Technical Manual Hitachi ZX155W-7 Wheeled Excavator | TOLBS50-EN-00 (2022.09.29)

Technical Manual Hitachi ZX155W-7 Wheeled Excavator TOLBS50-EN-00 (2022.09.29) (Preview)

INTRODUCTION
– To The Reader
– Additional References
– Manual Composition
– Page Number
– Trademark
– Safety Alert Symbol and Headline Notations
– Units Used
SYMBOL AND ABBREVIATION
– Symbol and Abbreviation
CONTRASTING LIST OF PART NAME
– Contrasting List of Part Name between Technical Manual and Parts Catalog
SECTION AND GROUP CONTENTS
CONTENTS
GENERAL
– Specifications
— Specifications ZX155W-7
— Specifications ZX155W-7 (Rear Blade)
— Specifications ZX155W-7 (Rear Outrigger)
— Specifications ZX155W-7 (Front Blade, Rear Outrigger)
— Specifications ZX155W-7 (Front Outrigger, Rear Blade)
— Specifications ZX155W-7 (Front Outrigger, Rear Outrigger)
— Working Ranges ZX155W-7 Monoblock Boom
— Working Ranges ZX155W-7 2-Piece Boom
– Component Layout
— Main Component (Upperstructure)
— Main Component (Undercarriage)
— Main Component (Front Attachment)
— Electrical System (Overview)
— Electrical System (Cab)
— Electrical System (Switches)
— Electrical System (Rear Tray)
— Relay Layout
— Electrical System (Utility Space)
— Electrical System (Relays)
— Electrical System (Lights)
— Engine Oil Monitoring Sensor
— Hydraulic Oil Monitoring Sensor
— Engine
— Aftertreatment Device
— Pump Device
— Around Pump Device
— Control Valve
— Signal Control Valve
— Swing Shockless Valve
— Swing Device
— Swing Dampener Valve
— Accumulator Charging Valve
— Travel Shockless Valve
— Travel Device
— Brake Valve
— 7-Spool Solenoid Valve Unit
— 3-Spool Solenoid Valve Unit 1
— 3-Spool Solenoid Valve Unit 2
— 2-Spool Solenoid Valve Unit (For Assist) (Option)
— 2-Spool Solenoid Valve Unit (For Blade/Outrigger Cylinder) (Front) (Option)
— 2-Spool Solenoid Valve Unit (For Blade/Outrigger Cylinder) (Rear) (Option)
— Pump 1 and Pump 2 Flow Rate Control Solenoid Valve Unit
— Axle Lock/Brake Solenoid Valve Unit
— Transmission Control Solenoid Valve
— Cruise Stop Solenoid Valve
— Cruise Control Solenoid Valve
— Around DEF Tank
— Layout of Attachment Spec. Parts
— Auxiliary Control Solenoid Valve Unit
— Breaker Relief Solenoid Valve
— Selector Valve Control Valve
– Component Specifications
— Specifications of Engine
— Specifications of Engine Accessories
— Specifications of Hydraulic Component
— Specifications of Electrical Component
SYSTEM
– Controller
— Outline of Controller
— CAN Circuit
– Control System
— Outline of Control System
— Engine Control
— Engine Control System Layout
— Engine Protection Control
— Engine Control Dial Control
— ECO Control
— Power Mode (ECO/PWR Mode) Switch Control
— ECO Mode Control
— Travel HP Mode Control
— Engine Speed Holding Control When Decelerating
— Auto-Idle Control
— Hydraulic Oil Temperature Auto Warming-Up Control
— Radiator Coolant Temperature Auto Warming-Up Control
— Idle Speed-Up Control
— Engine Speed Slow Down Control
— Heater Control
— One-Touch Idle Control
— Attachment Operation Speed Increase Control (Option)
— Attachment Operation Speed Limit Control (Option)
— Pump Control
— Pump Control System Layout
— Speed Sensing Control
— Travel Speed Sensing Control
— Pump Torque Decrease Control (Radiator Coolant Temperature)
— Pump Torque Decrease Control (Hydraulic Oil Temperature)
— Digging Torque Increase Control
