Hitachi ZW 250-6 Wheel Loader Workshop + Troubleshooting + Operational Principle + Hydraulic Circuit Manual – PDF Download

Description

Hitachi ZW 250-6 Wheel Loader Workshop + Troubleshooting + Operational Principle + Hydraulic Circuit Manual

FILE DETAILS:

Hitachi ZW 250-6 Wheel Loader Workshop + Troubleshooting + Operational Principle + Hydraulic Circuit Manual

This Listing includes all of the manuals mentioned below:

1. Hitachi ZW 250-6 Wheel Loader Workshop Manual.pdf
2. Hitachi ZW 250-6 Hydraulic Circuit Diagram TTNEM50-EN-00.pdf
3. Hitachi ZW 250-6 Hydraulic Circuit Diagram.pdf
4. Hitachi ZW 250-6 Wheel Loader Operational Principle Technical Manual TONEM50-EN-00.pdf
5. Hitachi ZW 250-6 Wheel Loader Operational Principle Technical Manual TONEM50-EN-01.pdf
6. Hitachi ZW 250-6 Wheel Loader Troubleshooting Technical Manual.pdf
7. Hitachi ZW 250-6 Wheel Loader Workshop Manual WNEM50-EN-00.pdf
8. Hitachi ZW 250-6 Wheel Loader Workshop Manual WNEM50-EN-01.pdf

HITACHI ZW 250-6 WHEEL LOADER WORKSHOP + TROUBLESHOOTING + OPERATIONAL PRINCIPLE + HYDRAULIC CIRCUIT MANUAL – PDF DOWNLOAD:

SCREENSHOTS OF THE MANUAL:

DESCRIPTION:

Hitachi ZW 250-6 Wheel Loader Workshop + Troubleshooting + Operational Principle + Hydraulic Circuit Manual

• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
• This manual consists the Technical Manual and the Workshop Manual.
• Information included in the Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.

TABLE OF CONTENTS:

