Hitachi Zaxis 160LC-5N Excavator Diagnosis and Tests Service Technical Manual (TM12366)
Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for Hitachi Zaxis 160LC-5N Excavator, with workshop information to maintain, diagnose, and rebuild like professional mechanics.
Hitachi Excavator ZX160LC-5N 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.
TM12366 - Hitachi Zaxis160LC-5N Excavator Operation and Test Technical Manual.pdf
TM12368 - Hitachi Excavadora Zaxis160LC-5N.pdf
TM12367 - Hitachi Excavatrice Zaxis160LC-5N.pdf
PRODUCT DETAILS:
Total Pages: 1,531 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-5N Excavator - 1FFDBC70__E230001 (iT4/S3B)
TABLE OF CONTENTS....1
Section 9000: General Information....23
Group 01: Safety....23
Recognize Safety Information....26
Understand Signal Words....27
Follow Safety Instructions....28
Prepare for Emergencies....30
Wear Protective Clothing....31
Protect Against Noise....32
Inspect Machine....33
General Precautions for Cab....34
Use Handholds and Steps....35
Adjust the Operator's Seat....36
Ensure Safety Before Rising From or Leaving Operator’s Seat....37
Fasten Your Seat Belt....38
Move and Operate Machine Safely....39
Operate Only From Operator's Seat....40
Jump Starting....41
Keep Riders Off Machine....42
Precautions for Operations....43
Investigate Job Site Beforehand....44
Install OPG Guard....46
Provide Signals for Jobs Involving Multiple Machines....47
Confirm Direction of Machine to be Driven....48
Drive Machine Safely....49
Avoid Injury From Rollaway Accidents....53
Avoid Injury From Back-Over and Swing Accidents....54
Keep Person Clear From Working Area....56
Never Position Bucket Over Anyone....57
Avoid Undercutting....58
Avoid Tipping....59
Never Undercut a High Bank....61
Dig With Caution....62
Operate With Caution....63
Avoid Power Lines....64
Precautions for Lightning....65
Object Handling....66
Protect Against Flying Debris....67
Park Machine Safely....68
Handle Fluids Safely−Avoid Fires....69
Transport Safely....70
Practice Safe Maintenance....71
Warn Others of Service Work....73
Support Machine Properly....74
Stay Clear of Moving Parts....75
Prevent Parts From Flying....76
Store Attachments Safely....77
Prevent Burns....78
Replace Rubber Hoses Periodically....79
Avoid High-Pressure Fluids....80
Prevent Fires....82
Evacuating in Case of Fire....84
Beware of Exhaust Fumes....85
Precautions for Welding and Grinding....86
Avoid Heating Near Pressurized Fluid Lines....87
Remove Paint Before Welding or Heating....88
Beware of Asbestos and Silicon Dust and Other Contamination....89
Prevent Battery Explosions....90
Service Air Conditioning System Safely....91
Handle Chemical Products Safely....92
Dispose of Waste Properly....93
Never Ride Attachment....94
Notes for Muffler Filter....951
Precautions for Communication Terminal....96
FCC Notifications to User....97
Before Returning the Machine to the Customer....98
Section 9001: Diagnostics....99
Group 10: Main Controller (MCZ) Diagnostic Trouble Codes....108
Main Controller (MCZ) Diagnostic Trouble Codes....108
Controller Area Network 0 (CAN 0) Circuit Diagnostics....109
Controller Area Network 1 (CAN 1) Circuit Diagnostics....110
Interface Controller Area Network (N-CAN) Diagnostics....111
011000.02 - Abnormal EEPROM....99
011001.02 - Abnormal RAM....99
011002.02 - Abnormal A/D Converter....99
011003.03 - Abnormal Sensor Voltage....99
011006.02 - Engine Controller Communication Error....99
011007.02 - (CAN 0) Data Converter Communication Error 1....99
011008.02 - (CAN 1) Data Converter Communication Error 2....99
011009.02 - (CAN 0) Monitor Controller Communication Error 1....99
011010.02 - (CAN 1) Monitor Controller Communication Error 2....99
011100.02 - Abnormal Engine Speed....99
011101.03 - Engine Control Dial Sensor Circuit High Input....99
011101.04 - Engine Control Dial Sensor Circuit Low Input....99
011200.03 - Pump 1 Delivery Pressure Sensor Circuit High Input....99
011200.04 - Pump 1 Delivery Pressure Sensor Circuit Low Input....99
011202.03 - Pump 2 Delivery Pressure Sensor Circuit High Input....99
011202.04 - Pump 2 Delivery Pressure Sensor Circuit Low Input....99