— Pump Torque Increase Control (Swing and Boom Raise)
— Steering Pump Torque Decrease Control
— Pump Torque Restriction Control (During Engine Output Restriction)
— Pump 1 Flow Rate Limit Control at Creeper Mode Travel Speed
— Pump 1 Flow Rate Control
— Pump 2 Flow Rate Control
— Pump 1 Flow Rate Limit Control (Option)
— Pump 2 Flow Rate Limit Control (Option)
— Valve Control (Standard) (MC)
— Valve Control (Standard) (MC) System Layout
— Power Digging Control
— Auto-Power Lift Control
— Arm Regenerative Control
— Arm 1 Flow Rate Control
— Arm 2 Roll-In Pilot Cut Control
— Pump 1 Center Bypass Shut-Out Control
— Pump 2 Center Bypass Shut-Out Control
— Travel Make-Up Pressure Control
— Valve Control (Standard) (PLCU)
— Valve Control (Standard) (PLCU) System Layout
— Travel Motor Excessive Speed Control
— Travel Motor Displacement Angle Control
— Creeper Mode Travel Speed Control
— Working Brake Control
— Auto Axle Lock Control
— Automatic Working Brake Control
— Cruise Control
— Valve Control (Option) (MC)
— Valve Control (Option) (MC) System Layout
— Attachment Flow Rate Control
— Auxiliary Flow Combiner Control
— Breaker 1 (HSB Breaker) Control
— Auxiliary Overload Relief Valve Pressure Control
— Ride Control
— Valve Control (Option) (PLCU)
— Valve Control (Option) (PLCU) System Layout
— Auxiliary and Positioning Control
— Blade/Outrigger Control
— Blade/Outrigger Control (Operation Control Circuit)
— Assist Control
— Abnormal Operation Judgment Control
— Abnormal Center Signal Judgment Control
— Electric Lever Pilot Cut Control
— Other Control (MC)
— Work Mode Control
— Auto Shut-Down Control
— Automatic Engine Stop Control at Low Temperature
— Hydraulic Oil Overheat Alarm Control
— Auto-Lubrication Control (Option)
— Breaker Alarm Control (Option)
— Travel Alarm Control (Option)
— Swing Alarm Control (Option)
— Overload Alarm Control (Option)
— Other Control (PLCU)
— Forward/Reverse Shifting Restriction Control
— Travel Pilot Pressure Cut Control
— Travel Mode Selection Control (Fast Speed)
— Travel Mode Selection Control (Slow Speed)
— Brake Dragging Prevention Control
— Automatic Transmission Control
— Parking Mode Control
— Public Road Drive Mode Control
– Engine System
— Outline of ECM System
— Fuel Injection Control
— Fuel Injection Amount Control
— Fuel Injection Timing Control
— Fuel Injection Rate Control
— Fuel Injection Pressure Control
— Fuel Injection Amount Correction Control
— EGR Control
— Preheating Control
— Alarm Control
— Urea SCR System
— DEF Injection Control
— Start-Up Control
— DEF Defrosting Control (DEF Tank)
— DEF Defrosting Control (DEF Piping)
— DEF Thermal Control (DEF Tank)
— DEF Thermal Control (DEF Piping)
— After-Run Control
— Engine Output Restriction Control (INDUCEMENT)
— Insufficient DEF Level
— Malfunction of Urea SCR System/Malfunction of EGR System
— Urea SCR System Hardware Malfunction/EGR System Hardware Malfunction
— Outline of Aftertreatment Device
— Operation of Aftertreatment Device
— Aftertreatment Device Regeneration Control
– Hydraulic System
— Outline of Hydraulic System
— Pilot Circuit of Hydraulic System
— Operation Control Circuit (Front Attachment, Swing, and Travel)
— Operation Control Circuit (Auxiliary/Positioning, Blade/Outrigger, and Assist)
— Pump Control Circuit (Refer to COMPONENT OPERATION/Pump Device.)