Hitachi ZW 250-6 Wheel Loader Workshop Manual

Group 1 Precautions for Disassembling and
Assembling
Precautions for Disassembling and
Assembling…………………………………………………………W1-1-1-1
Group 2 Tightening
Tightening Bolts and Nuts…………………………………….W1-2-1-1
Piping Joint……………………………………………………………..W1-2-1-4
Group 3 Painting
Group 4 Bleeding Air
Bleed Air from the Hydraulic System…………………..W1-4-1-1
Bleed Air from the Fuel System…………………………….W1-4-1-2
Bleeding Air from Brake (Axle)……………………………..W1-4-1-3
Group 5 Preparation
Preparations for Inspection and Maintenance…..W1-5-1-1
Releasing Pressure from Front Attachment
Hydraulic Circuit………………………………………………..W1-5-1-6
Releasing Pressure from Ride Control
Accumulator……………………………………………………….W1-5-1-7
Releasing Pressure from Parking Brake
Accumulator……………………………………………………….W1-5-1-8
Releasing Pressure from Hydraulic Oil Tank……….W1-5-1-9
Releasing Pressure from Reserve Tank……………..W1-5-1-10
Group 1 Body
Center Hinge…………………………………………………………..W2-1-1-1
Pilot Valve (Two Lever Type )…………………………………W2-1-2-1
Group 2 Front Attachment
Pin and Bushing………………………………………………………W2-2-1-1
Standard Dimensions for Lift Arm and Bucket…..W2-2-2-1
Cylinder……………………………………………………………………W2-2-3-1
Group 1 Cab
Removal and Installation of Cab………………………….W3-1-1-1
Group 2 Counterweight
Removal and Installation of Counterweight………W3-2-1-1
Group 3 Center Hinge
Removal and Installation of Center Hinge………….W3-3-1-1
Group 4 Engine
Removal and Installation of Engine…………………….W3-4-1-1
Group 5 Radiator Assembly
Removal and Installation of Radiator
Assembly…………………………………………………………….W3-5-1-1
Group 6 Hydraulic Oil Tank
Removal and Installation of Hydraulic Oil
Tank……………………………………………………………………..W3-6-1-1
Group 7 Fuel Tank
Removal and Installation of Fuel Tank…………………W3-7-1-1
Group 8 Pump Device
Removal and Installation of Pump Device………….W3-8-1-1
Disassembly of Pump Device……………………………….W3-8-2-1
Assembly of Pump Device…………………………………….W3-8-2-3
Disassembly of Main Pump…………………………………..W3-8-3-1
Assembly of Main Pump………………………………………..W3-8-3-5
Disassembly of Regulator……………………………………..W3-8-4-1
Assembly of Regulator…………………………………………..W3-8-4-3
Disassembly of Priority Valve………………………………..W3-8-5-1
Assembly of Priority Valve…………………………………….W3-8-5-3
Structure of Pilot Pump…………………………………………W3-8-6-1
Group 9 Control Valve
Removal and Installation of Control Valve………….W3-9-1-1
Disassembly of Control Valve……………………………….W3-9-2-1
Assembly of Control Valve…………………………………….W3-9-2-8
Group 10 Pilot Valve
Removal and Installation of Pilot Valve
(Single Lever Type)………………………………………….W3-10-1-1
Removal and Installation of Pilot Valve
(Two Lever Type)……………………………………………..W3-10-2-1
Disassembly of Pilot Valve
(Single Lever Type)………………………………………….W3-10-3-1
Assembly of Pilot Valve (Single Lever Type)…….W3-10-3-4
Disassembly of Pilot Valve (Two Lever Type)……W3-10-4-1
Assembly of Pilot Valve (Two Lever Type)………..W3-10-4-7
Group 11 Brake Charge Valve
Removal and Installation of Brake Charge
Valve …………………………………………………………………W3-11-1-1
Structure of Brake Charge Valve ……………………….W3-11-2-1
Removal and Installation of Brake
Accumulator…………………………………………………….W3-11-3-1
Group 12 Manifold Valve
Removal and Installation of Manifold Valve…….W3-12-1-1
Disassembly of Manifold Valve………………………….W3-12-2-1
Assembly of Manifold Valve……………………………….W3-12-2-4
Group 13 Solenoid Valve
Removal and Installation of 2-Spool Solenoid
Valve Unit…………………………………………………………W3-13-1-1
Structure of 2-Spool Solenoid Valve Unit…………W3-13-2-1
Removal and Installation of Parking Brake
Solenoid Valve Unit…………………………………………W3-13-3-1
Structure of Parking Brake Solenoid Valve
Unit……………………………………………………………………W3-13-4-1
Structure of Parking Brake Solenoid Valve………W3-13-5-1
Group 14 Flow Regulator Valve
Removal and Installation of Flow Regulator
Valve………………………………………………………………….W3-14-1-1
Structure of Flow Regulator Valve…………………….W3-14-2-1
Group 15 Cooling Fan System
Removal and Installation of Fan Valve………………W3-15-1-1
