief Control Valve Operation....1302
Secondary Auxiliary Relief Valve Operation....1303
Selector Valve Solenoid Valve Operation....1304
Selector Valve Operation....1305
Auxiliary Shuttle Valve Operation....1307
Auxiliary High Flow Line Kit Operation....1309
Two Way Solenoid Kit Operation....1313
Two Pump Combined Flow Kit Operation....1316
Secondary Auxiliary Relief Kit Operation....1323
Low Flow Kit Operation....1327
Group 15: Diagnostic Information....1132
All Hydraulic Functions Slow....1132
Hydraulic Oil Overheats....1132
No Hydraulic Functions....1132
No Hydraulic Functions—Electrical Checks....1132
Function Does Not Stop When Control Lever Released....1132
Load Drifts Down When Control Lever is in Neutral Position....1132
Load Falls When Control Valve is Actuated To Raise Load....1132
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal....1132
Boom Down Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal....1132
Arm In Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal....1132
Swing Speed Slow During Arm in Function....1133
Boom Cannot Raise Track Off Ground....1133
Swing Function Does Not Operate in Both Directions....1133
Swing Speed Slow in Both Directions....1133
Swing Speed Slow or Does Not Operate in One Direction....1133
Upperstructure Drift With Swing Valve in Neutral....1133
Machine Freewheels Down an Incline....1133
Track Will Not Move in Either Direction....1133
Machine Mistracks....1133
Machine Mistracks Left During Combined Travel and Dig Functions....1133
Machine Will Not Shift Into Fast (rabbit) Speed....1133
Pump 1, Pump 2, and Pilot Pump Line Identification....1392
Control Valve Line Identification....1393
Swing Motor Line Identification....1397
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern....1398
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern....1400
Pilot Signal Manifold-to-Control Valve Line Connections....1402
Pilot Control Lever Pattern Selector Valve Line Connection—If Equipped....1403
Travel System Component Location....1404
Travel Hydraulic System Line Connections....1430
Auxiliary Attachment Schematic....1407
Auxiliary System Line Connections....1415
Hydraulic System Schematic....1417
Hydraulic System Component Location....1428
Hydraulic System Line Connections....1430
Group 25: Tests....1133
JT05800 Digital Thermometer Installation....1432
JT02156A Digital Pressure and Temperature Analyzer Kit Installation....1433
General Hydraulic Oil Cleanup Procedure....1434
Hydraulic Component Failure Cleanup Procedure....1437
Hydraulic Oil Tank Pressure Release Procedure....1440
Hydraulic Oil Warm-Up Procedure....1441
Pilot Pressure Regulating Valve Test and Adjustment....1444
Control Valve Spool Actuating Pilot Pressure Test....1448
Dig Regenerative Solenoid Valve Test and Adjustment....1451
Arm Regenerative Solenoid Valve Test and Adjustment....1456
Power Dig/Travel Speed Solenoid Valve Test and Adjustment....1461
Torque Control Solenoid Valve Test and Adjustment....1466
Pump Control Pilot Pressure Signal Test....1470
Main Relief and Power Dig Valve Test and Adjustment....1473
Circuit Relief Valve Test and Adjustment....1479
Swing Motor Crossover Relief Valve Test and Adjustment....1485
Travel Motor Crossover Relief Valve Test and Adjustment....1489
Pump Regulator Test and Adjustment—Minimum Flow....1494
Pump Regulator Test and Adjustment—Maximum Flow....1497
Pump Flow Test....1500
Comprehensive Pump Flow Test....1504
Control Pressure Pump Flow Test....1510
Swing Motor Leakage Test....1516
Travel Motor Leakage Test....1519
Cylinder Drift Test—Boom, Arm, and Bucket....1523
Upperstructure Drift Test....1526
Section 9031: Heating and Air Conditioning....1529
Group 05: Theory of Operation....1038
Air Conditioning System Cycle of Operation....1532
Group 15: Diagnostic Information....1529
Air Conditioning System Does Not Operate....1529
Air Conditioning System Does Not Cool Interior of Cab....1529
Air Conditioning System Runs Constantly, Too Cold....1529
Heating System Does Not Operate....1529
Heating System Does Not Warm Interior of Cab....1529
Interior Windows Continue to Fog....1529
Heater and Air Conditioner Component Location....1556
Group 25: Tests....1529
R134a Refrigerant Cautions and Proper Handling....1558
R134a Oil Charge Capacity....1559
R134a Refrigerant Charge Capacity....1560
Heater and Air Conditioner Operational Checks....1561
Air Conditioner Compressor Clutch Test....1564
R134a Refrigerant Leak Test....1565
R134a Refrigerant Hoses and Tubing Inspection....1566
Air Conditioner High/Low-Pressure Switch Test....1567
Air Conditioner Freeze Control Switch Test....1570
Air Conditioning System Test....1571
Operating Pressure Diagnostic Chart....1574
Section 9900: Dealer Fabricated Tools....1576
Group 99: Dealer Fabricated Tools....1576
DFT1218 Split Flange Hose Cap....1578
Hitachi Zaxis 160LC-6N Excavator Diagnosis and Tests Service Technical Manual (TM13999X19)