011206.03 - Pump 1 Flow Control Pressure Sensor Circuit High Input....99
011206.04 - Pump 1 Flow Control Pressure Sensor Circuit Low Input....99
011208.03 - Pump 2 Flow Control Pressure Sensor Circuit High Input....99
011208.04 - Pump 2 Flow Control Pressure Sensor Circuit Low Input....99
011301.03 - Swing Pilot Pressure Sensor Circuit High Input....99
011301.04 - Swing Pilot Pressure Sensor Circuit Low Input....99
011302.03 - Boom Up Pilot Pressure Sensor Circuit High Input....99
011302.04 - Boom Up Pilot Pressure Sensor Circuit Low Input....99
011303.03 - Arm In Pilot Pressure Sensor Circuit High Input....99
011303.04 - Arm In Pilot Pressure Sensor Circuit Low Input....99
011304.03 - Travel Pilot Pressure Sensor Circuit High Input....99
011304.04 - Travel Pilot Pressure Sensor Circuit Low Input....100
011307.03 - Front Attachment Pilot Pressure Sensor Circuit High Input....100
011307.04 - Front Attachment Pilot Pressure Sensor Circuit Low Input....100
011400.02 - Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback....100
011400.03 - Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current....100
011400.04 - Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current....100
011401.02 - Torque Control Solenoid Valve Abnormal Feedback....100
011401.03 - Torque Control Solenoid Valve Feedback High Current....100
011401.04 - Torque Control Solenoid Valve Feedback Low Current....100
011402.02 - 3-Spool Solenoid Valve Unit (SF) Abnormal Feedback....100
011402.03 - 3-Spool Solenoid Valve Unit (SF) Feedback High Input....100
011402.04 - 3-Spool Solenoid Valve Unit (SF) Feedback Low Input....100
011403.02 - 3-Spool Solenoid Valve Unit (SC) Abnormal Feedback....100
011403.03 - 3-Spool Solenoid Valve Unit (SC) Feedback High Input....100
011403.04 - 3-Spool Solenoid Valve Unit (SC) Feedback Low Input....100
011407.02 - 3-Spool Solenoid Valve Unit (SG) Abnormal Feedback....100
011407.03 - 3-Spool Solenoid Valve Unit (SG) Feedback High Input....100
011407.04 - 3-Spool Solenoid Valve Unit (SG) Feedback Low Input....100
011408.02 - 2-Spool Solenoid Valve Unit (SJ) Abnormal Feedback....100
011408.03 - 2-Spool Solenoid Valve Unit (SJ) Feedback High Input....100
011408.04 - 2-Spool Solenoid Valve Unit (SJ) Feedback Low Input....100
011409.02 - 2-Spool Solenoid Valve Unit (SZ) Abnormal Feedback....100
011409.03 - 2-Spool Solenoid Valve Unit (SZ) Feedback High Input....100
011409.04 - 2-Spool Solenoid Valve Unit (SZ) Feedback Low Input....100
011410.02 - Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback....100
011410.03 - Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current....100
011410.04 - Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current....100
011434.02 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback....100
011434.03 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current....100
011434.04 - Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current....100
011435.02 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback....100
011435.03 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current....100
011435.04 - Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current....100
011436.02 - Breaker Relief Proportional Solenoid Valve Abnormal Feedback....101
011436.03 - Breaker Relief Proportional Solenoid Valve Feedback High Current....101
011436.04 - Breaker Relief Proportional Solenoid Valve Feedback Low Current....101
011457.02 - 2-Speed Activation Solenoid Disconnected or Not Present....101
011458.02 - Selector Valve Solenoid Valve Disconnected or Not Present....101
011459.02 - Idle Stop Relay Circuit Malfunction....101
015011.03 - Hydraulic Oil Temperature Sensor Circuit High Input (Pilot)....101
015011.04 - Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot)....101
015016.03 - Right Analog Stroke Sensor Circuit High Input....101
015016.04 - Right Analog Stroke Sensor Circuit Low Input....101
011810.03 - Electric Lever Operating Pressure Sensor 1 High Voltage....101
011810.04 - Electric Lever Operating Pressure Sensor 1 Low Voltage....101
011812.02 - OPT Electric Lever 1 Neutral Abnormal....101
011813.02 - OPT Electric Lever 1 Abnormal Operation....938
