Technical Manual Hitachi ZX55U-6EB Excavator TAET40-EN-00 (2023.04.26) (Preview)
TAET40-EN-00
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
Symbols and abbreviations
CONTRASTING LIST OF PART NAME
Contrasting List of Part Name between Technical Manual and Parts Catalog
SAFETY
Recognize Safety Information
Understand Signal Words
Compliance with safety instructions
Prepare for Emergencies
Wear Appropriate Clothing
Clothing for Electrical Equipment Maintenance
Inspect Machine
General Precautions for the Cab
Use Handholds and Steps
Adjust the Operator’s Seat
Ensure Safety Before Leaving or Standing up from Operator’s Seat
Fasten Your Seat Belt
Move and Operate Machine Safely
Operate Only from Operator’s Seat
Jump Starting
Checking Lead-Acid Battery Level and Supplementary Charging
Keep Riders off Machine
Precautions for Operations
Investigate Job Site Beforehand
Never use at Dangerous Sites
Provide Signals for Jobs Involving Multiple Machines
Restriction of Attachment Installation
Confirm Direction of Machine to Be Driven
Drive Machine Safely
Avoid Injury from Rollaway Accidents
Avoid Injury from Back-Over and Swing Accidents
Keep People Clear from Working Area
Never Position the Bucket Over Anyone
Avoid Undercutting
Avoid Tipping
Never Undercut a High Bank
Dig with Caution
Operate with Caution
Avoid Power Lines
Precautions for Lightning
Lifting Application
Protect Against Flying Debris and Falling Object
Park Machine Safely
Handle Fluids Safely−Avoid Fires
Transport Safely
Practice Safe Maintenance
Warn Others of Service Work
Support Machine Properly
Stay Clear of Moving Parts
Prevent Parts from Flying
Avoid Injury from Attachment Falling Accident
Prevent Burns
Replace Rubber Hoses Periodically
Avoid High-Pressure Fluids
Prevent Fires
Damaged Cover Around Battery
Evacuating in Case of Fire
Precautions for Welding and Grinding
Avoid Heating Near Pressurized Fluid Lines
Avoid Applying Heat to Lines Containing Flammable Fluids
Precautions for Handling Accumulator
Remove Paint Before Welding or Heating
Beware of Asbestos and Silicon Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Disposal of Equipment and Consumable Parts
Never Ride Attachment
Precautions for Communication Terminal
Precautions for the Communication Terminal
Precautions about Operator’s Station Protections when Overturned
Before Returning the Machine to the Customer
SECTION AND GROUP CONTENTS
CONTENTS
GENERAL
Specifications
Specifications ZX55U-6EB
Dimensions ZX55U-6EB
Work Ranges/Dimensions ZX55U-6EB
Component Layout
Main Component
Electrical System (Overview)
Electrical System (Relays) 1
Electrical System (Relays) 2
Electrical System (Monitor, Switches)
Electrical System (Battery Chamber)
Swing Device
Travel Device
Electric Motor Revolution Sensing Valve
Pilot Filter
Control Valve
2-Spool Solenoid Valve Unit
Port Layout of Control Valve (Main Circuit)
Port Layout of Control Valve (Pilot Circuit)
Floor Harness
Main Harness
Light Harness (LED)
Cab Intermediate Wire Harness
Air Conditioner Floor Harness
DCDC Output Harness
Charging Switch Harness
Condenser Fan Harness
Inverter Harness
High Voltage Harness (Compressor)
High Voltage Harness (Heater)
High Voltage Harness (Lithium Ion Battery)
High Voltage Harness (Charger)
High Voltage Harness (DCDC)
High Voltage Harness (Inlet)
High Voltage Harness (Inverter)
High Voltage Harness (Electric Motor M1)
High Voltage Harness (Electric Motor M2)
High Voltage Harness (Electric Motor M3)
Lithium Ion Battery
Junction Box
Inverter
Electric Motor
Onboard Charger
AC Box
DC-DC Converter
Heater
Electric Compressor
Filter Box
Component Specifications
Specifications of Coolers