Structure of Fan Valve………………………………………….W3-15-2-1
Removal and Installation of Fan Motor…………….W3-15-3-1
Structure of Fan Motor………………………………………..W3-15-4-1
Removal and Installation of Pilot Pump…………..W3-15-5-1
Disassembly of Pilot Pump…………………………………W3-15-6-1
Assembly of Pilot Pump………………………………………W3-15-6-3
Group 16 Ride Control Accumulator
Removal and Installation of Ride Control
Accumulator…………………………………………………….W3-16-1-1
Group 17 Battery Disconnect Switch
Removal and Installation of Battery
Disconnect Switch………………………………………….W3-17-1-1
Group 18 Aftertreatment Device
Removal and Installation of Aftertreatment
Device……………………………………………………………….W3-18-1-1
Group 19 DEF Tank
Removal and Installation of DEF Tank………………W3-19-1-1
Group 20 Coolant Control Valve
Removal and Installation of Coolant Control
Valve………………………………………………………………….W3-20-1-1
Group 21 DEF Supply Module
Removal and Installation of DEF Supply
Module……………………………………………………………..W3-21-1-1
Group 22 Exterior Components
Removal and Installation of Exterior
Components……………………………………………………W3-22-1-1
Group 1 Tire
Removal and Installation of Front Tire………………..W4-1-1-1
Removal and Installation of Rear Tire………………….W4-1-2-1
Group 2 Drive Unit
Removal and Installation of Drive Unit……………….W4-2-1-1
Disassembly and Assembly of Drive Unit……………W4-2-2-1
Removal and Installation of Torque Converter….W4-2-3-1
Disassembly and Assembly of Transmission ……..W4-2-4-1
Disassembly and Assembly of Transmission
Control Valve ……………………………………………………..W4-2-5-1
Removal and installation of parking brake
(Replace the brake friction pad)………………………W4-2-6-1
Group 3 Axle
Removal and Installation of Front Axle……………….W4-3-1-1
Removal and Installation of Rear Axle…………………W4-3-2-1
Disassembly of Axle……………………………………………….W4-3-3-1
Assembly of Axle………………………………………………….W4-3-3-17
Group 4 Propeller Shaft
Removal and Installation of Propeller Shaft……….W4-4-1-1
Group 5 Brake Valve
Removal and Installation of Brake Valve……………..W4-5-1-1
Disassembly of Brake Valve…………………………………..W4-5-2-1
Disassembly of Brake Valve…………………………………..W4-5-2-2
Assembly of Brake Valve………………………………………..W4-5-2-3
Assembly of Brake Valve………………………………………..W4-5-2-4
Group 6 Steering Device
Removal and Installation of Steering Pilot
Valve…………………………………………………………………….W4-6-1-1
Disassembly of Steering Pilot Valve …………………..W4-6-2-1
Assembly of Steering Pilot Valve………………………….W4-6-2-4
Removal and Installation of Steering Valve
(Without Emergency Steering)………………………..W4-6-3-1
Removal and Installation of Steering Valve
(With Emergency Steering)……………………………..W4-6-4-1
Disassembly of Steering Valve……………………………..W4-6-5-1
Assembly of Steering Valve…………………………………..W4-6-5-4
Disassembly of Emergency Steering Check
Block…………………………………………………………………….W4-6-6-1
Assembly of Emergency Steering Check Block….W4-6-6-3
Removal and Installation of Steering Cylinder…..W4-6-7-1
Disassembly of Steering Cylinder………………………..W4-6-8-1
Assembly of Steering Cylinder……………………………..W4-6-8-5
Removal and Installation of Steering
Accumulator……………………………………………………….W4-6-9-1
Removal and Installation of Left Stop Valve…….W4-6-10-1
Removal and Installation of Right Stop Valve….W4-6-11-1
Disassembly of Stop Valve………………………………….W4-6-12-1
Assembly of Stop Valve……………………………………….W4-6-12-2
Group 7 Emergency Steering Device
Removal and Installation of Emergency Steering
Pump……………………………………………………………………W4-7-1-1
Group 1 Front Attachment
Removal and Installation of Front Attachment….W5-1-1-1
Removal and Installation of Bell Crank……………….W5-1-2-1
Removal and Installation of Bucket……………………..W5-1-3-1
Removal and Installation of Bushing…………………..W5-1-4-1
Group 2 Cylinder
Removal and Installation of Lift Arm Cylinder……W5-2-1-1
Removal and Installation of Bucket Cylinder……..W5-2-2-1
Disassembly of Lift Arm Cylinder and Bucket
Cylinder……………………………………………………………….W5-2-3-1
Assembly of Lift Arm Cylinder and Bucket
Cylinder……………………………………………………………….W5-2-3-5

