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Hitachi ZW330 Wheel Loader Operational Principle Technical Manual (TO92C1-E-00) – PDF Download
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- Hitachi ZW330 Wheel Loader Operational Principle Technical Manual
- Part No:TO92C1-E-00
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Description
Hitachi ZW330 Wheel Loader Operational Principle Technical Manual (TO92C1-E-00)
File Details:
Hitachi ZW330 Wheel Loader Operational Principle Technical Manual (TO92C1-E-00)
- Manual Language:English
- Downloadable:Yes
- Pages: 493
- Size: 17.9 MB
- Format:PDF
HITACHI ZW330 WHEEL LOADER OPERATIONAL PRINCIPLE TECHNICAL MANUAL (TO92C1-E-00) – PDF DOWNLOAD:
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Description:
Hitachi ZW330 Wheel Loader Operational Principle Technical Manual (TO92C1-E-00)
- To ensure good machine performance, reduce failures or problems, and prolong the service life of each component, it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.
- To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Technical Manual.
- For the engine, refer to the engine Shop Manual provided by the engine manufacturer.
- The purpose of this manual is to provide information on the product and the correct maintenance and repair methods. Please read this manual to ensure correct troubleshooting and good repair service.
- This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or requests, please inform us.
Table Of Contents:
Hitachi ZW330 Wheel Loader Operational Principle Technical Manual (TO92C1-E-00)
TO92C1-E-00....................................................................................... 1 Foreword.......................................................................................... 2 Safety Symbols.................................................................................... 3 CONTENTS.......................................................................................... 4 00 General Information............................................................................ 16 How to Use Manual............................................................................. 17 Safety precautions........................................................................ 17 Symbols................................................................................... 18 Outline....................................................................................... 19 Layout of main components................................................................. 19 Inspection and maintenance table.......................................................... 20 Recommended Lubricants.................................................................... 23 Coolant................................................................................... 25 Coolant specification................................................................. 25 Recommended mixture of antifreeze..................................................... 25 Lubrication chart......................................................................... 26 Weight of main components................................................................. 27 Bolt tightening torque.................................................................... 28 Hexagon bolt.......................................................................... 28 Flanged hexagon bolt.................................................................. 31 Hose band tightening torque............................................................... 32 Liquid gasket and screw lock agent........................................................ 33 Cautions regarding parts removal...................................................... 33 Cautions regarding reassembly......................................................... 33 Screw lock agent application procedure................................................ 34 How to wind a seal tape............................................................... 34 Cautions regarding welding repair service................................................. 35 MEMO.......................................................................................... 37 03 Measurement for Performance Check.............................................................. 38 Cautions on Safety............................................................................ 39 Standard Measurement Values for Performance Check............................................. 40 MEMO.......................................................................................... 43 12 Function & Structure Chassis Group............................................................. 44 Front Chassis................................................................................. 45 Loading linkage........................................................................... 45 Loading linkage pin....................................................................... 47 Rear Chassis.................................................................................. 48 Fuel tank................................................................................. 48 Floor board mount......................................................................... 49 Floor board........................................................................... 49 Viscous mount......................................................................... 49 Center Pin.................................................................................... 50 Upper center pin.......................................................................... 50 Lower center pin.......................................................................... 50 Dust seal................................................................................. 51 13 Check & Adjustment Chassis Group............................................................... 52 Linkage Pin................................................................................... 53 Liner..................................................................................... 53 Adjustment............................................................................ 54 Bucket hinge pin section.............................................................. 55 How to assemble....................................................................... 55 Center Pin.................................................................................... 56 Adjusting shim............................................................................ 56 Installing bearing cover.................................................................. 56 Installing bearing outer ring............................................................. 57 22 Function & Structure Power Group............................................................... 58 Power Line.................................................................................... 59 Engine / Transmission......................................................................... 60 Engine / transmission mount............................................................... 60 Radiator...................................................................................... 61 Radiator mount............................................................................ 62 Torque converter oil cooler............................................................... 63 Propeller Shaft............................................................................... 64 Second propeller shaft assembly........................................................... 65 Front differential - Transmission..................................................... 65 Third propeller shaft assembly............................................................ 66 Transmission - Rear differential...................................................... 66 Axle Assembly................................................................................. 67 Axle Support.................................................................................. 68 Differential Gear............................................................................. 70 Torque proportioning type................................................................. 70 Function of T.P.D..................................................................... 72 Operation of T.P.D.................................................................... 73 Limited Slip Differential (option)........................................................ 74 Structure............................................................................. 74 LSD function.......................................................................... 77 LSD operation......................................................................... 77 23 Check & Adjustment Power Group................................................................. 