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Hitachi ZW330 Wheel Loader Operational Principle Technical Manual (TO92C1-E-D1) – PDF Download
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- Hitachi ZW330 Wheel Loader Operational Principle Technical Manual
- Part No:TO92C1-E-D1
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Description
Hitachi ZW330 Wheel Loader Operational Principle Technical Manual (TO92C1-E-D1)
File Details:
Hitachi ZW330 Wheel Loader Operational Principle Technical Manual (TO92C1-E-D1)
- Manual Language:English
- Downloadable:Yes
- Pages: 553
- Size: 23.5 MB
- Format:PDF
HITACHI ZW330 WHEEL LOADER OPERATIONAL PRINCIPLE TECHNICAL MANUAL (TO92C1-E-D1) – PDF DOWNLOAD:
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Description:
Hitachi ZW330 Wheel Loader Operational Principle Technical Manual (TO92C1-E-D1)
- 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 Shop 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-D1)
TO92C1-E-01....................................................................................... 1 Foreword.......................................................................................... 3 Safety Symbols.................................................................................... 4 CONTENTS.......................................................................................... 5 General Information............................................................................... 17 How to Use Manual............................................................................. 18 Safety precautions........................................................................ 18 Symbols................................................................................... 19 Outline....................................................................................... 20 Layout of main components................................................................. 20 Inspection and maintenance table.......................................................... 21 Recommended Lubricants.................................................................... 24 Coolant................................................................................... 26 Lubrication chart......................................................................... 27 Weight of main components................................................................. 28 Bolt tightening torque.................................................................... 29 Hose band tightening torque............................................................... 33 Liquid gasket and screw lock agent........................................................ 34 How to wind a seal tape............................................................... 35 Cautions regarding welding repair service................................................. 36 Measurement for Performance Check................................................................. 39 Cautions on Safety............................................................................ 40 Standard Measurement Values for Performance Check............................................. 41 Function & Structure Chassis Group................................................................ 45 Front Chassis................................................................................. 46 Loading linkage........................................................................... 46 Loading linkage pin....................................................................... 48 Rear Chassis.................................................................................. 49 Fuel tank................................................................................. 49 Floor board mount......................................................................... 50 Center Pin.................................................................................... 51 Upper center pin.......................................................................... 51 Lower center pin.......................................................................... 51 Dust seal................................................................................. 52 Check & Adjustment Chassis Group.................................................................. 53 Linkage Pin................................................................................... 54 Liner..................................................................................... 54 Center Pin.................................................................................... 57 Adjusting shim............................................................................ 57 Installing bearing cover.................................................................. 57 Installing bearing outer ring............................................................. 58 Function & Structure Power Group.................................................................. 59 Power Line.................................................................................... 60 Engine / Transmission......................................................................... 61 Engine / transmission mount............................................................... 61 Radiator...................................................................................... 62 Radiator mount............................................................................ 63 Torque converter oil cooler............................................................... 64 Propeller Shaft............................................................................... 65 Second propeller shaft assembly........................................................... 66 Third propeller shaft assembly............................................................ 67 Axle Assembly................................................................................. 68 Axle Support.................................................................................. 70 Torque Proportional Differential Gear (TPD)................................................... 72 Function of T.P.D......................................................................... 74 Operation of T.P.D........................................................................ 75 Limited Slip Differential (option)............................................................ 76 LSD structure................................................................................. 76 LSD function.............................................................................. 79 LSD operation............................................................................. 79 Check & Adjustment Power Group.................................................................... 81 Engine........................................................................................ 82 Measuring engine speed.................................................................... 82 Measuring engine oil pressure............................................................. 82 Propeller Shaft............................................................................... 83 Propeller shaft phase..................................................................... 83 Second propeller shaft alignment.......................................................... 83 Propeller shaft tightening torque......................................................... 84 Axle.......................................................................................... 85 Axle nut tightening procedure............................................................. 85 Differential gear adjustment procedure.................................................... 86 Function & Structure Torque Converter and Transmission Group...................................... 91 Torque Converter.............................................................................. 92 Torque converter structure................................................................ 92 Power flow path........................................................................... 92 Torque multiplication..................................................................... 92 Torque Converter (Lock-up) (Option)........................................................... 93 Lock-up clutch structure.................................................................. 94 Lock-up clutch function (only forward).................................................... 94 Torque Converter Gear Pump.................................................................... 96 Gear pump specifications.................................................................. 96 Transmission.................................................................................. 97 Clutch combination........................................................................ 97 Shift lever position...................................................................... 97 Downshift button operation................................................................ 97 Gear train and number of teeth............................................................ 98 Clutch specifications..................................................................... 