Specifications of Hydraulic Component
Specifications of Electrical Component
Specifications of Electric Drive Compornent
SYSTEM
Control System
Outline of Control System
Machine Control
Charging Switch Control
Operating Mode Control
Inverter/Electric Motor Control
Inverter Startup Control
Electric Motor Control Dial Control
Auto-Idle Control
ECO Mode Control
Electric Motor Speed Limit Control by Remaining Capacity and Temperature of Lithium Ion Battery
Lithium Ion Battery Control
Lithium Ion Battery Relay Connection Control
Calculation of Remaining Lithium Ion Battery Level
Lithium Ion Battery Full-Charge Judgment
Charger Control
Charger Startup Control
Output Voltage Limit Control
Output Current Limit Control
Input Current Limit Control
Recharging Control
AC Cable Charging Permission Judgment Control
Electric Fan Control
Hydraulic Oil Cooling Fan Speed Control
Radiator Cooling Fan Speed Control
Pump Control
Power Decrease Control
Other Control
Overload Alarm Control
Hydraulic System
Outline of Hydraulic System
Pilot Circuit of Hydraulic System
Operation Control Circuit
Pump Control Circuit (Flow Rate Control Circuit)
Travel Motor Displacement Angle Control Circuit
Swing Parking Brake Release Circuit
Neutral Circuit (When Control Lever in Neutral)
Single Operation Circuit (Control Lever in Operated)
Combined Operation Circuit (Combined Operation of Swing and Boom Raise)
Operation of Differential Reducing Valve (Hydraulic System)
Operation of Pressure Compensator (Hydraulic System)
Electrical System
Outline of Electrical System
Main Circuit of Electrical System
Electric Power Circuit (Key Switch: OFF)
CAN Circuit
Electric Power Circuit (Key Switch: ON)
Charging Circuit (Key Switch: ON)
Pilot Shut-Off Circuit (Key Switch: ON)
COMPONENT OPERATION
Pump Device
Outline of Pump Device
Components in Pump Device
Outline of Main Pump P1
Flow Rate Control
Flow Rate Control by Command Signal Pressure (Delivery Flow Rate of Main Pump is Minimum When the Control Lever is in Neutral)
Flow Rate Control by Signal Pressure (Delivery Flow Rate of Main Pump Increases)
Flow Rate Control by Command Signal Pressure (Delivery Flow Rate of Main Pump Decreases)
Outline of Torque Control Solenoid Valve
Operation of Torque Control Solenoid Valve (PWR Mode)
Operation of Torque Control Solenoid Valve (ECO Mode)
Flow Rate Control by Own Pump Pressure
Electric Motor Revolution Sensing Valve
Outline of Electric Motor Revolution Sensing Valve
Components in Electric Motor Revolution Sensing Valve
Operation of Electric Motor Revolution Sensing Valve (When Electric Motor Stops)
Operation of Electric Motor Revolution Sensing Valve (While Electric Motor is Running (Output Curve: A to B)
Operation of Electric Motor Revolution Sensing Valve (While Electric Motor is Running (Output Curve: B to C))
Swing Device
Outline of Swing Device
Outline of Swing Reduction Gear
Outline of Swing Motor
Outline of Swing Parking Brake
Operation of Swing Parking Brake (When Brake is Released)
Operation of Swing Parking Brake (When Brake is Applied)
Outline of Valve Unit
Operation of Make-Up Valve
Outline of Swing Relief Valve
Low-Pressure Relief Operation (Shockless Function) of Swing Relief Valve
High-Pressure Relief Operation (Overload Prevention) of Swing Relief Valve
Control Valve
Outline of Control Valve
Components in Control Valve
Main Circuit of Control Valve
Pilot Operation Control Circuit of Control Valve
Outline of Main Relief Valve
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
Operation of Make-Up Valve
Outline of Boom Anti-Drift Valve
Operation of Boom Anti-Drift Valve (When Boom Spool is in Neutral)