— Valve Control Circuit (Refer to COMPONENT OPERATION/Control Valve, Travel Device.)
— Axle Lock Release Circuit (Refer to COMPONENT OPERATION/Axle, Others (Undercarriage).)
— Swing Parking Brake Release Circuit (Refer to COMPONENT OPERATION/Swing Device.)
— Working Brake Circuit (Brake Valve)
— Service Brake Circuit
— Blade/Outrigger Control Circuit
— Steering Circuit
— Main Circuit of Hydraulic System
— Neutral Circuit
— Flow Combiner Circuit (Front Attachment)
— Relief Circuit
— Combined Operation Circuit
— Arm 1 Flow Rate Control Circuit
— Pump 2 Center Bypass Shut-Out Control Circuit
— Bucket Regenerative Cut Circuit
— Bucket Flow Rate Control Circuit
— Arm Regenerative Circuit
— Boom Lower Meter-In Cut Control
— Boom Cylinder Bottom Pressure: High (With the Front Attachment above the Ground)
— Boom Cylinder Bottom Pressure: Low (With Track Raised off the Ground)
— Breaker/Pulverizer/Crusher Circuit (Option) of Hydraulic System
— Auxiliary Flow Combiner Circuit
— When Performing Single Operation of Auxiliary Flow Combiner Circuit
— When Performing Combined Operation of Auxiliary Flow Combiner Circuit
— Breaker 1 (HSB Breaker) Circuit
— Breaker 2 (NPK Breaker) Circuit
– Electrical System
— Outline of Electrical System
— Main Circuit of Electrical System
— Electric Power Circuit (Key Switch: OFF)
— CAN Circuit
— Accessory Circuit (Key Switch: ACC)
— Starting Circuit (Key Switch: START)
— Charging Circuit (Key Switch: ON)
— Alternator Operation
— Regulator Operation
— Surge Voltage Prevention Circuit
— Pilot Shut-Off Circuit (Key Switch: ON)
— Auto Shut-Down Circuit/Automatic Engine Stop Circuit at Low Temperature
— Engine Stop Circuit
— Emergency Stop Circuit
— Monitor Circuit of Electrical System
— Security Circuit
— Aerial Angle Circuit
— Control Lever Automatic Pilot Shut-Off Circuit
— Seat Belt Reminder Circuit
— Radio Circuit
— Air Conditioner Circuit
— Accessory Circuit of Electrical System
— Work Light Circuit (Work Light Switch: 1 Position)
— Work Light Circuit (Work Light Switch: 2 Position)
— Wiper Circuit
— Washer Circuit
— Cab Light Circuit (Cab Light Switch: Door Interlocking Position (Key Switch: ON))
— Cab Light Circuit (Cab Light Switch: ON Position)
— Horn Circuit
— Lighting Circuit of Electrical System
— Light Lighting Circuit (Clearance Light, License Plate Light, Tail Light)
— Light Lighting Circuit (Headlight)
— Light Lighting Circuit (High Beam)
— Light Lighting Circuit (Passing)
— Turn Signal Light Circuit (Turn Signal Switch: Left-Turn Position)
— Turn Signal Light Circuit (Turn Signal Switch: Right-Turn Position)
— Hazard Light Circuit
— Brake Light Circuit
— Beacon Light Circuit (Option)
COMPONENT OPERATION
– Pump Device
— Outline of Pump Device
— Outline of Main Pump
— Operational Principle of Main Pump
— Increasing and Decreasing of Main Pump Delivery Flow Rate
— Outline of Regulator
— Regulator Control Function
— Control by Pump Control Pressure
— Control by Own and Partner Pump Delivery Pressure (Regulators for Pump 1 and Pump 2)
— Control by Pilot Pressure from Torque Control Solenoid Valves
— Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valves (Pump Flow Rate Limit Control)
— Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valves (Pump Flow Rate Control)
— Flow Rate Increase Control by Pump Control Pressure
— Flow Rate Decrease Control by Pump Control Pressure
— Flow Rate Decrease Control by Own and Partner Pump Delivery Pressure (Regulators for Pump 1 and Pump 2)