99 Clutch Pack...................................................................................100 Forward and 3rd speed clutches............................................................100 Reverse and 2nd speed clutches............................................................101 1st speed clutch..........................................................................102 4th speed clutch..........................................................................103 Power Flow Path in the Transmission...........................................................104 Forward...................................................................................104 Reverse...................................................................................106 Hydraulic System Diagram......................................................................107 Hydraulic Circuit Diagram.....................................................................108 Oil Flow......................................................................................109 Oil flow in the torque converter line.....................................................109 Oil flow to the clutch....................................................................109 T/C and T/M Oil Circulation...................................................................110 Control Valve.................................................................................111 System diagram............................................................................112 Modulation Mechanism..........................................................................113 Clutch control oil pressure curve.........................................................114 Traveling at forward 1st speed............................................................115 Changing from forward 1st speed to reverse 1st speed......................................116 Trimmer engagement........................................................................117 Clutch engagement starting................................................................118 Clutch Solenoid Valve.........................................................................119 For forward/reverse and speed clutches....................................................119 For trimmer...............................................................................121 Lock-up clutch solenoid valve (option)........................................................123 Check & Adjustment Torque Converter and Transmission Group........................................125 Clutch Oil Pressure...........................................................................126 Measuring clutch oil pressure.............................................................126 Clutch oil pressure standard value........................................................126 Function & Structure Hydraulic Group..............................................................127 Flushing Hydraulic Circuit....................................................................128 Purpose of flushing.......................................................................128 Cautions on Hydraulic Parts Replacement.......................................................129 Hydraulic Circuit Symbols.....................................................................130 Hydraulic lines...........................................................................130 Pumps & motors............................................................................130 Cylinders.................................................................................130 Operation methods.........................................................................131 Pressure control valve....................................................................131 Flow control valve........................................................................131 Directional control valve.................................................................132 Check valve...............................................................................132 Miscellaneous hydraulic symbols...........................................................133 Hydraulic System Operation....................................................................134 Hydraulic system operation outline........................................................134 Layout of Hydraulic Units.....................................................................136 Hydraulic Tank................................................................................137 Hydraulic Tank (S/N 9001~9100)............................................................137 Hydraulic tank breather valve (tank cap) (S/N 9001~9100)..................................138 Hydraulic tank (S/N 9101~)................................................................139 Hydraulic tank specifications.............................................................141 Hydraulic oil level check.................................................................142 Hydraulic Pump................................................................................143 Main pump.................................................................................143 Steering pump.............................................................................144 Hydraulic pump principle..................................................................145 Hydraulic pump wear plate.................................................................146 Hydraulic pump bushing lubrication........................................................146 Hydraulic Cylinder............................................................................147 Boom cylinder.............................................................................147 Bucket cylinder...........................................................................148 Steering cylinder.........................................................................150 Hydraulic cylinder specifications.........................................................151 Loading System................................................................................152 Reducing Valve (for Pilot Pressure)...........................................................153 Pilot valve (S/N 9001~9004)...................................................................154 Pilot valve (S/N 9005~9100)...................................................................159 Pilot valve (S/N 9101~).......................................................................164 Multiple Control Valve (KML35A/2T203).........................................................169 Multiple control valve specifications.....................................................170 Multiple control valve main relief valve..................................................171 Multiple control valve overload relief valve (with make-up function)......................173 Multiple control valve make-up valve......................................................175 Multiple control valve bucket spool.......................................................176 Multiple control valve boom spool.........................................................178 Adapter (Orifice).............................................................................181 Ride Control (OPT)............................................................................182 Ride control hydraulic circuit............................................................182 Ride control function.....................................................................182 Ride control operation....................................................................183 Ride control valve assembly...............................................................185 Accumulator (for ride control)............................................................190 Steering System...............................................................................191 Orbitrol®.....................................................................................192 Orbitrol® structure.......................................................................192 Orbitrol® specifications..................................................................193 Orbitrol® operation.......................................................................194 Orbitrol® feed-back mechanism operation...................................................196 Steering speed and flow rate control......................................................197 Hydraulic pump oil amount and steering force..............................................197 Orbit rotor operation principle...........................................................198 Steering Valve (KVS25-A3.0/20)................................................................199 Steering valve operation..................................................................201 Steering plunger variable throttle........................................................203 Steering valve flow control plunger.......................................................204 Steering valve main relief valve..........................................................205 Steering valve overload relief valve......................................................207 Steering pilot circuit and its operation..................................................209 Stop