011816.02 - OPT Solenoid 1 Feedback Abnormal....101
011816.03 - OPT Solenoid 1 Feedback Current High....101
011816.04 - OPT Solenoid 1 Feedback Current Low....101
011817.02 - OPT Solenoid 2 Feedback Abnormal....101
011817.03 - OPT Solenoid 2 Feedback Current High....101
011817.04 - OPT Solenoid 2 Feedback Current Low....101
011901.03 - Hydraulic Oil Temperature Sensor Circuit High Input....101
011901.04 - Hydraulic Oil Temperature Sensor Circuit Low Input....101
020010.02 - Abnormal Muffler Filter....951
020011.02 - Electric Lever Alarm....101
020012.02 - Line Filter Restriction Alarm....101
020303.02 - Electric Lever Pilot Cut Alarm....101
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes....364
Engine Control Unit (ECU) Diagnostic Trouble Codes....364
000081.00 - High Muffler Filter Differential Pressure (P2453)....101
000081.01 - Low Muffler Filter Differential Pressure (P2452)....101
000081.02 - Zero-Point Calibration of Muffler Filter Differential Pressure Sensor is Abnormal (P2456)....101
000081.03 - Muffler Filter Differential Pressure Sensor Circuit High Input (P2455)....101
000081.04 - Muffler Filter Differential Pressure Sensor Circuit Low Input (P2454)....102
000091.02 - Accelerator Pedal Position Sensor 1-2 Correlation (P2138)....102
000091.03 - Accelerator Pedal Position Sensor 1 High Input (P2123)....102
000091.03 - Accelerator Pedal Position Sensor 2 High Input (P2128)....102
000091.04 - Accelerator Pedal Position Sensor 1 Low Input (P2122)....102
000091.04 - Accelerator Pedal Position Sensor 2 Low Input (P2127)....102
000100.03 - Engine Oil Pressure Sensor Circuit High Input (P0523)....102
000100.04 - Engine Oil Pressure Sensor Circuit Low Input (P0522)....102
000102.00 - Over Boost-Pressure (P0234)....102
000102.01 - Declined Boost Pressure (P0299)....102
000102.03 - Boost Pressure Sensor Circuit High Input (P0238)....102
000102.04 - Boost Pressure Sensor Circuit Low Input (P0237)....102
000105.03 - Boost Temperature Sensor Circuit High Input (P1113)....102
000105.04 - Boost Temperature Sensor Circuit Low Input (P1112)....102
000108.03 - Atmospheric Pressure Sensor Circuit High Input (P2229)....102
000108.04 - Atmospheric Pressure Sensor Circuit Low Input (P2228)....102
000110.00 - Overheat (P0217)....102
000110.03 - Engine Coolant Temperature Circuit High Input (P0118)....102
000110.04 - Engine Coolant Temperature Circuit Low Input (P0117)....102
000132.03 - Air Flow Sensor Circuit High Input (P0103)....102
000132.04 - Air Flow Sensor Circuit Low Input (P0102)....102
000157.00 - Pressure Increase in Common Rail (Secondary) (P0088)....102
000157.03 - Common Rail Pressure Sensor Circuit High Input (P0193)....102
000157.04 - Common Rail Pressure Sensor Circuit Low Input (P0192)....102
000157.15 - Abnormal Common Rail Pressure (Over Pumping) (P0089)....102
000157.16 - Pressure Increase in Common Rail (Primary) (P0088)....102
000158.03 - Abnormally High Battery System Voltage (P0563)....102
000172.03 - Intake Air Temperature Sensor Circuit High Input (P0113)....102
000172.04 - Intake Air Temperature Sensor Circuit Low Input (P0112)....102
000173.00 - Abnormally High Exhaust Temperature Sensor 1 (CSF Inlet) (P0426)....102
000173.03 - Exhaust Temperature Sensor 1 Circuit High Input (CSF Inlet) (P0428)....102
000173.04 - Exhaust Temperature Sensor 1 Circuit Low Input (CSF Inlet) (P0427)....102
000174.03 - Combustion Temperature Sensor Circuit High Input (P0183)....102
000174.04 - Combustion Temperature Sensor Circuit Low Input (P0182)....103
000190.00 - Engine Overrun (P0219)....103
000628.02 - Abnormal ROM (P0601)....103
000633.07 - Common Rail Pressure Limiter Open (P0087)....103
000636.02 - Abnormal Cam Angle Sensor (No Signal) (P0340)....103
000636.07 - Phase Difference Between Cam and Sensor (P0016)....103
000639.02 - Abnormal CAN Time-Out (U0101)....103
000639.19 - Abnormal CAN Bus (U0073)....103
000651.05 - Cylinder 1 Injector Circuit Open (P0201)....103
000652.05 - Cylinder 2 Injector Circuit Open (P0202)....103
000653.05 - Cylinder 3 Injector Circuit Open (P0203)....103
000654.05 - Cylinder 4 Injector Circuit Open (P0204)....103