— Flow Rate Increase Control by Own and Partner Pump Delivery Pressure (Regulators for Pump 1 and Pump 2)
— Flow Rate Decrease Control by Pilot Pressure from Torque Control Solenoid Valve
— Flow Rate Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valves (Pump 1 and Pump 2)
— Outline of Maximum Flow Rate Limit Control Solenoid Valve and Torque Control Solenoid Valve
— Operation of Maximum Flow Rate Limit Control Solenoid Valve and Torque Control Solenoid Valve
— Outline of Pilot Pump, Steering Pump and Assist Pump (Option)
— Outline of Pump Delivery Pressure Sensor
— Outline of Pump Control Pressure Sensor
– Swing Device
— Outline of Swing Device
— Outline of Swing Reduction Gear
— Outline of Swing Motor
— Outline of Swing Parking Brake
— When Swing Parking Brake is Released
— When Brake is Applied of Swing Parking Brake
— Outline of Valve Unit
— Operation of Make-Up Valve
— Outline of Swing Relief Valve
— Operation of Swing Relief Valve
— Outline of Swing Dampener Valve
— Operation of Swing Dampener Valve
— Output Curve of Swing Dampener Valve: Between A and B (When Relieving)
— Output Curve of Swing Dampener Valve: Operation of Combination Valve A between A and B (During Relief)
— Output Curve of Swing Dampener Valve: Operation of Combination Valve B between A and B (During Relief)
— Output Curve of Swing Dampener Valve: Between B and C (Pressure Begins to Decrease)
— Output Curve of Swing Dampener Valve: Operation of Combination Valve A between B and C (Pressure Begins to Decrease)
— Output Curve of Swing Dampener Valve: Between C and D (Port BM Pressure Decreases)
— Output Curve of Swing Dampener Valve: Operation of Combination Valve B between C and D (Port BM Pressure Decreases)
— Output Curve of Swing Dampener Valve: Between D and E (During Aftershock)
— Output Curve of Swing Dampener Valve: Operation of Combination Valve A between D and E (During Aftershock)
— Output Curve of Swing Dampener Valve: Operation of Combination Valve B between D and E (During Aftershock)
– Control Valve
— Outline of Control Valve
— Components in Control Valve
— Main Circuit of Control Valve
— Pilot Operation Control Circuit of Control Valve
— External Pilot Pressure Circuit of Control Valve
— Outline of Main Relief Valve
— Relief Operation of Main Relief Valve
— Pressure Increasing Operation of Main Relief Valve
— Outline of Overload Relief Valve (With Make-Up Function)
— Relief Operation of Overload Relief Valve
— Make-Up Operation of Overload Relief Valve
— Outline of Make-Up Valve
— Make-up Operation of Make-Up Valve
— Outline of Regenerative Valve
— Operation of Boom Regenerative Valve
— Operation When Performing Bucket Regenerative Operation
— Operation When Performing Bucket Regenerative Cut Operation
— Operation When Performing Arm Regenerative Operation
— Operation When Releasing Arm Regenerative Operation
— Outline of Anti-Drift Valve
— Holding Operation of Anti-Drift Valve
— Releasing Operation of Anti-Drift Valve
— Outline of Flow Rate Control Valve
— Normal Operation of Flow Rate Control Valve
— Flow Rate Control Operation of Flow Rate Control Valve
— Outline of Boom Lower Meter-In Cut Valve
— Operation of Boom Lower Meter-In Cut Valve (With the Track off the Ground)
— Operation of Boom Lower Meter-In Cut Valve (With the Front Attachment above the Ground)
— Outline of Auxiliary Flow Combiner Valve and Pump 1 Bypass Shut-Out Valve