Operation of Boom Anti-Drift Valve (When Operating Boom Raise)
Operation of Boom Anti-Drift Valve (When Operating Boom Lower)
Flow Rate Control Circuit of Control Valve
Outline of Unload Valve
Operation of Unload Valve (When in Neutral)
Operation of Unload Valve (When Pressure P1 Increases)
Outline of Differential Reducing Valve
Operation of Differential Reducing Valve (When the Force to Push to the Left is Stronger)
Operation of Differential Reducing Valve (When the Force to Push to the Left is Weaker)
Outline of Pressure Compensator
Operation of Pressure Compensator (When the Differential Pressure between Pressure PIN and Pressure PL is Higher Than Pressure PLS)
Operation of Pressure Compensator (When the Differential Pressure between Pressure PIN and Pressure PL is Lower Than Pressure PLS)
Pilot Valve
Outline of Pilot Valve
Outline of Front Attachment/Swing Pilot Valve
Outline of Travel Pilot Valve
Outline of Boom Swing, Blade, Auxiliary 1, and Auxiliary 2 Pilot Valves
Operation of Front Attachment/Swing and Travel Pilot Valve
When Front Attachment/Swing and Travel Pilot Valves are in Neutral (Output Curve: A to B)
During Metering or Decompressing of Front Attachment/Swing and Travel Pilot Valves (Output Curve: C to D)
Full Stroke of Travel Pilot Valve (Output Curve: E to F)
Operation of Boom Swing, Blade, Auxiliary 1, and Auxiliary 2 Pilot Valves
When Boom Swing, Blade, Auxiliary 1, and Auxiliary 2 Pilot Valves are in Neutral (Output Curve: A to B)
During Metering or Pressure Decrease of Boom Swing, Blade, Auxiliary 1, and Auxiliary 2 Pilot Valves (Output Curve: C to D)
Outline of Shockless Function (Only Travel Pilot Valve)
Operation of Shockless Function
Travel Device
Outline of Travel Device
Outline of Travel Reduction Gear
Outline of Travel Motor
Operation of Travel Motor
Outline of Parking Brake
Operation of Parking Brake (When Brake is Released)
Operation of Parking Brake (When Brake is Applied)
Outline of Travel Brake Valve
Operation of Counterbalance Valve (During Travel)
Operation of Counterbalance Valve (When Descending a Slope)
Outine of Anti-Cavitation Valve
Operation of Anti-Cavitation Valve (During Travel)
Operation of Anti-Cavitation Valve (When Traveling is Stopped)
Operation of Travel Mode Selector Valve (Slow Speed Operation)
Operation of Travel Mode Selector Valve (Fast Speed Operation)
Operation of Travel Mode Selector Valve (When Electric Motor Stops)
Auto Swash Angle Control
Others (Upperstructure)
Outline of 2-Spool Solenoid Valve Unit
Operation of Pilot Shut-Off Solenoid Valve (Pilot Shut-Off Lever: LOCK Position)
Operation of Pilot Shut-Off Solenoid Valve (Pilot Shut-Off Lever: UNLOCK Position)
Operation of Travel Mode Selector Solenoid Valve (Slow Speed Position)
Operation of Travel Mode Selector Solenoid Valve (Fast Speed Position)
Operation of Pilot Relief Valve
Outine of Auxiliary Flow Rate Selector Valve (Option)
Auxiliary Flow Rate Selector Valve Operation (When OFF)
Auxiliary Flow Rate Selector Valve Operation (When ON)
Outine of Hose Rupture Valve
Hose Rupture Valve Operation (When Control Lever is in Neutral)
Operation of Hose Rupture Valve (During Boom Lower Operation)
Others (Undercarriage)
Outline of Swing Bearing
Outline of Center Joint
Outline of Track Adjuster
Electric Drive Compornents
Outline of Lithium Ion Battery
Outline of Junction Box
Outline of Inverter
Outline of Electric Motor
Outline of Charger
Outline of AC Box
Outline of DC-DC Converter
Outline of Heater
Outline of Electric Compressor
Outline of Filter Box
OPERATIONAL PERFORMANCE TEST
Introduction
Operational Performance Tests
Preparation for Performance Tests
Standard