000723.02 - Crank Position Sensor Failure (No Signal) (P0335)....103
000723.02 - Crank Position Sensor Failure (Abnormal Signal) (P0336)....103
000987.05 - Malfunction Indicator Control Circuit (P0650)....103
001077.02 - Abnormal CPU (P0606)....103
001079.02 - Abnormal 5V-Electric Power Circuit #1 (P0641)....103
001080.02 - Abnormal 5V-Electric Power Circuit #2 (P0651)....103
001131.03 - Manifold Temperature Sensor Circuit High Input (P041C)....103
001131.04 - Manifold Temperature Sensor Circuit Low Input (P041D)....103
001239.01 - Pressure Decline in Common Rail (No Pumping Pressure) (P0093)....103
001239.17 - Pressure Decline in Common Rail (Lack of Pumping Pressure) (P1093)....103
001347.03 - SCV Drive Circuit + Short Circuit B (P0092)....103
001347.04 - SCV Drive Circuit Open or Short Circuited to GND (P0091)....103
001381.03 - Fuel Filter Restriction Sensor Circuit High Input (P1294)....103
001381.04 - Fuel Filter Restriction Sensor Circuit Low Input (P1293)....103
001485.05 - Abnormal Main Relay Circuit (Inactivation) (P0685)....103
001485.06 - Abnormal Main Relay Circuit (Kept Closed) (P0687)....103
010001.02 - EGR Position Error (Brushless Type) (P0409)....103
010001.13 - Abnormal EGR Zero-Point Calibration (P1404)....103
010002.02 - Abnormal EGR Valve Control Circuit (P0404)....103
010003.02 - Abnormal Injector Common 1 Circuit (P2146)....103
010004.02 - Abnormal Injector Common 2 Circuit (P2149)....103
010005.01 - Abnormal Charge Circuit (Bank 1) (P1261)....104
010006.01 - Abnormal Charge Circuit (Bank 2) (P1262)....104
010007.02 - Abnormal CPU Monitor IC (P0606)....104
010008.02 - Abnormal A/D Converter (P060B)....104
010009.02 - Abnormal 5V-Electric Power Circuit #3 (P0697)....104
010010.02 - Abnormal 5V-Electric Power Circuit #4 (P1655)....104
010012.02 - Abnormal 12V Circuit (P0560)....104
010013.02 - Abnormal EEPROM/Abnormal HDEEPROM (P1621)....104
010022.02 - Abnormal Intake Throttle Control Circuit (P0638)....104
010022.03 - Intake Throttle Position Sensor Circuit High Input (P0123)....104
010022.04 - Intake Throttle Position Sensor Circuit Low Input (P0122)....104
010023.03 - EVRV Vacuum Sensor High Input (P2528)....104
010023.04 - EVRV Vacuum Sensor Low Input (P2527)....104
010023.20 - Abnormal Turbo EVRV (P0045)....104
010024.03 - Exhaust Temperature Sensor 2 Circuit High Input (DOC Inlet) (P042D)....104
010024.04 - Exhaust Temperature Sensor 2 Circuit Low Input (DOC Inlet) (P042C)....104
010025.05 - Muffler Filter Light Failure (P1669)....104
010026.00 - Muffler Filter PM Over-Restriction 2 (P1455)....104
010026.15 - Muffler Filter PM Over-Restriction (P242F)....104
010027.00 - Muffler Filter Cleaning Decision Error (P1471)....104
010028.00 - Abnormally High Exhaust Temperature Sensor 2 (DOC Outlet) (P042B)....104
010029.00 - Over Frequent Muffler Filter Regeneration Time-Out (P2458)....104
010032.02 - QR Code Error (P0602)....104
010033.02 - Abnormal RAM (P0604)....104
010040.19 - Abnormal ISO-CAN Bus (U0001)....104
Group 30: Monitor Controller (DSZ) Diagnostic Trouble Codes....461
Monitor Controller (DSZ) Diagnostic Trouble Codes....461
013002.02 - ECU Communication Error....104
013003.02 - Main Controller (MCZ) Communication Error 1....104
013004.02 - Main Controller (MCZ) Communication Error 2....104
013005.02 - Monitor Controller (DSZ) Communication Error 1....104
013006.02 - Monitor Controller (DSZ) Communication Error 2....104
013007.02 - Machine Controller (BCZ) Communication Error....104
020113.02 - System Error Alarm....105
Group 40: Information Controller (ICZ) Diagnostic Trouble Codes....470
Information Controller (ICZ) Diagnostic Trouble Codes....470
013303.02 - Abnormal Monitor Internal Temperature Sensor....105
013304.02 - Alternator Alarm....105
013310.03 - Shorted Circuit in Coolant Temperature Sensor....105
013311.03 - Fuel Level Sensor Open Circuit....105
013311.04 - Fuel Level Sensor Shorted Circuit....105
014001.02 - Flash Memory Read/Write Error....105
014002.02 - External RAM Read/Write Error....105
014003.02 - Abnormal EEPROM....105
014006.02 - Communication Terminal : Communication Error....105
014008.02 - Abnormal Internal RAM....105