— Operation of Auxiliary Flow Combiner Valve and Pump 1 Bypass Shut-Out Valve (During Single Operation)
— Operation of Auxiliary Flow Combiner Valve and Pump 1 Bypass Shut-Out Valve (During Combined Operation)
— Outline of Pump 2 Bypass Shut-Out Valve
— Operation of Pump 2 Bypass Shut-Out Valve
– Pilot Valve
— Outline of Pilot Valve
— Outline of Front Attachment/Swing Pilot Valve
— Outline of Travel Pilot Valve
— Operation of Front Attachment/Swing Pilot Valve
— When Front Attachment/Swing Pilot Valve in Neutral (Output Curve: A to B)
— During Metering or Decompressing of Front Attachment/Swing Pilot Valve (Output Curve: C to D)
— Full Stroke of Front Attachment/Swing Pilot Valve (Output Curve: E to F)
— Operation of Travel Pilot Valve
— Neutral of Travel Pilot Valve (Output Curve: A to B)
— During Metering or Decompressing of Travel Pilot Valve (Output Curve: C to D)
– Electric Lever
— Outline of Electric Lever
— Operation of Auxiliary/Positioning Pedal (Electric Lever)
— Operation of Blade/Outrigger Lever (Electric Lever)
— Operation of AFL (Electric Lever)
– Transmission
— Outline of Transmission
— Operation of Transmission
— Operation of Transmission (Slow Speed Selection)
— Operation of Transmission (Fast Speed Selection)
— Operation of Transmission (Parking Brake)
— Shift Interlock Control
— Shockless Function of Transmission
— Outline of Parking Brake Release Device
— Operation of Parking Brake Release Device
– Axle
— Outline of Front Axle
— Structure of Differential Gear
— Purpose of Differential Gear
— Basic Operational Principle of Differential Gear
— Operation of Differential Gear
— Outline of Reduction Gear
— Brake Operation of Reduction Gear
— Outline of Steering Cylinder
— Outline of Rear Axle
— Structure of Reduction Gear (Rear Axle)
– Travel Motor
— Outline of Travel Motor
— Layout of Travel Motor
— Rotor Section of Travel Motor
— Outline of Regulator (Travel Motor)
— Control Function of Regulator (Travel Motor)
— Operation of Travel Motor (Slow Speed (Large Displacement Angle) Selection)
— Operation of Travel Motor (Fast Speed (Small Displacement Angle) Selection)
— Operation of Travel Motor (Slow Speed Selection (at Heavy Load))
— Outline of Travel Relief Valve
— Outline of Travel Brake Valve
— Operation of Travel Brake Valve (When Traveling)
— Operation of Travel Brake Valve (When Traveling on a Down Slope)
– Signal Control Valve
— Outline of Signal Control Valve
— Pilot Valve Side of Pilot Port
— Control Valve Side of Pilot Port
— Outline of Shuttle Valve
— Outline of Shockless Valve
— Operation of Shockless Valve (During Boom Raise Operation)
— Operation of Shockless Valve (During Boom Lower Operation or When Stopping Boom Raise Operation (Shock Reducing Operation))
— Operation of Pump 1 Flow Rate Control Valve and Pump 2 Flow Rate Control Valve
— Operation of Swing Parking Brake Release Spool
— Operation of Bucket Flow Rate Control Valve Control Spool
– Steering Valve
— Outline of Steering Valve
— Structure of Steering Valve
— Operation of Steering Valve (Left Steering)
— Operation of Steering Valve (When Steering Pump Is Stopped (When Engine Is Stopped))
— Outline of Overload Relief Valve
— Operation of Overload Relief Valve
— Outline of Make-Up Valve
— Operation of Make-Up Valve
— Outline of Relief Valve
— Operation of Relief Valve
– Brake Valve
— Outline of Brake Valve
— Operation of Brake Valve (Brake Pedal is in Neutral) (Output Curve: A to B)
— Operation of Brake Valve (Brake Pedal is in Step Position) (Output Curve: C to D)