78 Engine........................................................................................ 79 Measuring engine speed.................................................................... 79 Measurement instrument................................................................ 79 Standard measurement value............................................................ 79 Measuring engine oil pressure............................................................. 79 Measurement instrument................................................................ 79 Install position...................................................................... 79 Standard measurement value............................................................ 79 Propeller Shaft............................................................................... 80 Propeller shaft phase..................................................................... 80 Second propeller shaft alignment.......................................................... 80 Tightening torque......................................................................... 81 Axle.......................................................................................... 82 Axle nut tightening procedure............................................................. 82 Differential gear adjustment procedure.................................................... 83 Preload adjustment.................................................................... 83 Bearing installation.................................................................. 84 Oil seal installation................................................................. 84 Adjusting tooth contact............................................................... 85 MEMO.......................................................................................... 87 32 Function & Structure T/C and T/M Group......................................................... 88 Torque Converter.............................................................................. 89 Torque converter structure................................................................ 89 Power flow path........................................................................... 89 Torque multiplication..................................................................... 89 Torque Converter (Lock-up) (Option)........................................................... 90 Lock-up clutch structure.................................................................. 91 Lock-up clutch function (only forward).................................................... 91 Torque Converter Gear Pump.................................................................... 93 Gear pump specifications.................................................................. 93 Transmission.................................................................................. 94 Clutch combination........................................................................ 94 Shift lever position...................................................................... 94 Downshift button operation................................................................ 94 Gear train and number of teeth............................................................ 95 Clutch specifications..................................................................... 96 Friction plate: mm (in)............................................................... 96 Clutch Pack................................................................................... 97 Forward and 3rd speed clutches............................................................ 97 Reverse and 2nd speed clutches............................................................ 98 1st speed clutch.......................................................................... 99 4th speed clutch..........................................................................100 Power Flow Path in the Transmission...........................................................101 Forward...................................................................................101 Forward 1st speed.....................................................................101 Forward 2nd speed.....................................................................101 Forward 3rd speed.....................................................................102 Forward 4th speed.....................................................................102 Reverse...................................................................................103 Reverse 1st speed.....................................................................103 Reverse 2nd, 3rd, and 4th speeds......................................................103 Hydraulic System Diagram......................................................................104 Hydraulic Circuit Diagram.....................................................................105 Oil Flow......................................................................................106 Oil flow in the torque converter line.....................................................106 From torque converter gear pump to torque converter...................................106 From torque converter to cooling circuit..............................................106 From cooler to lubrication circuit....................................................106 Oil flow to the clutch....................................................................106 To forward and reverse clutches.......................................................106 To speed clutch.......................................................................106 T/C and T/M Oil Circulation...................................................................107 Control Valve.................................................................................108 System diagram............................................................................109 Modulation Mechanism..........................................................................110 Clutch control oil pressure curve.........................................................111 Traveling at forward 1st speed............................................................112 Pressure holding......................................................................112 Changing from forward 1st speed to reverse 1st speed......................................113 Releasing forward clutch and feeding initial oil to reverse clutch....................113 Trimmer engagement........................................................................114 Low-pressure holding..................................................................114 Clutch engagement starting................................................................115 Pressure increase.....................................................................115 Clutch Solenoid Valve.........................................................................116 For forward/reverse and speed clutches....................................................116 After power-off (clutch disengaged status)............................................116 After power-on (clutch engaged status)................................................117 For trimmer...............................................................................118 After power-off (high clutch pressure status).........................................118 After power-on (just after switching clutch)..........................................119 33 Check & Adjustment T/C and T/M Group...........................................................122 Clutch Oil Pressure...........................................................................123 Measuring clutch oil pressure.............................................................123 42 Function & Structure Hydraulic Group...........................................................124 Flushing Hydraulic Circuit....................................................................125 Purpose of flushing.......................................................................125 Cautions on Hydraulic Parts Replacement.......................................................126 Hydraulic Circuit Symbols.....................................................................127 Hydraulic lines...........................................................................127 Pumps & motors............................................................................127 Cylinders.................................................................................127 Operation methods.........................................................................128 Pressure control valve....................................................................128 Flow control valve........................................................................128 Directional control valve.................................................................129 Check