Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-00)
File Details:
Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-00)
- Manual Language:English
- Pages: 507
- Size: 16.2 MB
- Downloadable:Yes
- Format:PDF
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Description:
Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-00)
To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
The machine specification and description according to destination may be explained on this manual.
Be sure to thoroughly read this manual for correct product information and service procedures.
If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
Additional References
Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.
Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.
Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.
Table Of Contents:
Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-00)
TONEM50-EN-00.................................................................... 1 CONTENTS..................................................................... 3 INTRODUCTION................................................................. 9 To The Reader............................................................ 9 Additional References.................................................... 9 Manual Composition....................................................... 9 Page Number.............................................................. 9 Trademark................................................................ 9 Safety Alert Symbol and Headline Notations............................... 10 Units Used............................................................... 10 SYMBOL AND ABBREVIATION...................................................... 11 SECTION AND GROUPCONTENTS.................................................... 13 SECTION 1 GENERAL............................................................ 15 Group 1 Specifications................................................... 17 Specifications....................................................... 17 Group 2 Component Layout................................................. 19 Main Component (Overview)............................................ 19 Main Component....................................................... 20 Electrical System (Overview)......................................... 22 Air Cleaner and Radiator Assembly.................................... 23 Battery Box.......................................................... 25 Hydraulic Oil Tank................................................... 26 Fuel Tank............................................................ 27 Drive Unit........................................................... 28 Front Axle........................................................... 29 Cab.................................................................. 30 Engine............................................................... 36 Aftertreatment Device................................................ 37 Fan Valve............................................................ 38 Pump Device.......................................................... 39 Multiple Control Valve............................................... 39 Manifold Valve....................................................... 40 Parking Brake Solenoid Valve......................................... 40 Brake Charge Valve................................................... 40 2-Spool Solenoid Valve Unit.......................................... 40 Emergency Steering Block............................................. 41 Emergency Steering Pump.............................................. 41 Flow Regulator Valve................................................. 41 DEF Tank............................................................. 42 DEF Supply Module.................................................... 42 Group 3 Component Specifications......................................... 43 Engine............................................................... 43 Engine Accessories................................................... 47 Hydraulic Component.................................................. 48 Electrical Component................................................. 54 SECTION 2 SYSTEM............................................................. 57 Group 1 Controller....................................................... 59 Outline.............................................................. 59 CAN Circuit.......................................................... 60 Group 2 Control System................................................... 63 Outline.............................................................. 63 Engine Control (ECM)................................................. 66 Pump Control......................................................... 99 Transmission Control (TCU)...........................................104 Fan Control, Valve Control...........................................123 Other Controls.......................................................133 Control by Electrical and Hydraulic CombinedCircuit..................157 Group 3 Engine System....................................................163 Outline..............................................................163 ECM System...........................................................164 Fuel Injection Control...............................................166 Fuel Injection Volume Correction Control.............................174 EGR Control..........................................................176 Preheating Control...................................................178 Variable Turbocharger Control........................................179 Alarm Control........................................................180 Urea SCR System......................................................181 Engine Output Restriction Control(INDUCEMENT)........................192 Aftertreatment Device................................................198 Aftertreatment Device Regeneration Control...........................200 Group 4 Hydraulic System.................................................203 Outline..............................................................203 Pilot Circuit........................................................204 Main Circuit.........................................................236 Steering Control Circuit.............................................238 Front Attachment Control Circuit.....................................242 Fan Circuit..........................................................250 Emergency Steering Circuit (Option)..................................252 Group 5 Electrical System................................................255 Outline..............................................................255 Main Circuit.........................................................256 Electric Power Circuit (Key Switch: OFF).............................258 CAN Circuit..........................................................260 Accessory Circuit (Key Switch: ACC)..................................262 Starting Circuit (Key Switch: START).................................264 Neutral Engine Start Circuit.........................................266 Charging Circuit (Key Switch: ON)....................................268 Surge Voltage Prevention Circuit.....................................272 Pilot Shut-Off Circuit (Key Switch: ON)..............................274 Auto Idling Stop Circuit.............................................276 Engine Stop Circuit..................................................278 Monitor Circuit......................................................281 Air Conditioner Circuit..............................................282 Steering Column Monitor Circuit......................................285 Head Light Circuit...................................................286 Hazard Light Circuit (Key Switch: OFF)...............................292 Turn Signal Light Circuit............................................294 Horn Circuit (Key Switch: OFF).......................................296 Reverse Light/Buzzer Circuit.........................................298 Brake Light Circuit..................................................300 Parking Brake Circuit................................................302 Accessory Circuit....................................................307 Work Light Circuit...................................................308 Wiper Circuit........................................................310 Cab Dome Light Circuit...............................................316 SECTION 3 COMPONENT OPERATION................................................321 Group 1 Pump Device......................................................323 Hydraulic Pump Outline...............................................323 Main Hydraulic Pump..................................................324 Regulator............................................................326 Steering Priority Valve..............................................342 Steering Main Relief Valve...........................................343 Pilot Pump...........................................................344 Pump Delivery Pressure Sensor........................................344 Group 2 Control Valve....................................................345 Outline..............................................................345 Hydraulic Circuit....................................................350 Main Relief Valve....................................................356 Overload Relief Valve (with Make-UpFunction).........................358 Anti-Drift Valve.....................................................362 Lift Arm Flow Rate Control Valve.....................................366 Charge-Cut Valve in Ride Control Spool...............................370 Drain Plug...........................................................374 Pump Flow Rate Control Valve.........................................376 Group 3 Cooling Fan System...............................................379 Pilot Pump...........................................................379 Fan Motor............................................................380 Fan Control Valve....................................................381 Group 4 Steering Pilot Valve.............................................389 Outline..............................................................389 Structure............................................................390 Operation............................................................391 Group 5 Steering Valve...................................................395 Outline..............................................................395 Operation............................................................398 Steering Overload Relief Valve.......................................400 Group 6 Pilot Valve......................................................403 Outline (Fingertip Control Type Pilot Valve for Front Attachment)....403 Operation............................................................404 Electromagnetic Detent...............................................408 Outline (Joystick Type Pilot Valve for Front Attachment).............410 Operation............................................................411 Electromagnetic Detent...............................................418 Group 7 Brake Charge Valve / Manifold Valve..............................419 Outline..............................................................419 Brake Charge Valve...................................................420 Manifold Valve.......................................................425 Pilot Relief Valve...................................................426 Torque Control Solenoid Valve........................................427 Control Lever Lock Solenoid Valve....................................429 Service Brake Accumulator............................................430 Pilot Accumulator....................................................431 Group 8 Drive Unit.......................................................433 Outline..............................................................433 Torque Converter.....................................................438 Transmission.........................................................442 Operation of Transmission............................................444 Transmission Control Valve...........................................460 Drive Unit Circuit...................................................462 Parking Brake Manual Release.........................................463 Group 9 Axle.............................................................465 Outline..............................................................465 Differential.........................................................466 Torque Proportioning Differential (TPD)..............................470 Limited Slip Differential (LSD) (Option).............................472 Service Brake........................................................474 Final Drive Planetary / Axle Shaft...................................476 Group 10 Brake Valve.....................................................477 Outline..............................................................477 Operation............................................................480 Group 11 Others..........................................................487 Propeller Shaft......................................................487 2-Spool Solenoid Valve Unit..........................................488 Parking Brake Solenoid Valve Unit....................................490 Parking Brake Solenoid Valve.........................................492 Parking Brake Accumulator............................................494 Flow Regulator Valve.................................................495 Steering Accumulator.................................................498 Ride Control Accumulator (Option)....................................498 Torque Converter Cooler Check Valve..................................499 Stop Valve...........................................................500 Pilot Oil Filter.....................................................502 Emergency Steering Check Block (Option)..............................503 Emergency Steering Pump (Option).....................................504 SERVICE MANUAL REVISION REQUEST FORM.........................................507
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