Hitachi ZW250-5B Wheel Loader Operational Principle Technical Manual (TONEC-EN-00)
File Details:
Hitachi ZW250-5B Wheel Loader Operational Principle Technical Manual (TONEC-EN-00)
- Manual Language:English
- Pages:455
- Size: 11.4 MB
- Downloadable:Yes
- Format:PDF
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Description:
Hitachi ZW250-5B Wheel Loader Operational Principle Technical Manual (TONEC-EN-00)
To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
Be sure to thoroughly read this manual for correct product information and service procedures.
If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
Additional References
Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.
Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.
Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.
Table Of Contents:
Hitachi ZW250-5B Wheel Loader Operational Principle Technical Manual (TONEC-EN-00)
TONEC-EN-00.................................................................................................. 1 INTRODUCTION............................................................................................. 3 To The Reader........................................................................................ 3 Additional References................................................................................ 3 Manual Composition................................................................................... 3 Page Number.......................................................................................... 3 Safety Alert Symbol and Headline Notations........................................................... 4 Units Used........................................................................................... 4 Symbol and Abbreviation.................................................................................. 5 Symbol and Abbreviation.............................................................................. 5 SECTION AND GROUP CONTENTS............................................................................... 7 SECTION 1 GENERAL........................................................................................ 9 Group 1 Specifications............................................................................... 11 Specifications................................................................................... 11 Group 2 Component Layout............................................................................. 13 Main Component (Overview)........................................................................ 13 Main Component................................................................................... 14 Main Component................................................................................... 15 Electric Component Layout (Overview)............................................................. 16 Electrical System (Cab).......................................................................... 17 Engine and Fan Pump.............................................................................. 25 Pump Device...................................................................................... 27 Drive Unit....................................................................................... 27 Control Valve.................................................................................... 28 Manifold Valve................................................................................... 29 Brake Charge Valve............................................................................... 29 Parking Brake Solenoid Valve..................................................................... 29 3-Spool Solenoid Valve Unit...................................................................... 29 Steering Valve................................................................................... 30 Flow Regulator Valve............................................................................. 30 Emergency Steering Pump.......................................................................... 30 Group 3 Component Specifications..................................................................... 31 Engine........................................................................................... 31 Engine Accessories............................................................................... 35 Hydraulic Component.............................................................................. 37 Electrical Component............................................................................. 42 SECTION 2 SYSTEM......................................................................................... 47 Group 1 Controller................................................................................... 49 Outline.......................................................................................... 49 CAN Circuit...................................................................................... 50 Group 2 Control System............................................................................... 53 Outline.......................................................................................... 53 Engine Control................................................................................... 56 Pump Control..................................................................................... 85 Transmission Control............................................................................. 90 Fan Control, Valve Control.......................................................................109 Control by Electric and Hydraulic Combined Circuit...............................................145 Group 3 ECM System...................................................................................151 Outline..........................................................................................151 Fuel Injection Control...........................................................................152 Fuel Injection Amount Correction Control.........................................................160 EGR Control......................................................................................162 Preheating Control...............................................................................164 Alarm Control....................................................................................165 Muffler Filter...................................................................................166 Operation........................................................................................167 Muffler Filter Regenerative Control..............................................................168 Variable Turbocharger Control....................................................................170 Group 4 Hydraulic System.............................................................................171 Outline..........................................................................................171 Pilot Circuit....................................................................................172 Parallel Circuit Flow Rate Control...............................................................204 Main Circuit.....................................................................................208 Fan Circuit......................................................................................222 Emergency Steering Circuit (Optional) (Refer to Control System / Emergency Steering Control.)....224 Group 5 Electrical System............................................................................227 Outline..........................................................................................227 Main Circuit.....................................................................................228 Electric Power Circuit (Key Switch: OFF).........................................................230 CAN Circuit......................................................................................232 Accessory Circuit (Key Switch: ACC)..............................................................234 Starting Circuit (Key Switch: START).............................................................236 Neutral Engine Start Circuit.....................................................................238 Charging Circuit (Key Switch: ON)................................................................240 Surge Voltage Prevention Circuit.................................................................244 Pilot Shut-Off Circuit (Key Switch: ON)..........................................................246 Auto Shut-Down Circuit (Optional)................................................................248 Engine Stop Circuit..............................................................................250 Monitor