valve...............................................................................129 Miscellaneous hydraulic symbols...........................................................130 Hydraulic System Operation....................................................................131 Hydraulic system operation outline........................................................131 Loading system........................................................................131 Steering system.......................................................................131 Efficient loading system..............................................................132 Fan motor system......................................................................132 Ride control system (OPT).............................................................132 Layout of Hydraulic Units.....................................................................133 Hydraulic Tank................................................................................134 Hydraulic tank breather valve (tank cap)..................................................135 Hydraulic tank specifications.............................................................136 Hydraulic oil level check.................................................................137 Hydraulic Pump................................................................................138 Main pump.................................................................................138 Main pump specifications..............................................................138 Steering pump.............................................................................139 Steering pump specifications..........................................................139 Hydraulic pump principle..................................................................140 Hydraulic pump wear plate.................................................................141 Hydraulic pump bushing lubrication........................................................141 Hydraulic Cylinder............................................................................142 Boom cylinder.............................................................................142 Bucket cylinder...........................................................................143 Steering cylinder.........................................................................143 Hydraulic cylinder specifications.........................................................144 Loading System................................................................................145 Reducing Valve (for Pilot Pressure)...........................................................146 Pilot Valve...................................................................................147 Pilot valve function......................................................................149 Pilot valve operation (modulated position)................................................149 Pre-detent and detent magnet solenoid.....................................................151 Multiple Control Valve (KML35A/2T203).........................................................152 Multiple control valve specifications.....................................................153 Multiple control valve main relief valve..................................................154 Main relief valve operation...........................................................154 Adjusting set pressure................................................................155 Multiple control valve overload relief valve (with make-up function)......................156 Overload relief valve operation.......................................................156 Make-up valve operation...............................................................157 Adjusting set pressure................................................................157 Multiple control valve make-up valve......................................................158 Make-up valve operation...............................................................158 Multiple control valve bucket spool.......................................................159 Bucket spool operation................................................................159 Multiple control valve boom spool.........................................................161 Boom spool operation..................................................................161 Adapter (Orifice).............................................................................164 Ride Control (OPT)............................................................................165 Ride control hydraulic circuit............................................................165 Ride control function.....................................................................165 Ride control operation....................................................................166 Preparation mode (ride control switch is OFF).........................................166 Running mode (ride control switch is ON)..............................................167 Ride control valve assembly...............................................................168 Solenoid valve........................................................................171 Accumulator (for ride control)............................................................173 Accumulator function..................................................................173 Steering System...............................................................................174 Orbitrol®.....................................................................................175 Orbitrol® structure.......................................................................175 Valve part............................................................................175 Rotor part............................................................................176 Orbitrol® specifications..................................................................176 Orbitrol® operation.......................................................................177 Neutral...............................................................................177 Turn..................................................................................178 Orbitrol® feed-back mechanism operation...................................................179 Steering speed and flow rate control......................................................180 Hydraulic pump oil amount and steering force..............................................180 Orbit rotor operation principle...........................................................181 Steering Valve (KVS25-A3.0/20)................................................................182 Steering valve operation..................................................................184 Neutral position (steering spool in "Neutral")........................................184 Left turn position....................................................................185 Steering plunger variable throttle........................................................186 Steering valve flow control plunger.......................................................187 Steering valve main relief valve..........................................................188 When the pressure is at the preset value or less......................................188 When the pressure exceeds the preset value............................................189 Steering valve overload relief valve......................................................190 Overload relief valve operation.......................................................191 Make-up valve operation...............................................................191 Steering pilot circuit and its operation..................................................192 Flow amplifier notch and pilot orifice................................................193 Stop Valve....................................................................................194 Stop valve function.......................................................................195 Stop valve operation......................................................................195 Reducing Valve (for Orbitrol®)................................................................196 Steering Line Filter..........................................................................197 Efficient Loading System......................................................................198 Efficient loading system outline..........................................................198 The operation condition of ELS........................................................198 Mounting of the ELS valve.................................................................199 Mounting of the variable kickout sensor...................................................200 Efficient loading system operation........................................................201 