Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-01) – PDF Download

Description

Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-01)

File Details:

Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-01)

• Manual Language:English
• Pages: 545 
• Size: 25.5 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZW250-6 WHEEL LOADER OPERATIONAL PRINCIPLE TECHNICAL MANUAL (TONEM50-EN-01) – PDF DOWNLOAD:

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Description:

Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-01)

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-01)

TONEM50-EN-01................................................................  1
CONTENTS.....................................................................  3
INTRODUCTION.................................................................  9
SYMBOL AND ABBREVIATION...................................................... 11
SECTION AND GROUP CONTENTS................................................... 13
SECTION 1 GENERAL............................................................ 15
	Group 1 Specifications................................................... 17
		Specifications....................................................... 17
		Weight of Main Components............................................ 18
	Group 2 Component Layout................................................. 21
		Main Component (Overview)............................................ 21
		Main Component....................................................... 22
		Electrical System (Overview)......................................... 24
		Air Cleaner / Radiator Assembly...................................... 25
		Battery Box.......................................................... 27
		Hydraulic Oil Tank................................................... 28
		Fuel Tank............................................................ 29
		Drive Unit........................................................... 30
		Front Axle........................................................... 31
		Cab.................................................................. 32
		Engine............................................................... 39
		Aftertreatment Device................................................ 40
		Fan Valve............................................................ 41
		Pump Device.......................................................... 42
		Multiple Control Valve............................................... 42
		Manifold Valve....................................................... 43
		Parking Brake Solenoid Valve......................................... 43
		Brake Charge Valve................................................... 43
		2-Spool Solenoid Valve Unit.......................................... 43
		Steering Valve Block................................................. 44
		Emergency Steering Pump.............................................. 44
		Flow Regulator Valve................................................. 44
		DEF Tank............................................................. 45
		DEF Supply Module.................................................... 45
		Joystick Steering Hydraulic Component Layout......................... 46
		Joystick Steering Cab Components..................................... 48
	Group 3 Component Specifications......................................... 51
		Engine............................................................... 51
		Engine Accessories................................................... 55
		Hydraulic Component.................................................. 56
		Electrical Component................................................. 62
SECTION 2 SYSTEM............................................................. 65
	Group 1 Controller....................................................... 67
		Outline.............................................................. 67
		CAN Circuit.......................................................... 68
	Group 2 Control System................................................... 71
		Outline.............................................................. 71
		Engine Control (ECM)................................................. 76
		Pump Control.........................................................107
		Transmission Control (TCU)...........................................112
		Fan Control, Valve Control...........................................131
		Other Controls.......................................................141
		Control by Electrical and Hydraulic Combined Circuit.................165
		JSS Control System...................................................171
	Group 3 Engine System....................................................179
		Outline..............................................................179
		ECM System...........................................................180
		Fuel Injection Control...............................................182
		Fuel Injection Volume Correction Control.............................190
		EGR Control..........................................................192
		Preheating Control...................................................194
		Variable Turbocharger Control........................................195
		Alarm Control........................................................196
		Urea SCR System......................................................197
		Engine Output Restriction Control (INDUCEMENT).......................208
		Aftertreatment Device................................................214
		Aftertreatment Device Regeneration Control...........................216
	Group 4 Hydraulic System.................................................219
		Outline..............................................................219
		Pilot Circuit........................................................220
		Main Circuit.........................................................252
		Steering Control Circuit.............................................254
		Front Attachment Control Circuit.....................................258
		Fan Circuit..........................................................266
		Emergency (Secondary) Steering Circuit...............................268
		Joystick Steering Hydraulic System...................................271
	Group 5 Electrical System................................................277
		Outline..............................................................277
		Main Circuit.........................................................278
		Electric Power Circuit (Key Switch: OFF).............................280
		CAN Circuit..........................................................282
		Accessory Circuit (Key Switch: ACC)..................................284
		Starting Circuit (Key Switch: START).................................286
		Neutral Engine Start Circuit.........................................288
		Charging Circuit (Key Switch: ON)....................................290
		Surge Voltage Prevention Circuit.....................................294
		Pilot Shut-Off Circuit (Key Switch: ON)..............................296
		Auto Shut-Down (Idling Stop) Circuit.................................298
		Engine Stop Circuit..................................................300
		Monitor Circuit......................................................303