014021.02 - Communication Terminal Security Error....105
014022.02 - SIM Card Error....105
014023.02 - Security Error....105
020100.02 - Overheat Alarm....105
020101.02 - Engine Warning Alarm....105
020102.02 - Engine Oil Pressure Alarm....105
020105.02 - Hydraulic Oil Filter Restriction Alarm....105
020106.02 - Air Cleaner Restriction Alarm....105
020107.02 - Water Separator Alarm....105
020109.02 - Pilot Control Shut-Off Lever Alarm....105
020110.02 - Fuel Filter Restriction Alarm....105
020114.02 - Overheat Alarm....105
020133.02 - Crane Function Alarm....105
020137.02 - Muffler Filter Alarm....105
020141.02 - Muffler Temperature Alarm....105
020142.02 - Intake Air Temperature Alarm....105
020145.02 - Boost Temperature Increase Alarm....105
020146.02 - Fuel Temperature Increase Alarm....105
020149.02 - EGR Gas Temperature Alarm....105
Group 50: Air Conditioner Controller (ACF) Diagnostic Trouble Codes....520
Air Conditioner Controller (ACF) Diagnostic Trouble Codes....520
11 - Open Circuit in Air Recirculation Sensor....106
12 - Short-Circuited Air Recirculation Sensor....106
13 - Open Circuit in Ambient Air Temperature Sensor....106
14 - Short-Circuited Ambient Air Temperature Sensor....106
18 - Short-Circuited Solar Radiation Sensor....106
21 - Open Circuit in Air Conditioner Freeze Control Switch....106
22 - Short-Circuited Air Conditioner Freeze Control Switch....106
43 - Abnormal Air Conditioner and Heater Blower Port Change Servomotor....106
44 - Abnormal Air Conditioner and Heater Mixer Servomotor....106
91 - Communication Error....106
92 - CAN Bus Off Error....106
Section 9005: Operational Checkout Procedure....547
Group 10: Operational Checkout Procedure....547
Operational Checkout....612
Section 9010: Engine....676
Group 05: Theory of Operation....938
Isuzu Engine....693
Engine Fuel System Component Location....679
Engine Cooling System Component Location....680
Cold Weather Starting Aid....681
Engine Speed Control System Operation....938
Group 15: Diagnostic Information....676
Isuzu Engine....693
Group 20: Adjustments....676
Isuzu Engine....693
Group 25: Tests....676
Isuzu Engine....693
Section 9015: Electrical System....694
Group 05: System Information....694
Electrical Diagram Information....707
Group 10: System Diagrams....694
Explanation of Wire Markings....716
Fuse and Relay Specifications....717
System Functional Schematic, Component Location, and Wiring Diagram Master Legend....722
System Functional Schematic....731
Cab Harness (W1) Component Location....753
Cab Harness (W1) Wiring Diagram....760
Machine Harness (W2) Component Location....769
Machine Harness (W2) Wiring Diagram....775
Monitor Harness (W3) Component Location....780
Monitor Harness (W3) Wiring Diagram....781
Engine Harness (W4) Component Location....783
Engine Harness (W4) Wiring Diagram....785
Pump Harness (W8) Component Location....786
Pump Harness (W8) Wiring Diagram....787
Muffler Filter Parked Cleaning Switch Harness (W9) Component Location....789
Muffler Filter Parked Cleaning Switch Harness (W9) Wiring Diagram....790
Pilot Shutoff Switch Harness (W11) Component Location....791
Pilot Shutoff Switch Harness (W11) Wiring Diagram....792
Auxiliary Fuse Box Harness (W13) Component Location....793
Auxiliary Fuse Box Harness (W13) Wiring Diagram....794
Heated Air Seat Harness (W14) Component Location....796
Heated Air Seat Harness (W14) Wiring Diagram....797
Multi-Function Pilot Control Lever Harness (W15) Component Location....798
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram....800
Travel Alarm Cancel Switch Harness (W16) Component Location....801
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram....802
Attachment Harness (W17) Component Location....803
Attachment Harness (W17) Wiring Diagram....805
Rear Camera Harness (W19) Component Location....806
Rear Camera Harness (W19) Wiring Diagram....807
Service ADVISOR™ Harness (W20) Component Location (S.N. —230196)....808
Service ADVISOR™ Harness (W20) Wiring Diagram (S.N. —230196)....809
Pilot Shutoff Valve Harness (W21) Component Location....810
Pilot Shutoff Valve Harness (W21) Wiring Diagram....811