Hitachi ZW 250-6 Wheel Loader Troubleshooting Manual

Group 1 Introduction
Operational Performance Tests………………………………… T4-1-1
Preparation for Performance Tests………………………….. T4-1-2
Group 2 Standard
Operational Performance Standard Table……………… T4-2-1
Main Pump P-Q Diagram…………………………………………T4-2-10
Sensor Activating Range………………………………………….T4-2-12
Group 3 Engine Test
Engine Speed……………………………………………………………… T4-3-1
Lubricant Consumption……………………………………………. T4-3-3
Group 4 Machine Performance Test
Travel Speed……………………………………………………………….. T4-4-1
Service Brake Function Check………………………………….. T4-4-4
Service Brake Wear Amount……………………………………… T4-4-6
Parking Brake Function Check…………………………………. T4-4-7
Bucket Stopper Clearance, Lever (Bell Crank)
Stopper Clearance…………………………………………………. T4-4-8
Hydraulic Cylinder Cycle Time…………………………………T4-4-10
Cylinder Drift Check………………………………………………….T4-4-12
Bucket Levelness……………………………………………………….T4-4-13
Control Lever Operating Force………………………………..T4-4-14
Control Lever Stroke…………………………………………………T4-4-16
Group 5 Component Test
Primary Pilot Pressure (Including Brake Circuit)……. T4-5-1
Secondary Pilot Pressure…………………………………………… T4-5-4
Solenoid Valve Set Pressure……………………………………… T4-5-6
Main Pump Delivery Pressure………………………………….. T4-5-8
Loading Circuit Main Relief Set Pressure……………….T4-5-10
Steering Circuit Relief Set Pressure…………………………T4-5-14
Loading Overload Relief Valve Set Pressure………….T4-5-16
Main Pump Flow Rate Measurement…………………….T4-5-18
Service Brake Pressure (Front and Rear)………………..T4-5-26
Parking Brake Release Pressure………………………………T4-5-28
Brake Accumulator Pressure……………………………………T4-5-30
Brake Warning Pressure (Pressure-Decreasing)……T4-5-32
Brake Warning Pressure (Pressure-Increasing)……..T4-5-34
Transmission Clutch Pressure………………………………….T4-5-36
Torque Converter Pressure………………………………………T4-5-38
Group 6 Adjustment
Rewrite of Aftertreatment Device Serial No…………… T4-6-1
Clean DEF Tank…………………………………………………………… T4-6-2
Transmission Learning………………………………………………. T4-6-3
Lift Arm Angle Sensor Learning……………………………….. T4-6-3
Digging Position Adjustment…………………………………… T4-6-3
Group 1 Diagnosing Procedure
Introduction………………………………………………………………… T5-1-1
Diagnosis Procedure………………………………………………….. T5-1-2
Electric System Inspection………………………………………… T5-1-5
Precautions for Inspection and Maintenance………… T5-1-6
Instructions for Disconnecting Connectors…………… T5-1-8
Fuse Inspection………………………………………………………….T5-1-10
Fusible Link Inspection…………………………………………….T5-1-12
Battery Voltage Check………………………………………………T5-1-13
Alternator Check……………………………………………………….T5-1-14
Continuity Check………………………………………………………T5-1-16
Voltage and Current Measurement………………………..T5-1-18
Check by False Signal……………………………………………….T5-1-25
Test Harness……………………………………………………………….T5-1-26
Surge Voltage and Surge Suppression Diodes……..T5-1-28
Group 2 Monitor
Outline…………………………………………………………………………. T5-2-1