Circuit..................................................................................253 Air Conditioner Circuit..........................................................................254 Steering Column Monitor Circuit..................................................................257 Head Light Circuit...............................................................................258 Hazard Light Circuit (Key Switch: OFF)...........................................................264 Turn Signal Light Circuit:.......................................................................266 Horn Circuit (Key Switch: OFF)...................................................................268 Reverse Light/Reverse Buzzer Circuit.............................................................270 Brake Light Circuit..............................................................................272 Parking Brake Circuit............................................................................274 Accessory Circuit................................................................................279 Work Light Circuit...............................................................................280 Wiper Circuit....................................................................................282 Cab Light Circuit................................................................................288 SECTION 3 COMPONENT OPERATION............................................................................293 Group 1 Pump Device..................................................................................295 Outline..........................................................................................295 Main Pump........................................................................................296 Regulator........................................................................................298 Priority Valve...................................................................................314 Steering Main Relief Valve.......................................................................315 Pilot Pump.......................................................................................316 Pump Delivery Pressure Sensor....................................................................316 Group 2 Control Valve................................................................................317 Outline..........................................................................................317 Hydraulic Circuit................................................................................324 Main Relief Valve................................................................................328 Overload Relief Valve (with Make-Up Function)....................................................330 Anti-Drift Valve.................................................................................334 Flow Rate Control Valve..........................................................................338 Ride Control.....................................................................................342 Ride Control Accumulator.........................................................................346 Drain Plug.......................................................................................347 Pump Control Valve...............................................................................348 Group 3 Cooling Fan System...........................................................................351 Fan Pump.........................................................................................351 Fan Motor........................................................................................352 Fan Valve........................................................................................353 Group 4 Steering Pilot Valve.........................................................................361 Outline..........................................................................................361 Structure........................................................................................362 Operation........................................................................................363 Group 5 Steering Valve...............................................................................367 Outline..........................................................................................367 Operation........................................................................................370 Steering Overload Relief Valve...................................................................372 Group 6 Pilot Valve..................................................................................375 Outline (Fingertip Control Type Pilot Valve for Front Attachment)................................375 Operation........................................................................................376 Electromagnetic Detent...........................................................................380 Outline (Joystick Type Pilot Valve for Front Attachment).........................................381 Operation........................................................................................383 Electromagnetic Detent...........................................................................390 Group 7 Charging Circuit.............................................................................391 Outline..........................................................................................391 Brake Charge Valve...............................................................................392 Manifold Valve...................................................................................397 Pilot Relief Valve...............................................................................398 Torque Control Solenoid Valve / Front Control Lever Lock Solenoid Valve..........................399 Service Brake Accumulator........................................................................400 Pilot Accumulator................................................................................401 Group 8 Drive Unit...................................................................................403 Outline..........................................................................................403 Torque Converter.................................................................................408 Transmission.....................................................................................410 Operation of Transmission........................................................................412 Transmission Control Valve.......................................................................418 Drive Unit Circuit...............................................................................420 Group 9 Axle.........................................................................................421 Outline..........................................................................................421 Differential.....................................................................................422 Torque Proportioning Differential (TPD)..........................................................426 Limited Slip Differential (LSD) (Optional).......................................................428 Service Brake....................................................................................430 Final Drive / Axle Shaft.........................................................................432 Group 10 Brake Valve.................................................................................433 Outline..........................................................................................433 Operation........................................................................................436 Group 11 Others......................................................................................443 Solenoid Valve...................................................................................443 Flow Regulator Valve.............................................................................445 Propeller Shaft..................................................................................446 Torque Converter Cooler Check Valve..............................................................447 Parking Brake Solenoid Valve.....................................................................448 Emergency Steering Check Block...................................................................450 Emergency Steering Pump..........................................................................451 SERVICE MANUAL REVISION REQUEST FORM.....................................................................455
Please Note:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
Bodhi Conor –
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