Operational Performance Standard Table
Electric Motor Performance Standards
Travel System Performance Standards
Swing System Performance Standards
Front Attachment System Performance Standards
Lever System Performance Standards
Combined Operation System Performance Standards
Component System Performance Standards
Main Pump P-Q Diagram
Electric Motor Control Dial Activating Range
Low Pressure Sensor Activating Range
Electric Motor Test
Electric Motor Speed
Machine Performance Test
Travel Speed
Track Revolution Speed
Mistrack Check
Travel Parking Leakage
Swing Speed
Swing Function Drift Check
Swing Motor Leakage
Maximum Swingable Slant Angle
Swing Bearing Play
Hydraulic Cylinder Cycle Time
Dig Function Drift Check
Control Lever Operating Force
Control Lever Stroke
Combined Operation of Boom Raise and Swing Function Check
Clearance of Front Attachment Connecting Part
Component Test
Primary Pilot Pressure
Secondary Pilot Pressure
Main Relief Set Pressure
Overload Relief Valve Set Pressure
Pump Driving Torque
Swing Motor Drainage
Travel Motor Drainage
Electric Motor Revolution Sensing Valve Output Pressure (Pressure PGR)
Pump Delivery Pressure
TROUBLESHOOTING
Diagnosing Procedure
Introduction
Diagnosis Procedure
Electrical System Inspection
Precautions for Inspection and Maintenance
Fuse Inspection
Fuse Connection Destination
Slow Blow Fuse Inspection
Battery Voltage Check
Continuity Check
Voltage Inspection Method
Voltage and Current Measurement of 5-Volt Circuits
Check by False Signal
Removal of Monitor Controller
Installation of Monitor Controller
Removal of MC
Installation of MC
Mounting Position of Boom Bottom Pressure Sensor
Mounting Position of Auto-Idle Pressure Sensor
Inspection and Cleaning of Condenser
Inspection Method of Electrical Component
Power System Circuit Diagram
Precautions During Maintenance of Electrically Powered Equipment
Measurement of Residual Voltage
Manual Discharge of Residual Voltage
Appearance Check of Electric Equipment
Testing the Protection Equipotential Bonding Circuit
Measuring Point on Power System Equipment
Removal of Service Plug
Installation of Service Plug
Disconnection of High-Voltage Connector (Lithium Ion Battery)
Connection of High-Voltage Connector (Lithium Ion Battery)
Disconnection of High-Voltage Connector (Charger)
Connection of High-Voltage Connector (Charger)
Disconnection of High-Voltage Connector (Junction Box)
Connection of High-Voltage Connector (Junction Box)
Disconnection of Control Connector (Charger)
Connection of Control Connector (Charger)
Disconnection of Control Connector (AC Box)
Connection of Control Connector (AC Box)
Disconnection of Control Connector (Junction Box)
Connection of Control Connector (Junction Box)
Disconnection of Control Connector (Lithium Ion Battery)
Connection of Control Connector (Lithium Ion Battery)
Disconnection of Control Connector (Electric Motor and Inverter)
Connection of Control Connector (Electric Motor and Inverter)
Disconnection of Control Connector (DC-DC Converter)
Connection of Control Connector (DC-DC Converter)
Disconnection of Control Connector (Junction Box and Electric Compressor)
Connection of Control Connector (Junction Box and Electric Compressor)
Disconnection of Input Connector (AC Box)
Connection of Input Connector (AC Box)
Measurement of Insulation Resistance of Junction Box
Measurement of Insulation Resistance of Electric Motor
Measurement of Insulation Resistance of Power Supply Inlet
Voltage Detector
Inspection Method of Filter Box
Monitor
Basic Screen of Monitor
Operating Procedures of Service Menu
How to Display Service Menu
Monitoring
Monitoring List
Setting