		Steering Column Monitor Circuit......................................307
		Head Light Circuit...................................................308
		Hazard Light Circuit (Key Switch: OFF)...............................314
		Turn Signal Light Circuit............................................316
		Horn Circuit (Key Switch: OFF).......................................318
		Reverse Light/Buzzer Circuit.........................................320
		Brake Light Circuit..................................................322
		Parking Brake Circuit................................................324
		Accessory Circuit....................................................329
		Work Light Circuit...................................................330
		Wiper Circuit........................................................332
		Cab Dome Light Circuit...............................................338
		JSS Electrical System................................................341
		Outline..............................................................342
		Joystick Steering Electrical Circuit.................................346
		Forward/Reverse Switch Electrical Circuit............................348
SECTION 3 COMPONENT OPERATION................................................353
	Group 1 Pump Device......................................................355
		Hydraulic Pump Outline...............................................355
		Main Hydraulic Pump..................................................356
		Regulator............................................................358
		Steering Priority Valve..............................................374
		Steering Main Relief Valve...........................................375
		Pilot Pump...........................................................376
		Pump Delivery Pressure Sensor........................................376
	Group 2 Control Valve....................................................377
		Outline..............................................................377
		Hydraulic Circuit....................................................382
		Main Relief Valve....................................................388
		Overload Relief Valve (with Make-Up Function)........................390
		Anti-Drift Valve.....................................................394
		Lift Arm Flow Rate Control Valve.....................................398
		Charge-Cut Valve in Ride Control Spool...............................402
		Drain Plug...........................................................406
		Pump Flow Rate Control Valve.........................................408
	Group 3 Cooling Fan System...............................................411
		Fan Pump.............................................................411
		Fan Motor............................................................412
		Fan Control Valve....................................................413
	Group 4 Steering Pilot Valve.............................................421
		Outline..............................................................421
		Structure............................................................422
		Operation............................................................423
	Group 5 Steering Valve...................................................427
		Outline..............................................................427
		Operation............................................................430
		Steering Overload Relief Valve.......................................432
		Outline (Fingertip Control Type Pilot Valve for Front Attachment)....435
	Group 6 Pilot Valve......................................................436
		Operation............................................................436
		Electromagnetic Detent...............................................440
		Outline (Joystick Type Pilot Valve for Front Attachment).............442
		Operation............................................................443
		Electromagnetic Detent...............................................450
	Group 7 Brake Charge Valve / Manifold Valve..............................451
		Outline..............................................................451
		Brake Charge Valve...................................................452
		Manifold Valve.......................................................457
		Pilot Relief Valve...................................................458
		Torque Control Solenoid Valve........................................459
		Control Lever Lock Solenoid Valve....................................461
		Service Brake Accumulator............................................462
		Pilot Accumulator....................................................463
	Group 8 Drive Unit.......................................................465
		Outline..............................................................465
		Torque Converter.....................................................470
		Transmission.........................................................474
		Operation of Transmission............................................476
		Transmission Control Valve...........................................492
		Drive Unit Circuit...................................................494
		Parking Brake Manual Release.........................................495
	Group 9 Axle.............................................................497
		Outline..............................................................497
		Differential.........................................................498
		Torque Proportioning Differential (TPD)..............................502
		Limited Slip Differential (LSD) (Option).............................504
		Service Brake........................................................506
		Final Drive Planetary / Axle Shaft...................................508
	Group 10 Brake Valve.....................................................509
		Outline..............................................................509
		Operation............................................................512
	Group 11 Others..........................................................519
		Propeller Shaft......................................................519
		2-Spool Solenoid Valve Unit..........................................520
		Parking Brake Solenoid Valve Unit....................................522
		Parking Brake Solenoid Valve.........................................524
		Parking Brake Accumulator............................................526
		Flow Regulator Valve.................................................527
		Steering Accumulator.................................................530
		Ride Control Accumulator.............................................530
		Torque Converter Cooler Check Valve..................................531
		Stop Valve...........................................................532
		Pilot Oil Filter.....................................................534
		Emergency (Secondary) Steering Check Block...........................535
		Emergency (Secondary) Steering Pump..................................536
		Joystick Steering Control Valve......................................538
SERVICE MANUAL REVISION REQUEST FORM.........................................545

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