Operating Procedures of Service Menu………………….. T5-2-2
Troubleshooting…………………………………………………………. T5-2-4
Monitoring………………………………………………………………….. T5-2-6
Controller Version……………………………………………………..T5-2-16
Issued Warning Record…………………………………………….T5-2-17
Communication Terminal Status…………………………….T5-2-22
Machine Setting………………………………………………………..T5-2-24
Aftertreatment Device No……………………………………….T5-2-33
Engine Tachometer…………………………………………………..T5-2-34
Transmission Oil Temperature Gauge and
DEF/AdBlue Level Gauge…………………………………….T5-2-35
Coolant Temperature Gauge…………………………………..T5-2-36
Group 3 e-Service
Outline…………………………………………………………………………. T5-3-1
List of Operation Data……………………………………………….. T5-3-2
Snapshot Data…………………………………………………………….. T5-3-6
Communication System……………………………………………. T5-3-7
Group 4 Component Layout
Main Component (Overview)…………………………………… T5-4-1
Main Component……………………………………………………….. T5-4-2
Electrical System (Overview)……………………………………. T5-4-4
Air Cleaner and Radiator Assembly…………………………. T5-4-5
Battery Box………………………………………………………………….. T5-4-7
Hydraulic Oil Tank………………………………………………………. T5-4-8
Fuel Tank……………………………………………………………………… T5-4-9
Drive Unit……………………………………………………………………T5-4-10
Front Axle……………………………………………………………………T5-4-11
Cab………………………………………………………………………………T5-4-12
Engine…………………………………………………………………………T5-4-18
Aftertreatment Device……………………………………………..T5-4-19
Fan Valve…………………………………………………………………….T5-4-20
Pump Device……………………………………………………………..T5-4-21
Multiple Control Valve………………………………………………T5-4-21
Manifold Valve……………………………………………………………T5-4-22
Parking Brake Solenoid Valve………………………………….T5-4-22
Brake Charge Valve……………………………………………………T5-4-22
2-Spool Solenoid Valve Unit…………………………………….T5-4-22
Steering Valve…………………………………………………………….T5-4-23
Emergency Steering Pump …………………………………….T5-4-23
Flow Regulator Valve………………………………………………..T5-4-23
DEF Tank……………………………………………………………………..T5-4-24
DEF Supply Module…………………………………………………..T5-4-24
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By
Using Fault Codes) Procedure……………………………… T5-5-1
MPDr. Fault Code Reference Table…………………………… T5-5-3
MC Fault Code List……………………………………………………… T5-5-9
Monitor Controller (Monitor) Fault Code List……….T5-5-21
Monitor Controller (Information) Fault Code
List…………………………………………………………………………..T5-5-22
Column Display Controller Fault Code List……………T5-5-25
Air Conditioner Controller Fault Code List…………….T5-5-27
Communication Terminal Fault Code List……………..T5-5-28
ECM Fault Code List…………………………………………………..T5-5-29
TCU Fault Code List…………………………………………………..T5-5-59
MC Fault Codes 111000 to 111002…………………………T5-5-79
MC Fault Code 111003……………………………………………..T5-5-80
MC Fault Codes 111006, 111007, 111009,
111011……………………………………………………………………T5-5-83
Monitor Controller (Monitor) Fault Codes
113002, 113003, 113005, 113012………………………T5-5-83
CAN1 Harness Check………………………………………………..T5-5-84