While the ELS is not operating........................................................201 While the ELS is operating............................................................201 Fan Motor System..............................................................................202 Mounting of fan motor.....................................................................202 Fan Motor Line................................................................................203 Hydraulic circuit (fan motor normal rotation).............................................205 Safety valve (with suction function)..................................................205 Flow control valve....................................................................206 Flow control solenoid valve...........................................................207 Fan motor.............................................................................208 Reversing Fan Motor Line (OPT)................................................................211 Reversing fan motor function..............................................................211 Fan motor.............................................................................212 Reversing fan control chart...........................................................214 Hydraulic circuit (Reverse rotation)......................................................215 Relief valve..............................................................................216 Secondary Steering............................................................................217 Secondary steering circuit................................................................217 Secondary steering operation..........................................................217 Secondary steering motor and pump.....................................................218 MEMO..........................................................................................219 43 Check & Adjustment Hydraulic Group.............................................................220 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)...............221 Loading circuit relief valve setting pressures............................................221 Measuring loading circuit main relief pressure........................................222 Measuring loading circuit overload relief pressure....................................224 Measuring pilot circuit relief pressure...............................................225 Ride control circuit reducing valve setting pressures (OPT)...............................226 Measuring ride control circuit reducing pressure......................................227 Steering circuit relief valve setting pressures...........................................229 Measuring steering circuit overload relief pressure...................................232 Measuring pilot circuit relief pressure (reducing pressure)...........................233 Hydraulic Cylinder............................................................................234 Cylinder natural drift....................................................................234 Stop Valve....................................................................................236 Stop valve adjustment procedure...........................................................236 52 Function & Structure Brake Group...............................................................238 Brake System Outline..........................................................................239 Service brake.............................................................................239 Parking brake.............................................................................239 Adjustment of axle internal pressure......................................................239 Brake Units Layout............................................................................240 Unloader Valve................................................................................241 Unloader valve operation..................................................................242 Valve Unit....................................................................................243 Accumulator low pressure sensor...........................................................244 Accumulator...................................................................................245 In-Line Filter................................................................................246 Brake Valve...................................................................................247 Brake valve performance chart.............................................................248 Brake valve outline.......................................................................249 While the valve is not operating......................................................249 While the valve is operating..........................................................250 While the valve is releasing..........................................................250 Service Brake.................................................................................251 Service brake operation...................................................................251 Service brake friction plate..............................................................252 Service brake steel plate.................................................................252 Service brake piston......................................................................253 Brake circuit air bleeding procedure......................................................254 Bleeding air from brake pipes and axle housing hubs...................................255 Bleeding air from parking brake housing...............................................255 Parking Brake.................................................................................256 Parking brake operation...................................................................257 Operation of parking brake............................................................258 Parking brake friction disc...............................................................259 Friction plate........................................................................259 Steel plate...........................................................................260 Parking brake solenoid valve..............................................................261 Solenoid valve operation..............................................................261 Solenoid valve specifications.........................................................261 Parking Brake Manual Release..................................................................262 Brake Circuit Check Valve.....................................................................263 Auto Brake....................................................................................264 Auto brake circuit........................................................................264 Auto brake operation set value............................................................265 Solenoid valve (for Autobrake circuit)....................................................266 Solenoid specifications...............................................................266 Pressure Sensor (for stop lamp and declutch)..................................................267 Pressure sensor (for stop lamp)...........................................................267 Pressure sensor (for Declutch)............................................................268 53 Check & Adjustment Brake Group.................................................................270 Brake Circuit Oil Pressure....................................................................271 Unloader valve setting pressure...........................................................271 Measurement instrument................................................................272 Gauge port............................................................................272 Standard measurement value............................................................272 Measurement procedure.................................................................272 Brake valve oil pressure..................................................................273 Measurement instrument................................................................273 Gauge port............................................................................273 Measurement procedure.................................................................273 Brake valve performance...............................................................274 Service Brake.................................................................................275 Service brake performance check...........................................................275 Condition.............................................................................275 Standard measurement