— Operation of Brake Valve (When the Working Brake is Applied)
– Others (Upperstructure)
— Outline of Pilot Shut-Off Solenoid Valve
— Pilot Shut-Off Lever: LOCK Position
— Pilot Shut-Off Lever: UNLOCK Position
— Outline of Transmission Control Solenoid Valve
— Operation of Transmission Control Solenoid Valve (Pressure Decrease)
— Operation of Transmission Control Solenoid Valve (Fast Speed Selection)
— Operation of Transmission Control Solenoid Valve (Slow Speed Selection)
— Operation of Transmission Control Solenoid Valve (Parking Brake)
— Outline of Solenoid Valve
— Outline of 3-Spool Solenoid Valve Unit 1
— Outline of 3-Spool Solenoid Valve Unit 2
— Outline of Axle Lock/Brake Solenoid Valve Unit
— Outline of Pump 1 and Pump 2 Flow Rate Control Solenoid Valve Unit
— Outline of Cruise Control Solenoid Valve
— Outline of Cruise Stop Solenoid Valve
— Outline of 7-Spool Solenoid Valve Unit
— Outline of 2-Spool Solenoid Valve Unit (For Assist) (Option)
— Outline of 2-Spool Solenoid Valve Unit (For Blade/Outrigger Cylinder) (Option)
— Outline of Auxiliary Control Solenoid Valve Unit (Option)
— Outline of Proportional Solenoid Valve
— Operation of Proportional Solenoid Valve (When in Neutral)
— Operation of Proportional Solenoid Valve (When Excited)
— Outline of ON/OFF Solenoid Valve
— Operation of ON/OFF Solenoid Valve (when in Neutral)
— Operation of ON/OFF Solenoid Valve (When in Operation)
— Outline of Travel Shockless Valve
— Operation of Travel Shockless Valve (Shockless Function)
— Operation of Travel Shockless Valve (Travel Operation Limit Function)
— Outline of Swing Shockless Valve
— Operation of Swing Shockless Valve (Shockless Function)
— Outline of Accumulator Charging Valve and Accumulator Manifold
— Operation of Accumulator Charging Valve and Accumulator Manifold (Between Pressure Charging Start and Pressure Charging Finish)
— Operation of Accumulator Charging Valve and Accumulator Manifold (After Pressure Charging Finish)
— Outline of Hose Rupture Valve
— Operation of Hose Rupture Valve (When Control Lever is in Neutral)
— Operation of Hose Rupture Valve (During Boom Lower Operation (Control Lever Stroke: Less than Half-Stroke))
— Operation of Hose Rupture Valve (During Boom Lower Operation (Control Lever Stroke: More than Half-Stroke))
— Outline of Accumulator
— Outline of Pilot Relief Valve Unit
— Outline of Recirculation Valve
— Outline of Selector Valve Control Valve (Option)
— Outline of Selector Valve Control Solenoid Valve
— Operation of Selector Valve Control Solenoid Valve (When in Neutral (Pulverizer or Crusher is Selected))
— Operation of Selector Valve Control Solenoid Valve (When in Operation (Breaker is Selected))
— Operation of Selector Valve (When in OFF (Pulverizer or Crusher is Selected))
— Operation of Selector Valve (When in ON (Breaker is Selected))
— Outline of Breaker Relief Solenoid Valve and Auxiliary Overload Relief Solenoid Valve
— Relief Operation of Breaker Relief Solenoid Valve and Auxiliary Overload Relief Solenoid Valve
– Others (Undercarriage)
— Outline of Swing Bearing
— Outline of Center Joint
— Outline of Slip Ring
— Outline of Axle Lock Cylinder and Blade/Outrigger Cylinder
— Operation of Operate Check Valve (Axle Lock Cylinder) (When Axle Lock is Released)
— Operation of Operate Check Valve (Axle Lock Cylinder) (When Operating the Axle Lock)
— Operation of Operate Check Valve (Blade/Outrigger Cylinder)
SERVICE MANUAL REVISION REQUEST FORM