Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-01)
File Details:
Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-01)
- Manual Language:English
- Pages: 545
- Size: 25.5 MB
- Downloadable:Yes
- Format:PDF
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Description:
Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-01)
To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
The machine specification and description according to destination may be explained on this manual.
Be sure to thoroughly read this manual for correct product information and service procedures.
If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
Additional References
Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.
Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.
Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.
Table Of Contents:
Hitachi ZW250-6 Wheel Loader Operational Principle Technical Manual (TONEM50-EN-01)
TONEM50-EN-01................................................................ 1 CONTENTS..................................................................... 3 INTRODUCTION................................................................. 9 SYMBOL AND ABBREVIATION...................................................... 11 SECTION AND GROUP CONTENTS................................................... 13 SECTION 1 GENERAL............................................................ 15 Group 1 Specifications................................................... 17 Specifications....................................................... 17 Weight of Main Components............................................ 18 Group 2 Component Layout................................................. 21 Main Component (Overview)............................................ 21 Main Component....................................................... 22 Electrical System (Overview)......................................... 24 Air Cleaner / Radiator Assembly...................................... 25 Battery Box.......................................................... 27 Hydraulic Oil Tank................................................... 28 Fuel Tank............................................................ 29 Drive Unit........................................................... 30 Front Axle........................................................... 31 Cab.................................................................. 32 Engine............................................................... 39 Aftertreatment Device................................................ 40 Fan Valve............................................................ 41 Pump Device.......................................................... 42 Multiple Control Valve............................................... 42 Manifold Valve....................................................... 43 Parking Brake Solenoid Valve......................................... 43 Brake Charge Valve................................................... 43 2-Spool Solenoid Valve Unit.......................................... 43 Steering Valve Block................................................. 44 Emergency Steering Pump.............................................. 44 Flow Regulator Valve................................................. 44 DEF Tank............................................................. 45 DEF Supply Module.................................................... 45 Joystick Steering Hydraulic Component Layout......................... 46 Joystick Steering Cab Components..................................... 48 Group 3 Component Specifications......................................... 51 Engine............................................................... 51 Engine Accessories................................................... 55 Hydraulic Component.................................................. 56 Electrical Component................................................. 62 SECTION 2 SYSTEM............................................................. 65 Group 1 Controller....................................................... 67 Outline.............................................................. 67 CAN Circuit.......................................................... 68 Group 2 Control System................................................... 71 Outline.............................................................. 71 Engine Control (ECM)................................................. 76 Pump Control.........................................................107 Transmission Control (TCU)...........................................112 Fan Control, Valve Control...........................................131 Other Controls.......................................................141 Control by Electrical and Hydraulic Combined Circuit.................165 JSS Control System...................................................171 Group 3 Engine System....................................................179 Outline..............................................................179 ECM System...........................................................180 Fuel Injection Control...............................................182 Fuel Injection Volume Correction Control.............................190 EGR Control..........................................................192 Preheating Control...................................................194 Variable Turbocharger Control........................................195 Alarm Control........................................................196 Urea SCR System......................................................197 Engine Output Restriction Control (INDUCEMENT).......................208 Aftertreatment Device................................................214 Aftertreatment Device Regeneration Control...........................216 Group 4 Hydraulic System.................................................219 Outline..............................................................219 Pilot Circuit........................................................220 Main Circuit.........................................................252 Steering Control Circuit.............................................254 Front Attachment Control Circuit.....................................258 Fan Circuit..........................................................266 Emergency (Secondary) Steering Circuit...............................268 Joystick Steering Hydraulic System...................................271 Group 5 Electrical System................................................277 Outline..............................................................277 Main Circuit.........................................................278 Electric Power Circuit (Key Switch: OFF).............................280 CAN Circuit..........................................................282 Accessory Circuit (Key Switch: ACC)..................................284 Starting Circuit (Key Switch: START).................................286 Neutral Engine Start Circuit.........................................288 Charging Circuit (Key Switch: ON)....................................290 Surge Voltage Prevention Circuit.....................................294 Pilot Shut-Off Circuit (Key Switch: ON)..............................296 Auto Shut-Down (Idling