value............................................................275 Service brake friction plate wear measurement.............................................276 Measurement procedure.................................................................277 Cautions on installing brake discs........................................................277 Parking Brake.................................................................................278 Parking brake performance check...........................................................278 Condition.............................................................................278 Standard measurement value............................................................278 62 Function & Structure Electrical Group..........................................................280 How to Use Electrical Wiring Diagram..........................................................281 Utilisation des schémas des câblages électriques (FRANÇAIS)...............................282 Verwendung des elektrischen Schaltplans (DEUTSCH).........................................283 Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)...................284 Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)................................285 Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)...............................286 Electrical Cable Color Codes..................................................................287 Electrical Circuit Symbols....................................................................288 Sensor Mount..................................................................................289 Fuse..........................................................................................290 Fuse box..................................................................................290 Fusible link..............................................................................292 Engine Start Circuit..........................................................................293 Engine start circuit diagram..............................................................293 Neutral starter...........................................................................293 Shift lever neutral (N) position......................................................293 Shift lever forward/reverse (F/R) position............................................294 Starter switch............................................................................295 ECM safety features...................................................................296 Battery relay.............................................................................296 Battery relay operation...............................................................296 Alternator I terminal wire................................................................297 Diode unit................................................................................297 Neutral relay.............................................................................298 Magnetic switch...........................................................................299 Voltage relay.............................................................................300 Power Generating/Charging Circuit.............................................................301 Alternator................................................................................301 ECM (Engine Controller).......................................................................302 Function of ECM...........................................................................302 Connection diagram........................................................................302 Monitor lamp test.........................................................................303 Failure diagnosis.........................................................................304 Engine diagnostic switch (option).....................................................304 Failure diagnostic chart..............................................................305 Increment decrement switch (option)...................................................306 Quantum fault code information............................................................307 Accelerator pedal.........................................................................313 Accelerator pedal installation........................................................314 Transmission Control Circuit and Monitor Circuit..............................................315 Machine control unit (MCU)................................................................315 Connector.............................................................................316 Machine control unit (MCU) connection diagram.............................................317 Machine control unit (MCU) function.......................................................319 Forward/reverse (F/R) shifting and speed change.......................................319 Automatic shift.......................................................................322 Automatic shift (with lock-up solenoid)...............................................322 Machine speed sensor..................................................................323 Switching from automatic to manual....................................................324 Downshift button operation............................................................324 Adjustable declutch preset switch.........................................................325 Back-up alarm.........................................................................326 Parking brake.........................................................................327 Auto brake............................................................................329 Machine control unit (MCU) failure warning............................................332 Secondary steering function...........................................................333 Monitoring system.........................................................................334 Items to be monitored and operation condition.........................................334 Operation monitor lamps...............................................................336 Instrument Panel and Switch...................................................................337 Instrument panel..........................................................................337 Instrument panel rear surface.............................................................338 Gauge circuit.............................................................................339 Fuel level sensor.........................................................................341 MODM..........................................................................................342 MODM function.............................................................................342 Monitor Changeover........................................................................342 Changing display from one function to next............................................343 Information Monitor.......................................................................345 Information monitor display...........................................................345 Unit conversion and language selection................................................348 Replacement Monitor.......................................................................349 Replacement time check................................................................349 Replacement interval set (timer reset)................................................353 Replacement interval pop-up...........................................................354 Display language......................................................................355 Fault Log Monitor.........................................................................355 Fault log history check...............................................................355 Selection of machine fault log and engine fault log...................................356 Machine fault log navigation..........................................................357 Engine fault log navigation...........................................................357 Clear fault log.......................................................................357 Clear active fault log (error pop up).................................................358 Input/Output Monitor......................................................................362 Input/Output monitor display..........................................................362 Parameter Setting Monitor.................................................................366 Parameter setting monitor display.....................................................366 Specification Setting Monitor.............................................................375 Specification setting monitor display.................................................375 