CAN3 Harness Check………………………………………………..T5-5-88
MC Fault Codes 111008, 111010, 111014,
111025……………………………………………………………………T5-5-91
Monitor Controller (Monitor) Fault Codes
113004, 113006, 113007……………………………………..T5-5-91
CAN2 Harness Check………………………………………………..T5-5-92
MC Fault Code 111100……………………………………………..T5-5-95
MC Fault Codes 111103, 111106, 111107……………..T5-5-96
MC Fault Codes 111205, 111207…………………………….T5-5-97
MC Fault Codes 111200, 111202, 111203……………..T5-5-98
MC Fault Codes 111217, 111312…………………………….T5-5-99
MC Fault Code 111204 …………………………………………. T5-5-100
MC Fault Codes 111206, 111208…………………………. T5-5-101
MC Fault Codes 111311, 111313…………………………. T5-5-102
MC Fault Code 111410………………………………………….. T5-5-103
MC Fault Code 111411………………………………………….. T5-5-104
MC Fault Code 111412………………………………………….. T5-5-105
MC Fault Code 111413………………………………………….. T5-5-106
MC Fault Code 111422………………………………………….. T5-5-107
MC Fault Code 111901………………………………………….. T5-5-108
MC Fault Code 111902………………………………………….. T5-5-109
MC Fault Codes 120000, 120002 to 120005………. T5-5-110
MC Fault Code 120014………………………………………….. T5-5-111
Monitor Controller Fault Code 115001………………. T5-5-113
Monitor Controller (Information) Fault Code
113311………………………………………………………………… T5-5-114
Monitor Controller (Monitor) Fault Code
120300………………………………………………………………… T5-5-115
Monitor Controller (Information) Fault Codes
120400, 120401…………………………………………………. T5-5-116
Column Display Controller Fault Codes 120500
to 120504…………………………………………………………… T5-5-117
Column Display Controller (Information) Fault
Codes 120505 to 120507…………………………………. T5-5-118
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis by Using
Trouble Symptom) Procedure……………………………… T5-6-1
Relationship between Machine Trouble
Symptoms and Related Parts………………………………. T5-6-3
Correlation between Trouble Symptoms and
Part Failures…………………………………………………………..T5-6-26
Engine System Troubleshooting…………………………….T5-6-46
All Actuator System Troubleshooting…………………….T5-6-52
Front Attachment System Troubleshooting………….T5-6-57
Steering System Troubleshooting………………………….T5-6-66
Travel System Troubleshooting………………………………T5-6-70
Brake System Troubleshooting……………………………….T5-6-79
Other System Troubleshooting……………………………….T5-6-83
Exchange Inspection………………………………………………..T5-6-97
Air Bleeding Procedures for Brake (Axle)……………….T5-6-99
Group 7 Air Conditioner
Outline…………………………………………………………………………. T5-7-1
Functions of Main Parts…………………………………………….. T5-7-4
Troubleshooting…………………………………………………………. T5-7-9
Air Conditioner Controller Fault Code List…………….T5-7-10
Air Conditioner Controller Fault Codes 11 to 22…..T5-7-11
Air Conditioner Controller Fault Codes 43 to 92…..T5-7-12
Work after Replacing Components………………………..T5-7-34
Refill Compressor Oil………………………………………………..T5-7-35
Charge Air Conditioner with Refrigerant………………T5-7-36
Hose and Pipe Tightening Torque…………………………..T5-7-44