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location....812
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram....813
Seat Heater Switch Harness (W24) Component Location....814
Seat Heater Switch Harness (W24) Wiring Diagram....815
Attachment Interface Harness (W25) Component Location....816
Attachment Interface Harness (W25) Wiring Diagram (S.N. —XXXXXX )....817
Travel Alarm Harness (W26) Component Location....818
Travel Alarm Harness (W26) Wiring Diagram....819
Starter Switch Harness (W29) Component Location....820
Starter Switch Harness (W29) Wiring Diagram....821
Data Converter Harness (W30) Component Location....822
Data Converter Harness (W30) Wiring Diagram....823
Data Converter Interface Harness (W31) Component Location....825
Data Converter Interface Harness (W31) Wiring Diagram....826
2-Speed Harness (W32) Component Location....828
2-Speed Harness (W32) Wiring Diagram....829
Heater and Air Conditioner Harness (W41) Component Location....830
Heater and Air Conditioner Harness (W41) Wiring Diagram....831
Travel Alarm Cancel Switch Jumper Harness (W48) Component Location....832
Travel Alarm Cancel Switch Jumper Harness (W48) Wiring Diagram....833
Heater and Air Conditioner Relay Harness (W51) Component Location....834
Heater and Air Conditioner Relay Harness (W51) Wiring Diagram....835
12-Volt Power Harness (W55) Component Location....837
12-Volt Power Harness (W55) Wiring Diagram....838
Auxiliary Solenoid Harness (W61) Component Location....839
Auxiliary Solenoid Harness (W61) Wiring Diagram....841
Auxiliary Function Lever (AFL) Harness (W75) Component Location....843
Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram....845
Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location....846
Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram....848
Satellite (SAT) Harness (W6003) Component Location....850
Satellite (SAT) Harness (W6003) Wiring Diagram....851
JDLink™ Harness (W6004) Component Location....852
JDLink™ Harness (W6004) Wiring Diagram....854
Group 15: Sub-System Diagnostics....696
Controller Area Network (CAN) Theory of Operation....938
Starting and Charging Circuit Theory of Operation....938
Monitor Controller (DSZ) Circuit Theory of Operation....938
Engine Control Unit (ECU) Circuit Theory of Operation....938
Exhaust Aftertreatment Circuit Theory of Operation....938
Main Controller (MCZ) Circuit Theory of Operation....938
Travel Alarm Circuit Theory of Operation....938
Machine Controller (BCZ) Circuit Theory of Operation....938
Windshield Wiper and Washer Circuit Theory of Operation....938
Lighting Circuit Theory of Operation....938
Pilot Shutoff Circuit Theory of Operation....938
Attachment Control Circuit Theory of Operation....938
Group 16: Monitor Operation....938
Service Menu....926
Troubleshooting....928
Monitoring....929
Controller Version....936
Issued Warning Record....937
Operation....938
Machine Setting....939
Monitor Setting....946
Alarm Setting....949
Engine Setting....950
Muffler Filter....951
Maintenance Mode....952
Rear View Camera Troubleshooting....953
Group 20: References....697
Reading Diagnostic Trouble Codes with Monitor Display....957
Service ADVISOR™ Diagnostic Application....958
Service ADVISOR™ Connection Procedure....959
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application....962
Clearing Engine Diagnostic Trouble Codes....965
MPDr Application....972
MPDr Connection Procedure....973
Fuse Test....975
Relay Test....985
Pressure Sensor Test....986
Solenoid Test....989
Proportional Solenoid Test....990
Temperature Sensor Test....991
Alternator Test....993
Controller Area Network (CAN) Circuit Test....995
Electrical Component Checks....1002
Battery Remove and Install....1010
Rear Cover Remove and Install....1012
Main Controller (MCZ) Remove and Install....1014
Machine Controller (BCZ) Remove and Install....1017
Engine Control Unit (ECU) Remove and Install....1020
Exhaust Differential Pressure Sensor Zero Point Calibration....1022
Ash Reset....1024
No Load Max....1025
Data Converter Remove and Install....1028
Monitor Controller (DSZ) Remove and Install....1029
Air Conditioner Controller (ACF) Remove and Install....1031