List of Setting Items
Issued Warning Record
List of Alarm
Inspection of Lead-Acid Battery and Hour Meter
Lithium Ion Battery Gauge
Factory Setting
Suncar INSIGHT
Outline of Suncar INSIGHT
List of Operation Data (Suncar INSIGHT)
Communication System (Suncar INSIGHT)
e-Service
Outline of e-Service
List of Operation Data (e-Service)
Troubleshooting A
Troubleshooting A (Base Machine Diagnosis by Using Fault Codes) Procedure
Contents of Troubleshooting A
Fault Code List
Lithium-Ion Battery Control Unit Fault Code List (Severe)
Lithium-Ion Battery Control Unit Fault Code List (Moderate)
Charger Fault Code List
Inverter Fault Code List
DC-DC Converter Fault Code List
Heater Fault Code List
Fault Code E: 7100, E: 7200, W: 7100
Fault Code W: 7400, W: 7500, W: 7600, W: 7700
Fault Code W: 2307
Fault Code W: 1310, W: 1311, W: 1312, W: 1313, W: 1314, W: 1315
CAN0 Wire Harness Check
CAN1 Wire Harness Check
CAN2 Wire Harness Check
LIN Wire Harness Check
Troubleshooting B
Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure
Contents of Troubleshooting B
Identification Symbol of Troubleshooting B
ES-1 Electric motor does not rotate.
ES-2 Auto-idle system is faulty.
ES-3 Electric motor does not rotate at low temperature.
ES-4 ECO mode is faulty.
ES-5 Electric motor does not stop.
ES-6 Electric motor speed does not increase.
C-1 Depressing charging switch does not work/Commercial power assist mode is not activated.
C-2 Power supply from the grid is interrupted while operating in commercial power assist mode or while charging.
C-3 Charging time is too long.
A-1 All actuator speeds are slow or power is weak.
A-2 All actuators do not work.
A-3 Actuator does not stop even if control lever is set to neutral.
A-4 Actuator does not stop even if control lever is set to neutral. (Amount of drift is large.)
F-1 All front attachment actuator power are weak.
F-2 Some cylinders are not operated or speeds are slow.
F-3 Only boom is not operated or its speed is slow.
F-4 Front attachment drifts remarkably.
F-5 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down.
F-6 Boom swing is not operated or moves slowly.
S-1 Swing speed is slow or is not operated.
S-2 Swing drifts remarkably when swinging is stopped.
T-1 Machine does not travel, travel slowly, or power is weak.
T-2 Fast travel can not be selected. Travel mode does not change from slow speed mode to fast speed mode.
T-3 Slow travel is not selected. Travel mode does not change from fast mode to slow mode.
T-4 One side travel is not operated or travel speed is slow. Machine mistracks.
BL-1 Blade is not operated or moves slowly.
How to Lower Boom in Case of Emergency and When Electric Motor Stops
Air Conditioner
Outline of Air Conditioner
Troubleshooting of Air Conditioner
Faulty Cooling
Air conditioner does not work. Control panel does not light at all.
Air vent air temperature control is impossible.
Blower motor does not rotate.
Air flow volume (I) and (II) are not shifted. (Air flow volume (I) and (II) are the same.)
Air flow volume (I) and (III) are not shifted. (Air flow volume (I) and (III) are the same.)
Air flow volume (II) and (III) are not shifted. (Air flow volume (II) and (III) are the same.)
Air flow volume (I), (II), and (III) are not shifted. (Air flow volume (I), (II), and (III) are the same.)
Air vent cannot be shifted.
Circulating/fresh air selection cannot be shifted.
Work after Replacing Components
Necessity of Purging
Procedures for Charging Air Conditioner with Refrigerant
Warm-up Operation
AIR CONDITIONER TROUBLE REPORT
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List
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