Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-00) – PDF Download

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Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-00)

File Details:

Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-00)

• Manual Language:English
• Pages: 507
• Size: 16.2 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZW250-6 WHEEL LOADER OPERATIONAL PRINCIPLE TECHNICAL MANUAL (TONEM50-EN-00) – PDF DOWNLOAD:

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Description:

Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-00)

To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
The machine specification and description according to destination may be explained on this manual.
 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.
Additional References
Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Manual and the Engine 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.
 Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.

Table Of Contents:

Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-00)

TONEM50-EN-00....................................................................  1
	CONTENTS.....................................................................  3
	INTRODUCTION.................................................................  9
		To The Reader............................................................  9
		Additional References....................................................  9
		Manual Composition.......................................................  9
		Page Number..............................................................  9
		Trademark................................................................  9
		Safety Alert Symbol and Headline Notations............................... 10
		Units Used............................................................... 10
	SYMBOL AND ABBREVIATION...................................................... 11
	SECTION AND GROUPCONTENTS.................................................... 13
	SECTION 1 GENERAL............................................................ 15
		Group 1 Specifications................................................... 17
			Specifications....................................................... 17
		Group 2 Component Layout................................................. 19
			Main Component (Overview)............................................ 19
			Main Component....................................................... 20
			Electrical System (Overview)......................................... 22
			Air Cleaner and Radiator Assembly.................................... 23
			Battery Box.......................................................... 25
			Hydraulic Oil Tank................................................... 26
			Fuel Tank............................................................ 27
			Drive Unit........................................................... 28
			Front Axle........................................................... 29
			Cab.................................................................. 30
			Engine............................................................... 36
			Aftertreatment Device................................................ 37
			Fan Valve............................................................ 38
			Pump Device.......................................................... 39
			Multiple Control Valve............................................... 39
			Manifold Valve....................................................... 40
			Parking Brake Solenoid Valve......................................... 40
			Brake Charge Valve................................................... 40
			2-Spool Solenoid Valve Unit.......................................... 40
			Emergency Steering Block............................................. 41
			Emergency Steering Pump.............................................. 41
			Flow Regulator Valve................................................. 41
			DEF Tank............................................................. 42
			DEF Supply Module.................................................... 42
		Group 3 Component Specifications......................................... 43
			Engine............................................................... 43
			Engine Accessories................................................... 47
			Hydraulic Component.................................................. 48
			Electrical Component................................................. 54
	SECTION 2 SYSTEM............................................................. 57
		Group 1 Controller....................................................... 59
			Outline.............................................................. 59
			CAN Circuit.......................................................... 60
		Group 2 Control System................................................... 63
			Outline.............................................................. 63
			Engine Control (ECM)................................................. 66
			Pump Control......................................................... 99
			Transmission Control (TCU)...........................................104
			Fan Control, Valve Control...........................................123
			Other Controls.......................................................133
			Control by Electrical and Hydraulic CombinedCircuit..................157
		Group 3 Engine System....................................................163
			Outline..............................................................163
			ECM System...........................................................164
			Fuel Injection Control...............................................166
			Fuel Injection Volume Correction Control.............................174
			EGR Control..........................................................176
			Preheating Control...................................................178
			Variable Turbocharger Control........................................179
			Alarm Control........................................................180
			Urea SCR System......................................................181
			Engine Output Restriction Control(INDUCEMENT)........................192
			Aftertreatment Device................................................198
			Aftertreatment Device Regeneration Control...........................200
		Group 4 Hydraulic System.................................................203
			Outline..............................................................203
			Pilot Circuit........................................................204
			Main Circuit.........................................................236
			Steering Control Circuit.............................................238
			Front Attachment Control Circuit.....................................242
			Fan Circuit..........................................................250
			Emergency Steering Circuit (Option)..................................252
		Group 5 Electrical System................................................255
			Outline..............................................................255
			Main Circuit.........................................................256
			Electric Power Circuit (Key Switch: OFF).............................258
			CAN Circuit..........................................................260
			Accessory Circuit (Key Switch: ACC)..................................262
			Starting Circuit (Key Switch: START).................................264