Valve....................................................................................211 Stop valve function.......................................................................212 Stop valve operation......................................................................212 Reducing Valve (for Orbitrol®)................................................................213 Steering Line Filter..........................................................................214 Efficient Loading System......................................................................215 Efficient loading system outline..........................................................215 Mounting of the ELS valve.................................................................216 Mounting of the variable kickout sensor...................................................217 Efficient loading system operation........................................................218 Fan Motor System..............................................................................219 Mounting of fan motor.....................................................................219 Fan Motor Line................................................................................220 Hydraulic circuit (fan motor normal rotation).............................................222 Reversing Fan Motor Line (OPT)................................................................229 Reversing fan motor function..............................................................229 Hydraulic circuit (Reverse rotation)......................................................233 Secondary Steering............................................................................234 Check & Adjustment Hydraulic Group................................................................237 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)...............238 Loading circuit relief valve setting pressures............................................238 Ride control circuit reducing valve setting pressures (OPT)...............................243 Steering circuit relief valve setting pressures...........................................246 Hydraulic Cylinder............................................................................251 Cylinder natural drift....................................................................251 Stop Valve....................................................................................253 Stop valve adjustment procedure...........................................................253 Function & Structure Brake Group..................................................................255 Brake System Outline..........................................................................256 Service brake.............................................................................256 Parking brake.............................................................................256 Adjustment of axle internal pressure......................................................256 Brake Units Layout............................................................................257 Unloader Valve................................................................................258 Unloader valve operation..................................................................259 Valve Unit....................................................................................260 Accumulator...................................................................................262 In-Line Filter................................................................................263 Brake Valve...................................................................................264 Brake valve performance chart.............................................................265 Brake valve outline.......................................................................266 Service Brake.................................................................................268 Service brake operation...................................................................269 Service brake friction plate..............................................................269 Service brake steel plate.................................................................269 Service brake piston......................................................................270 Brake circuit air bleeding procedure......................................................271 Parking Brake.................................................................................273 Parking brake operation...................................................................274 Parking brake friction disc...............................................................276 Parking brake solenoid valve..............................................................278 Parking Brake Manual Release..................................................................279 Brake Circuit Check Valve.....................................................................280 Auto Brake....................................................................................281 Auto brake circuit........................................................................281 Auto brake operation set value............................................................282 Solenoid valve (for Autobrake circuit)....................................................283 Pressure Sensor (for stop lamp and declutch)..................................................284 Pressure sensor (for stop lamp)...........................................................284 Pressure sensor (for Declutch)............................................................284 Check & Adjustment Brake Group....................................................................287 Brake Circuit Oil Pressure....................................................................288 Unloader valve setting pressure...........................................................288 Brake valve oil pressure..................................................................290 Service Brake.................................................................................292 Service brake performance check...........................................................292 Service brake friction plate wear measurement.............................................293 Cautions on installing brake discs........................................................294 Parking Brake.................................................................................295 Parking brake performance check...........................................................295 Function & Structure Electrical Group.............................................................297 How to Use Electrical Wiring Diagram..........................................................298 Utilisation des schémas des câblages électriques (FRANÇAIS)...................................299 Verwendung des elektrischen Schaltplans (DEUTSCH).............................................300 Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO).......................301 Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)....................................302 Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)...................................303 Electrical Cable Color Codes..................................................................304 Electrical Circuit Symbols....................................................................305 Sensor Mount..................................................................................306 Fuse..........................................................................................307 Fuse box..................................................................................307 Fusible link..............................................................................309 Engine Start Circuit..........................................................................310 Engine start circuit diagram..............................................................310 Neutral starter...........................................................................310 Starter switch............................................................................312 Battery relay.............................................................................313 Alternator I terminal wire................................................................314 Diode unit................................................................................314 Neutral relay.............................................................................315 Magnetic switch...........................................................................316 Voltage relay.............................................................................317 Power Generating/Charging Circuit.............................................................318 Alternator................................................................................318 ECM (Engine Controller).......................................................................319 Function of ECM...........................................................................319 Connection diagram........................................................................319 Monitor lamp test.........................................................................320 