Key Switch Remove and Install....1033
Right Switch Console Remove and Install....1034
Left Switch Console Remove and Install....1036
Travel Alarm Remove and Install....1038
Heater Control Disable and Enable....1039
Disconnect Tab Retainer Connectors....1040
Disconnecting Spring Wire Clip Connectors....1041
Replace DEUTSCH™ Connectors....1042
Replace DEUTSCH™ Rectangular or Triangular Connectors....1044
Install DEUTSCH™ Contact....1046
Replace WEATHER PACK™ Connector....1048
Install WEATHER PACK™ Contact....1050
Replace (Pull Type) Metri-Pack™ Connectors....1052
Replace (Push Type) Metri-Pack™ Connectors....1054
Replace CINCH™ Connectors....1055
Install CINCH™ Contact....1057
Repair 32 and 48 Way CINCH™ Connectors....1059
Remove Connector Body from Blade Terminals....1063
Section 9020: Power Train....1064
Group 05: Theory of Operation....938
Track Adjuster and Recoil Spring Operation....1066
Travel Gear Case Operation....1067
Group 15: Diagnostic Information....1064
Noisy or Loose Track Chain....1064
Tight Track Chain....1064
Frequent Track Chain Sag Adjustment Required....1064
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers....1064
Bent Track Shoes....1064
“Popping” of Track....1064
Cracked Track Link....1064
Chipped Link Rails....1064
Individual Undercarriage Component Wear....1064
Measure Swing Bearing Wear....1085
Section 9025: Hydraulic System....1089
Group 05: Theory of Operation....938
Hydraulic System Operation....1094
Pilot System Operation....1095
Pilot Pump, Pressure Regulating Valve and Filter Operation....1096
Pilot Shutoff Solenoid Valve Operation....1098
Pilot Control Valve Operation....1131
Travel Pilot Control Valve Operation....1131
Pilot Operation of Control Valve Operation....1131
Pilot Signal Manifold Operation....1111
Pump 1, Pump 2, and Drive Gear Case Operation....1119
Pump 1 and Pump 2 Regulator Operation....1122
Engine Speed Sensing Control Circuit Operation....1129
Control Valve Operation....1131
Control Valve Check Valves Identification and Operation....1146
Main Relief Valve Circuit Operation....1150
Circuit Relief and Anticavitation Valve Operation....1155
Travel Flow Combiner Valve Operation....1157
Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation....1160
Boom Lower Meter-In Cut Valve Operation....1165
Boom Regenerative Valve Circuit Operation....1169
Dig Regenerative Valve Circuit Operation....1172
Arm Regenerative Valve Circuit Operation....1176
Bucket Regenerative Valve Circuit Operation....1181
Boom and Arm Reduced Leakage Valves Operation....1184
Arm 1 Flow Rate Control Valve Circuit Operation....1186
Arm 2 Flow Rate Control Valve Circuit Operation....1190
Bucket Flow Rate Control Valve Circuit Operation....1194
Boom Flow Rate Control Valve Circuit Operation....1198
Auxiliary Flow Rate Control Valve Circuit Operation....1202
Swing Reduction Gear Case Operation....1207
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation....1208
Swing Motor Damper Valve....1212
Swing Motor Park Brake Release Circuit Operation....1223
Center Joint Operation....1224
Travel Motor and Park Brake Valve Operation....1225
Travel Motor Speed Circuit Operation....1233
Catalyzed Soot Filter (CSF) Burn Solenoid Valves....1237
Cylinder Operation....1239
Return Filter Operation....1241
Auxiliary System Operation....1242
Auxiliary Pilot Control Valve Operation....1243
Flow Rate Select Solenoid Valve Operation....1249
Flow Rate Pressure Reducing Valve Operation....1251
Secondary Auxiliary Relief Valve Solenoid Valve Operation....1253
Secondary Auxiliary Relief Control Valve Operation....1254
Secondary Auxiliary Relief Valve Operation....1255
Selector Valve Solenoid Valve Operation....1256
Selector Valve Operation....1257
Auxiliary Shuttle Valve Operation....1259
Auxiliary High Flow Line Kit Operation....1261
Two Way Solenoid Kit Operation....1265
Two Pump Combined Flow Kit Operation....1268
Secondary Auxiliary Relief Kit Operation....1275
Low Flow Kit Operation....1279
Group 15: Diagnostic Information....1090
All Hydraulic Functions Slow....1090
Hydraulic Oil Overheats....1090
No Hydraulic Functions....1090
No Hydraulic Functions—Electrical Checks....1090