Hitachi ZW 250-6 Wheel Loader Operational Principle Manual

Group 1 Specifications
Specifications……………………………………………………………… T1-1-1
Group 2 Component Layout
Main Component (Overview)…………………………………… T1-2-1
Main Component……………………………………………………….. T1-2-2
Electrical System (Overview)……………………………………. T1-2-4
Air Cleaner and Radiator Assembly…………………………. T1-2-5
Battery Box………………………………………………………………….. T1-2-7
Hydraulic Oil Tank………………………………………………………. T1-2-8
Fuel Tank……………………………………………………………………… T1-2-9
Drive Unit……………………………………………………………………T1-2-10
Front Axle……………………………………………………………………T1-2-11
Cab………………………………………………………………………………T1-2-12
Engine…………………………………………………………………………T1-2-18
Aftertreatment Device……………………………………………..T1-2-19
Fan Valve…………………………………………………………………….T1-2-20
Pump Device……………………………………………………………..T1-2-21
Multiple Control Valve………………………………………………T1-2-21
Manifold Valve……………………………………………………………T1-2-22
Parking Brake Solenoid Valve………………………………….T1-2-22
Brake Charge Valve……………………………………………………T1-2-22
2-Spool Solenoid Valve Unit…………………………………….T1-2-22
Emergency Steering Block……………………………………….T1-2-23
Emergency Steering Pump …………………………………….T1-2-23
Flow Regulator Valve………………………………………………..T1-2-23
DEF Tank……………………………………………………………………..T1-2-24
DEF Supply Module…………………………………………………..T1-2-24
Group 3 Component Specifications
Engine………………………………………………………………………….. T1-3-1
Engine Accessories…………………………………………………….. T1-3-5
Hydraulic Component……………………………………………….. T1-3-6
Electrical Component……………………………………………….T1-3-12
Group 1 Controller
Outline…………………………………………………………………………. T2-1-1
CAN Circuit………………………………………………………………….. T2-1-2
Group 2 Control System
Outline…………………………………………………………………………. T2-2-1
Engine Control (ECM)………………………………………………… T2-2-4
Pump Control…………………………………………………………….T2-2-37
Transmission Control (TCU)……………………………………..T2-2-42
Fan Control, Valve Control……………………………………….T2-2-61
Other Controls…………………………………………………………..T2-2-71
Control by Electrical and Hydraulic Combined
Circuit……………………………………………………………………..T2-2-95
Group 3 Engine System
Outline…………………………………………………………………………. T2-3-1
ECM System………………………………………………………………… T2-3-2
Fuel Injection Control………………………………………………… T2-3-4
Fuel Injection Volume Correction Control…………….T2-3-12
EGR Control………………………………………………………………..T2-3-14
Preheating Control……………………………………………………T2-3-16
Variable Turbocharger Control………………………………..T2-3-17
Alarm Control…………………………………………………………….T2-3-18
Urea SCR System……………………………………………………….T2-3-19
Engine Output Restriction Control
(INDUCEMENT)……………………………………………………..T2-3-30
Aftertreatment Device……………………………………………..T2-3-36
Aftertreatment Device Regeneration Control………T2-3-38
Group 4 Hydraulic System
Outline…………………………………………………………………………. T2-4-1
Pilot Circuit………………………………………………………………….. T2-4-2
Main Circuit………………………………………………………………..T2-4-34
Steering Control Circuit……………………………………………T2-4-36
Front Attachment Control Circuit…………………………..T2-4-40
Fan Circuit…………………………………………………………………..T2-4-48
Emergency Steering Circuit (Option)……………………..T2-4-50
Group 5 Electrical System
Outline…………………………………………………………………………. T2-5-1
Main Circuit…………………………………………………………………. T2-5-2
Electric Power Circuit (Key Switch: OFF)…………………. T2-5-4
CAN Circuit………………………………………………………………….. T2-5-6
Accessory Circuit (Key Switch: ACC)………………………… T2-5-8
Starting Circuit (Key Switch: START)……………………….T2-5-10
Neutral Engine Start Circuit……………………………………..T2-5-12
Charging Circuit (Key Switch: ON)………………………….T2-5-14
Surge Voltage Prevention Circuit……………………………T2-5-18
Pilot Shut-Off Circuit (Key Switch: ON)…………………..T2-5-20
Auto Idling Stop Circuit……………………………………………T2-5-22
Engine Stop Circuit……………………………………………………T2-5-24
Monitor Circuit…………………………………………………………..T2-5-27
Air Conditioner Circuit……………………………………………..T2-5-28
Steering Column Monitor Circuit……………………………T2-5-31
Head Light Circuit……………………………………………………..T2-5-32
Hazard Light Circuit (Key Switch: OFF)…………………..T2-5-38
Turn Signal Light Circuit…………………………………………..T2-5-40
Horn Circuit (Key Switch: OFF)………………………………..T2-5-42
Reverse Light/Buzzer Circuit……………………………………T2-5-44