All setting reset.....................................................................378 Electrical Detent Circuit.....................................................................381 Bucket leveler............................................................................381 Proximity switch......................................................................381 Detent solenoid...........................................................................382 Lift kickout & lower kickout..............................................................383 Location..............................................................................383 Lift kickout..........................................................................384 Lower kickout.........................................................................384 Sensor assy...............................................................................385 Detent solenoid...........................................................................387 Preset height adjustment..................................................................387 Diode.........................................................................................388 Diode check method........................................................................389 Caution for diode check method............................................................389 Continuity check mode.................................................................389 Diode check mode......................................................................389 Resistance check mode.................................................................390 Surge voltage and surge suppression diodes................................................391 72 Function & Structure Operator Station Group....................................................392 Cabin.........................................................................................393 Glass.....................................................................................394 1. Part number 32011-21690............................................................395 2. Part number 32011-21700............................................................395 3. Part number 32011-21500............................................................396 Wiper mount...............................................................................397 Front wiper...........................................................................397 Rear wiper............................................................................397 Wiper motor...............................................................................398 Operator Seat.................................................................................400 Steering and Transmission Shift Lever.........................................................401 Tilt case.................................................................................402 Column shaft..............................................................................403 Shift lever...............................................................................403 Air Conditioner...............................................................................404 Air conditioner components................................................................404 Air conditioner specifications (system performance)...................................404 Denso air conditioner structure...........................................................405 Cooling unit..........................................................................405 Heater and accessories................................................................407 Air distributor (hood & defroster selection box)......................................407 Air compressor (with magnetic clutch).................................................408 Condenser unit........................................................................408 Control unit..........................................................................409 Function of cooling mechanism.............................................................410 Principle of cooling..................................................................410 Refrigerant...........................................................................411 Refrigerant characteristics...........................................................412 Cooling circuit...........................................................................413 Electrical circuit........................................................................414 Control schematic drawing.............................................................414 Air conditioner functions of components...................................................415 Control panel.........................................................................415 Air conditioner unit..................................................................422 Compressor and magnetic clutch........................................................431 Condenser unit........................................................................434 Receiver dryer........................................................................436 Sight glass...........................................................................438 Pressure switches.....................................................................438 Pressure relief valve.................................................................440 Relay A...............................................................................441 Relay B...............................................................................441 Refrigerant hose......................................................................442 Charge of refrigerant.....................................................................443 Work procedure........................................................................444 Refrigerant charging tools............................................................446 Refrigerant charging procedure........................................................449 Troubleshooting using the gauge manifold..............................................455 Air conditioner troubleshooting...........................................................460 73 Check & Adjustment Operator Station Group......................................................468 Air Conditioner...............................................................................469 Adjustment of lubricating oil quantity when components of air conditioner are replaced....469 When the compressor is replaced.......................................................470 When the evaporator is replaced.......................................................471 When the condenser is replaced........................................................471 Adjustment of air gap (between hub and rotor) in compressor magnetic clutch...............472 Compressor V-belt adjustment..............................................................473 Belt adjustment procedure.............................................................473 Belt adjustment value.................................................................473 Parts to be replaced periodically.........................................................474 Air filters...........................................................................474 Receiver dryer........................................................................474 MEMO..........................................................................................475 Function & Structure Supplement...................................................................476 Foreword..........................................................................................477 Function & Structure Supplement...................................................................476 Quick Coupler.................................................................................478 Hydraulic line and electrical circuit.....................................................478 Solenoid valve............................................................................ 0 Solenoid valve specifications.........................................................481 Short Boom (OPT)..............................................................................483 Bucket cylinder...........................................................................484 Bucket cylinder specifications........................................................485 Maintenance Log...................................................................................486 Notes.............................................................................................490
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⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
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