			Neutral Engine Start Circuit.........................................266
			Charging Circuit (Key Switch: ON)....................................268
			Surge Voltage Prevention Circuit.....................................272
			Pilot Shut-Off Circuit (Key Switch: ON)..............................274
			Auto Idling Stop Circuit.............................................276
			Engine Stop Circuit..................................................278
			Monitor Circuit......................................................281
			Air Conditioner Circuit..............................................282
			Steering Column Monitor Circuit......................................285
			Head Light Circuit...................................................286
			Hazard Light Circuit (Key Switch: OFF)...............................292
			Turn Signal Light Circuit............................................294
			Horn Circuit (Key Switch: OFF).......................................296
			Reverse Light/Buzzer Circuit.........................................298
			Brake Light Circuit..................................................300
			Parking Brake Circuit................................................302
			Accessory Circuit....................................................307
			Work Light Circuit...................................................308
			Wiper Circuit........................................................310
			Cab Dome Light Circuit...............................................316
	SECTION 3 COMPONENT OPERATION................................................321
		Group 1 Pump Device......................................................323
			Hydraulic Pump Outline...............................................323
			Main Hydraulic Pump..................................................324
			Regulator............................................................326
			Steering Priority Valve..............................................342
			Steering Main Relief Valve...........................................343
			Pilot Pump...........................................................344
			Pump Delivery Pressure Sensor........................................344
		Group 2 Control Valve....................................................345
			Outline..............................................................345
			Hydraulic Circuit....................................................350
			Main Relief Valve....................................................356
			Overload Relief Valve (with Make-UpFunction).........................358
			Anti-Drift Valve.....................................................362
			Lift Arm Flow Rate Control Valve.....................................366
			Charge-Cut Valve in Ride Control Spool...............................370
			Drain Plug...........................................................374
			Pump Flow Rate Control Valve.........................................376
		Group 3 Cooling Fan System...............................................379
			Pilot Pump...........................................................379
			Fan Motor............................................................380
			Fan Control Valve....................................................381
		Group 4 Steering Pilot Valve.............................................389
			Outline..............................................................389
			Structure............................................................390
			Operation............................................................391
		Group 5 Steering Valve...................................................395
			Outline..............................................................395
			Operation............................................................398
			Steering Overload Relief Valve.......................................400
		Group 6 Pilot Valve......................................................403
			Outline (Fingertip Control Type Pilot Valve for Front Attachment)....403
			Operation............................................................404
			Electromagnetic Detent...............................................408
			Outline (Joystick Type Pilot Valve for Front Attachment).............410
			Operation............................................................411
			Electromagnetic Detent...............................................418
		Group 7 Brake Charge Valve / Manifold Valve..............................419
			Outline..............................................................419
			Brake Charge Valve...................................................420
			Manifold Valve.......................................................425
			Pilot Relief Valve...................................................426
			Torque Control Solenoid Valve........................................427
			Control Lever Lock Solenoid Valve....................................429
			Service Brake Accumulator............................................430
			Pilot Accumulator....................................................431
		Group 8 Drive Unit.......................................................433
			Outline..............................................................433
			Torque Converter.....................................................438
			Transmission.........................................................442
			Operation of Transmission............................................444
			Transmission Control Valve...........................................460
			Drive Unit Circuit...................................................462
			Parking Brake Manual Release.........................................463
		Group 9 Axle.............................................................465
			Outline..............................................................465
			Differential.........................................................466
			Torque Proportioning Differential (TPD)..............................470
			Limited Slip Differential (LSD) (Option).............................472
			Service Brake........................................................474
			Final Drive Planetary / Axle Shaft...................................476
		Group 10 Brake Valve.....................................................477
			Outline..............................................................477
			Operation............................................................480
		Group 11 Others..........................................................487
			Propeller Shaft......................................................487
			2-Spool Solenoid Valve Unit..........................................488
			Parking Brake Solenoid Valve Unit....................................490
			Parking Brake Solenoid Valve.........................................492
			Parking Brake Accumulator............................................494
			Flow Regulator Valve.................................................495
			Steering Accumulator.................................................498
			Ride Control Accumulator (Option)....................................498
			Torque Converter Cooler Check Valve..................................499
			Stop Valve...........................................................500
			Pilot Oil Filter.....................................................502
			Emergency Steering Check Block (Option)..............................503
			Emergency Steering Pump (Option).....................................504
	SERVICE MANUAL REVISION REQUEST FORM.........................................507

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