Function Does Not Stop When Control Lever Released....1090
Load Drifts Down When Control Lever is in Neutral Position....1090
Load Falls When Control Valve is Actuated To Raise Load....1090
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal....1090
Boom Down Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal....1090
Arm In Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal....1090
Swing Speed Slow During Arm in Function....1091
Boom Cannot Raise Track Off Ground....1091
Swing Function Does Not Operate in Both Directions....1091
Swing Speed Slow in Both Directions....1091
Swing Speed Slow or Does Not Operate in One Direction....1091
Upperstructure Drift With Swing Valve in Neutral....1091
Machine Freewheels Down an Incline....1091
Track Will Not Move in Either Direction....1091
Machine Mistracks....1091
Machine Mistracks Left During Combined Travel and Dig Functions....1091
Machine Will Not Shift Into Fast (rabbit) Speed....1091
Pump 1, Pump 2, and Pilot Pump Line Identification....1344
Control Valve Line Identification....1345
Swing Motor Line Identification....1349
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern....1350
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern....1352
Pilot Signal Manifold-to-Control Valve Line Connection....1354
Travel System Component Location....1357
Travel Hydraulic System Line Connection....1359
Auxiliary Attachment Schematic....1361
Auxiliary System Line Connections....1369
Hydraulic System Schematic....1371
Hydraulic System Component Location....1380
Hydraulic System Line Connections....1382
Group 25: Tests....1091
JT05800 Digital Thermometer Installation....1384
JT02156A Digital Pressure and Temperature Analyzer Kit Installation....1385
Hydraulic Oil Cleanup Procedure....1386
Hydraulic Oil Tank Pressure Release Procedure....1389
Hydraulic Oil Warm-Up Procedure....1390
Pilot Pressure Regulating Valve Test and Adjustment....1393
Control Valve Spool Actuating Pilot Pressure Test....1398
Dig Regenerative Solenoid Valve Test and Adjustment....1401
Arm Regenerative Solenoid Valve Test and Adjustment....1406
Power Dig Solenoid Valve Test and Adjustment....1411
Torque Control Solenoid Valve Test and Adjustment....1416
Pump Control Pilot Pressure Signal Test....1420
Main Relief and Power Dig Valve Test and Adjustment....1423
Circuit Relief Valve Test and Adjustment....1429
Swing Motor Crossover Relief Valve Test and Adjustment....1435
Travel Motor Crossover Relief Valve Test and Adjustment....1439
Pump Regulator Test and Adjustment—Minimum Flow....1444
Pump Regulator Test and Adjustment—Maximum Flow....1447
Pump Flow Test....1450
Comprehensive Pump Flow Test....1454
Swing Motor Leakage Test....1460
Travel Motor Leakage Test....1463
Cylinder Drift Test—Boom, Arm, and Bucket....1467
Upperstructure Drift Test....1469
Section 9031: Heating and Air Conditioning....1472
Group 05: Theory of Operation....938
Air Conditioning System Cycle of Operation....1475
Group 15: Diagnostic Information....1472
Air Conditioning System Does Not Operate....1472
No Air Flow From Heater and Air Conditioner Vents....1472
Air Conditioning Does Not Cool Interior of Cab....1472
Air Conditioning Runs Constantly, Too Cold....1472
Interior Windows Continue to Fog Using Air Conditioner....1472
Heater System Does Not Operate....1472
Heater Does Not Warm Interior of Cab....1472
Interior Windows Continue to Fog Using Heater....1472
Heater and Air Conditioner Component Location....1508
Group 25: Tests....1472
Refrigerant Cautions and Proper Handling....1511
Heater and Air Conditioner Operational Checks....1512
Air Conditioner Compressor Clutch Test....1515
Refrigerant Leak Test....1516
Refrigerant Hoses and Tubing Inspection....1517
Air Conditioner High/Low-Pressure Switch Test....1518
Air Conditioner Freeze Control Switch Test....1521
Air Conditioner Compressor Belt Check....1522
R134a Air Conditioning System Test....1523
Operating Pressure Diagnostic Chart....1526
Section 9900: Dealer Fabricated Tools....1527
Group 99: Dealer Fabricated Tools....1527
DFT1218 Split Flange Hose Cap....1529
Hitachi Zaxis160LC-5N Excavator Diagnosis and Tests Service Technical Manual (TM12366)