Stop) Circuit.................................298 Engine Stop Circuit..................................................300 Monitor Circuit......................................................303 Steering Column Monitor Circuit......................................307 Head Light Circuit...................................................308 Hazard Light Circuit (Key Switch: OFF)...............................314 Turn Signal Light Circuit............................................316 Horn Circuit (Key Switch: OFF).......................................318 Reverse Light/Buzzer Circuit.........................................320 Brake Light Circuit..................................................322 Parking Brake Circuit................................................324 Accessory Circuit....................................................329 Work Light Circuit...................................................330 Wiper Circuit........................................................332 Cab Dome Light Circuit...............................................338 JSS Electrical System................................................341 Outline..............................................................342 Joystick Steering Electrical Circuit.................................346 Forward/Reverse Switch Electrical Circuit............................348 SECTION 3 COMPONENT OPERATION................................................353 Group 1 Pump Device......................................................355 Hydraulic Pump Outline...............................................355 Main Hydraulic Pump..................................................356 Regulator............................................................358 Steering Priority Valve..............................................374 Steering Main Relief Valve...........................................375 Pilot Pump...........................................................376 Pump Delivery Pressure Sensor........................................376 Group 2 Control Valve....................................................377 Outline..............................................................377 Hydraulic Circuit....................................................382 Main Relief Valve....................................................388 Overload Relief Valve (with Make-Up Function)........................390 Anti-Drift Valve.....................................................394 Lift Arm Flow Rate Control Valve.....................................398 Charge-Cut Valve in Ride Control Spool...............................402 Drain Plug...........................................................406 Pump Flow Rate Control Valve.........................................408 Group 3 Cooling Fan System...............................................411 Fan Pump.............................................................411 Fan Motor............................................................412 Fan Control Valve....................................................413 Group 4 Steering Pilot Valve.............................................421 Outline..............................................................421 Structure............................................................422 Operation............................................................423 Group 5 Steering Valve...................................................427 Outline..............................................................427 Operation............................................................430 Steering Overload Relief Valve.......................................432 Outline (Fingertip Control Type Pilot Valve for Front Attachment)....435 Group 6 Pilot Valve......................................................436 Operation............................................................436 Electromagnetic Detent...............................................440 Outline (Joystick Type Pilot Valve for Front Attachment).............442 Operation............................................................443 Electromagnetic Detent...............................................450 Group 7 Brake Charge Valve / Manifold Valve..............................451 Outline..............................................................451 Brake Charge Valve...................................................452 Manifold Valve.......................................................457 Pilot Relief Valve...................................................458 Torque Control Solenoid Valve........................................459 Control Lever Lock Solenoid Valve....................................461 Service Brake Accumulator............................................462 Pilot Accumulator....................................................463 Group 8 Drive Unit.......................................................465 Outline..............................................................465 Torque Converter.....................................................470 Transmission.........................................................474 Operation of Transmission............................................476 Transmission Control Valve...........................................492 Drive Unit Circuit...................................................494 Parking Brake Manual Release.........................................495 Group 9 Axle.............................................................497 Outline..............................................................497 Differential.........................................................498 Torque Proportioning Differential (TPD)..............................502 Limited Slip Differential (LSD) (Option).............................504 Service Brake........................................................506 Final Drive Planetary / Axle Shaft...................................508 Group 10 Brake Valve.....................................................509 Outline..............................................................509 Operation............................................................512 Group 11 Others..........................................................519 Propeller Shaft......................................................519 2-Spool Solenoid Valve Unit..........................................520 Parking Brake Solenoid Valve Unit....................................522 Parking Brake Solenoid Valve.........................................524 Parking Brake Accumulator............................................526 Flow Regulator Valve.................................................527 Steering Accumulator.................................................530 Ride Control Accumulator.............................................530 Torque Converter Cooler Check Valve..................................531 Stop Valve...........................................................532 Pilot Oil Filter.....................................................534 Emergency (Secondary) Steering Check Block...........................535 Emergency (Secondary) Steering Pump..................................536 Joystick Steering Control Valve......................................538 SERVICE MANUAL REVISION REQUEST FORM.........................................545
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