Failure diagnosis.........................................................................321 Quantum fault code information............................................................324 Accelerator pedal.........................................................................330 Transmission Control Circuit and Monitor Circuit..............................................333 Machine control unit (MCU)................................................................333 Machine control unit (MCU) connection diagram.............................................335 Machine control unit (MCU) function.......................................................337 Adjustable declutch preset switch.........................................................343 Monitoring system.........................................................................352 Instrument Panel and Switch...................................................................355 Instrument panel..........................................................................355 Instrument panel rear surface.............................................................356 Gauge circuit.............................................................................357 Fuel level sensor.........................................................................359 MODM..........................................................................................360 MODM function.............................................................................360 Monitor Changeover........................................................................360 Information Monitor.......................................................................363 Replacement Monitor.......................................................................367 Fault Log Monitor.........................................................................373 Input/Output Monitor......................................................................379 Parameter Setting Monitor.................................................................383 Specification Setting Monitor.............................................................392 Electrical Detent Circuit.....................................................................398 Bucket leveler............................................................................398 Detent solenoid...........................................................................399 Lift kickout & lower kickout..............................................................400 Sensor assy...............................................................................402 Detent solenoid...........................................................................404 Preset height adjustment..................................................................404 Diode.........................................................................................405 Diode check method........................................................................406 Caution for diode check method............................................................406 Surge voltage and surge suppression diodes................................................408 Function & Structure Operator Station Group.......................................................409 Cabin.........................................................................................410 Glass.....................................................................................411 Wiper mount...............................................................................414 Wiper motor...............................................................................415 Operator Seat.................................................................................417 Steering and Transmission Shift Lever.........................................................418 Tilt case.................................................................................419 Column shaft..............................................................................420 Shift lever...............................................................................420 Air Conditioner...............................................................................421 Air conditioner components................................................................421 Denso air conditioner structure...........................................................422 Function of cooling mechanism.............................................................427 Cooling circuit...........................................................................430 Electrical circuit........................................................................431 Air conditioner functions of components...................................................432 Charge of refrigerant.....................................................................460 Air conditioner troubleshooting...........................................................477 Check & Adjustment Operator Station Group.........................................................485 Air Conditioner...............................................................................486 Adjustment of lubricating oil quantity when components of air conditioner are replaced....486 Adjustment of air gap (between hub and rotor) in compressor magnetic clutch...............489 Compressor V-belt adjustment..............................................................490 Parts to be replaced periodically.........................................................492 Function & Structure Supplement...................................................................493 Quick Coupler.................................................................................494 Short Boom (OPT)..............................................................................499 Drawing & Diagrams................................................................................503 Axle Assembly.................................................................................504 Torque Converter and Transmission.............................................................505 Hydraulic & Brake Circuit.....................................................................506 Brake Circuit.................................................................................507 Electrical Wiring Diagram.....................................................................508 (1/3).....................................................................................508 (2/3).....................................................................................509 (3/3).....................................................................................510 Electrical Wiring Diagram.....................................................................511 Way of looking at connectors..............................................................511 Electrical wiring diagram abbreviation chart..................................................513 Electrical Connection Diagram.................................................................514 (1/2).....................................................................................514 (2/2).....................................................................................515 Electrical Wiring Diagram (CAB)...............................................................516 Electrical Wiring Diagram (Cabin Air Conditioner).............................................518 Electrical Circuit Diagram (Cabin Air Conditioner)............................................519 Equipment Operation Table (Cabin Air Conditioner).............................................520 Electrical Equipment Layout...................................................................521 Front chassis.............................................................................521 Rear chassis..............................................................................523 Floor board...............................................................................527 Floor board (control box).................................................................528 Outline of MODM (Machine Operation Diagnostic Module) Operation...............................530 Main Menu.................................................................................531 Information Monitor.......................................................................532 Replacement Monitor.......................................................................533 Fault Log Monitor.........................................................................534 Input/Output Monitor......................................................................535 Parameter Setting Monitor.................................................................536 Specification Setting Monitor.............................................................537 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table.........................539 Maintenance Log...................................................................................541 Notes.............................................................................................550
Please Note:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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