Brake Light Circuit…………………………………………………….T2-5-46
Parking Brake Circuit…………………………………………………T2-5-48
Accessory Circuit……………………………………………………….T2-5-53
Work Light Circuit……………………………………………………..T2-5-54
Wiper Circuit………………………………………………………………T2-5-56
Cab Dome Light Circuit……………………………………………T2-5-62
Group 1 Pump Device
Hydraulic Pump Outline……………………………………………. T3-1-1
Main Hydraulic Pump………………………………………………… T3-1-2
Regulator…………………………………………………………………….. T3-1-4
Steering Priority Valve………………………………………………T3-1-20
Steering Main Relief Valve……………………………………….T3-1-21
Pilot Pump………………………………………………………………….T3-1-22
Pump Delivery Pressure Sensor………………………………T3-1-22
Group 2 Control Valve
Outline…………………………………………………………………………. T3-2-1
Hydraulic Circuit…………………………………………………………. T3-2-6
Main Relief Valve……………………………………………………….T3-2-12
Overload Relief Valve (with Make-Up Function)…..T3-2-14
Anti-Drift Valve…………………………………………………………..T3-2-18
Lift Arm Flow Rate Control Valve…………………………….T3-2-22
Charge-Cut Valve in Ride Control Spool ……………….T3-2-26
Drain Plug…………………………………………………………………..T3-2-30
Pump Flow Rate Control Valve ……………………………….T3-2-32
Group 3 Cooling Fan System
Pilot Pump…………………………………………………………………… T3-3-1
Fan Motor……………………………………………………………………. T3-3-2
Fan Control Valve……………………………………………………….. T3-3-3
Group 4 Steering Pilot Valve
Outline…………………………………………………………………………. T3-4-1
Structure……………………………………………………………………… T3-4-2
Operation…………………………………………………………………….. T3-4-3
Group 5 Steering Valve
Outline…………………………………………………………………………. T3-5-1
Operation…………………………………………………………………….. T3-5-4
Steering Overload Relief Valve…………………………………. T3-5-6
Group 6 Pilot Valve
Outline (Fingertip Control Type Pilot Valve for
Front Attachment)………………………………………………… T3-6-1
Operation…………………………………………………………………….. T3-6-2
Electromagnetic Detent……………………………………………. T3-6-6
Outline (Joystick Type Pilot Valve for Front
Attachment)…………………………………………………………… T3-6-8
Operation…………………………………………………………………….. T3-6-9
Electromagnetic Detent…………………………………………..T3-6-16
Group 7 Brake Charge Valve / Manifold Valve
Outline…………………………………………………………………………. T3-7-1
Brake Charge Valve…………………………………………………….. T3-7-2
Manifold Valve…………………………………………………………….. T3-7-7
Pilot Relief Valve…………………………………………………………. T3-7-8
Torque Control Solenoid Valve…………………………………. T3-7-9
Control Lever Lock Solenoid Valve…………………………T3-7-11
Service Brake Accumulator …………………………………….T3-7-12
Pilot Accumulator……………………………………………………..T3-7-13
Group 8 Drive Unit
Outline…………………………………………………………………………. T3-8-1
Torque Converter……………………………………………………….. T3-8-6
Transmission………………………………………………………………T3-8-10
Operation of Transmission……………………………………….T3-8-12
Transmission Control Valve……………………………………..T3-8-28
Drive Unit Circuit……………………………………………………….T3-8-30
Parking Brake Manual Release ……………………………….T3-8-31
Group 9 Axle
Outline…………………………………………………………………………. T3-9-1
Differential…………………………………………………………………… T3-9-2
Torque Proportioning Differential (TPD)………………… T3-9-6
Limited Slip Differential (LSD) (Option)………………….. T3-9-8
Service Brake……………………………………………………………..T3-9-10
Final Drive Planetary / Axle Shaft……………………………T3-9-12
Group 10 Brake Valve
Outline………………………………………………………………………..T3-10-1
Operation……………………………………………………………………T3-10-4
Group 11 Others
Propeller Shaft…………………………………………………………..T3-11-1
2-Spool Solenoid Valve Unit…………………………………….T3-11-2
Parking Brake Solenoid Valve Unit………………………….T3-11-4
Parking Brake Solenoid Valve………………………………….T3-11-6
Parking Brake Accumulator……………………………………..T3-11-8
Flow Regulator Valve………………………………………………..T3-11-9
Steering Accumulator…………………………………………… T3-11-12
Ride Control Accumulator (Option)……………………. T3-11-12
Torque Converter Cooler Check Valve………………… T3-11-13
Stop Valve……………………………………………………………….. T3-11-14
Pilot Oil Filter………………………………………………………….. T3-11-16
Emergency Steering Check Block (Option)……….. T3-11-17
Emergency Steering Pump (Option)…………………… T3-11-18

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
• The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
• Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer