Hitachi ZW550-G Wheel Loader Operational Principle Technical Manual
FILE DETAILS:
Hitachi ZW550-G Wheel Loader Operational Principle Technical Manual
Language : English
Pages : 587
Downloadable : YES
Format : PDF
Size : 28.6 MB
Part No : TONHD-E-00
DESCRIPTION:
Hitachi ZW550-G Wheel Loader Operational Principle Technical Manual
Foreword:
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. General Information Function and structure 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.
How to Use Manual:
Safety precautions :
- The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below.
- This manual is intended for properly trained and equipped service technicians.
- Any work on the machine must be performed by the trained personnel only. Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine.
- Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles. Place the machine on level and solid ground, and place chocks against the wheels to prevent movement.
- Remove the cable from the battery before starting the service work, and attach a “DO NOT OPERATE!” tag to the steering wheel. Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant pipe. Be sure to apply the articulation stopper before starting work.
- While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks. – When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate cribbing under the unit to prevent unexpected dropping.
TABLE OF CONTENTS:
Hitachi ZW550-G Wheel Loader Operational Principle Technical Manual
General Information 00-1
How to Use Manual 00-2
Safety precautions 00-2
Symbols 00-3
Outline 00-4
Layout of main components 00-4
Inspection and maintenance table 00-5
Recommended lubricants 00-8
Coolant 00-9
Lubrication chart 00-10
Weight of main components 00-11
Bolt tightening torque 00-12
Hose band tightening torque 00-16
Liquid gasket and screw lock agent 00-17
Measurement for Performance Check 03-1
Cautions on Safety 03-2
Standard Measurement Values for Performance Check 03-3
Function & Structure Chassis Group 12-1
Front Chassis 12-2
Loading linkage 12-2
Loading linkage pin 12-4
Rear Chassis 12-5
Fuel tank 12-5
Floor board mount 12-6
Center Pin 12-7
Upper center pin 12-7
Lower center pin 12-7
Dust seal 12-8
Check & Adjustment Chassis Group 13-1
Linkage Pin 13-2
Liner 13-2
Center Pin 13-6
Adjusting shim 13-6
Installing bearing cover 13-6
Installing bearing outer ring 13-6
Function & Structure Power Group 22-1
Power Line 22-2
Engine / Transmission 22-3
Engine / transmission mount 22-3
Radiator 22-4
Radiator mount 22-5
Propeller Shaft 22-6
First propeller shaft assembly 22-7
Second propeller shaft assembly 22-8
Third propeller shaft assembly 22-10
Axle Assembly 22-11
Axle Support 22-14
Differential Gear 22-20
Function of differential gear 22-24
Operation of differential gear 22-24
Check & Adjustment Power Group 23-1
Engine 23-2
Measuring engine speed 23-2
Measuring engine oil pressure 23-2
Propeller Shaft 23-3
Propeller shaft phase 23-3
Second propeller shaft alignment 23-3
Tightening torque 23-4
Axle 23-5
Axle nut tightening procedure 23-5
Function & Structure Torque Converter and Transmission Group 32-1
Torque Converter 32-2
Torque converter structure 32-3
Power flow path 32-3
Torque multiplication 32-3
Torque Converter Gear Pump 32-4
Gear pump specifications 32-4
Transmission 32-5
Clutch combination 32-6
Planetary gear 32-6
Shift lever position 32-6
Power up switch operation 32-6
Gear train and number of teeth 32-7
Clutch Pack 32-10
Power Flow Path in the Transmission 32-11
Forward 32-11
Reverse 32-14
Hydraulic System Diagram 32-16
Hydraulic Circuit Diagram 32-17
T/C and T/M Oil Circulation 32-18
Oil flow in the torque converter line 32-19
Oil flow to the clutch 32-19
Modulator Valve Unit 32-20
Interior schematic (not exact representation) 32-22
Modulation Mechanism 32-23
Modulator valve function 32-23
Modulator valve operation 32-25
Clutch Solenoid Valve 32-26
Check & Adjustment Torque Converter and Transmission Group 33-1
Clutch Oil Pressure and Time Lag 33-2
Measuring clutch oil pressure 33-2
Measuring clutch time lag 33-4
Function & Structure Hydraulic Group 42-1
Flushing Hydraulic Circuit 42-2
Purpose of flushing 42-2
Cautions on Hydraulic Parts Replacement 42-3
Hydraulic Circuit Symbols 42-4
Hydraulic lines 42-4
Pumps & motors 42-4
Cylinders 42-4
Operation methods 42-5
Pressure control valve 42-5
Flow control valve 42-5
Directional control valve 42-6
Check valve 42-6
Miscellaneous hydraulic symbols 42-7
Hydraulic System Operation 42-8
Hydraulic system operation outline 42-8
Layout of Hydraulic Units 42-10
Hydraulic Tank 42-11
Hydraulic tank specifications 42-11
Hydraulic oil level check 42-11
Hydraulic tank (S/N 0101~0200, 9001~) 42-12
Hydraulic tank (S/N 0201~) 42-14
Hydraulic Pump 42-16
Loading and pilot and brake pump 42-17
Pump specifications 42-17
Steering pump 42-18
Steering pump specifications 42-18
Hydraulic pump principle 42-19
Hydraulic pump wear plate 42-20
Hydraulic pump bushing lubrication 42-20
Hydraulic Cylinder 42-21
Boom cylinder 42-21
Bucket cylinder 42-21
Steering cylinder 42-22
Hydraulic cylinder specifications 42-22
Loading System 42-23
Reducing Valve (for Pilot Pressure) 42-24
Pilot Valve (S/N 0101~0140, 9001~9020) 42-25
Pilot valve operation 42-27
Pilot valve detent magnet solenoid 42-29
Detent adjustment procedure 42-29
Pilot valve (S/N 0141~0172, 9021~) 42-30
Pilot valve operation 42-32
Pre-detent and detent magnet solenoid 42-34
Pilot valve (S/N 0173~0176) 42-35
Pilot valve (S/N 0177~) 42-40
Multiple Control Valve (KML35A/2T103) 42-45
Multiple control valve specifications 42-46
Multiple control valve main relief valve 42-47
Multiple control valve overload relief valve 42-49
Multiple control valve bucket spool 42-52
Multiple control valve boom spool 42-54
Adapter (Orifice) 42-57
Vibration Damper (OPT) 42-58
Vibration damper operation 42-59
Vibration damper hydraulic line 42-68
Steering System 42-69
Orbitrol® 42-70
Orbitrol® structure 42-70
Orbitrol® specifications 42-71
Orbitrol® operation 42-72
Orbitrol® feed-back mechanism operation 42-74
Steering speed and flow rate control 42-75
Hydraulic pump oil amount and steering force 42-75
Orbit rotor operation principle 42-76
Steering Valve (KVS32-A40/21) 42-77
Steering valve operation 42-79
Steering spool variable throttle 42-81
Steering valve flow control spool 42-82
Steering valve main relief valve 42-83
Steering valve overload relief valve 42-85
Steering pilot circuit and its operation 42-87
Stop Valve 42-89
Stop valve function 42-91
Stop valve operation 42-92
Reducing Valve (for Orbitrol®) 42-93
Steering Line Filter 42-94
Fan Motor System 42-95
Fan Motor Line (S/N 0101~0120, 9001~9010) 42-96
Fan Motor (GM30C) 42-98
Valve Assembly (for Fan Motor) 42-99
Relief Valve (Two-step Relief) 42-100
Solenoid Valve (for Fan Speed Control) 42-103
Fan Motor Line (S/N 0121~, 9011~) 42-104
Fan Motor (GM30W) 42-106
Thermo Sensing Valve 42-107
Fan Motor Relief Valve Assembly 42-109
Emergency Steering 42-111
Emergency steering operation 42-112
Emergency steering hydraulic line 42-112
Emergency steering oil flow 42-113
Emergency steering pump 42-115
Check & Adjustment Hydraulic Group 43-1
Loading/Steering Circuit Relief Valve 43-2
Loading circuit relief valve setting pressures 43-2
Steering circuit relief valve setting pressures 43-7
Hydraulic Cylinder 43-11
Cylinder natural drift 43-11
Stop Valve 43-13
Stop valve adjustment procedure 43-13
Fan Motor Revolution 43-14
Fan maximum revolution measurement (S/N 0101~0120, 9001~9010) 43-14
Fan maximum revolution measurement (S/N 0121~, 9011~) 43-16
Function & Structure Brake Group 52-1
Brake System Outline 52-2
Service brake 52-2
Parking brake 52-2
Auto brake 52-2
Adjustment of axle internal pressure 52-2
Brake Units Layout 52-3
Unloader Valve 52-4
Unloader valve operation 52-6
Reducing valve 52-7
Valve Unit (Main Brake Manifold Block) 52-8
Brake Accumulator Line 52-9
Accumulator 52-10
In-Line Filter 52-11
Brake Valve 52-12
Brake main valve (left pedal) 52-12
Brake pilot valve (right pedal) 52-13
Brake valve performance chart 52-14
Brake valve outline 52-15
Stop Lamp Pressure Switch 52-18
Pressure switch (for stop lamp) 52-18
Pressure switch (for Declutch) 52-19
Service Brake 52-20
Service brake operation 52-20
Service brake friction plate 52-21
Service brake steel plate 52-22
Service brake piston 52-23
Service brake pedal stroke adjusting mechanism 52-24
Parking Brake 52-28
Parking brake operation 52-30
Parking brake solenoid valve 52-31
Parking Brake Manual Release 52-32
Parking Brake Spring Chamber 52-34
Brake Circuit Check Valve 52-35
Auto Brake 52-36
Auto brake operation set value 52-36
Auto brake circuit 52-36
Solenoid valve (for auto brake circuit) 52-37
Shuttle Valve 52-38
Check & Adjustment Brake Group 53-1
Brake Circuit Oil Pressure 53-2
Unloader valve setting pressure 53-2
Brake valve oil pressure 53-6
Service Brake 53-8
Service brake performance check 53-8
Service brake friction plate wear measurement 53-9
Parking Brake 53-12
Parking brake performance check 53-12
Parking brake clearance adjustment 53-14
Function & Structure Electrical Group 62-1
How to Use Electrical Wiring Diagram 62-2
Electrical Cable Color Codes 62-8
Electrical Circuit Symbols 62-9
Sensor Mount 62-10
Fuse 62-11
Fuse box 62-12
Fusible link 62-13
Engine Start Circuit 62-14
Engine start circuit diagram 62-14
Neutral starter 62-15
Starter switch 62-16
Battery relay 62-17
Alternator I terminal wire 62-17
Diode unit 62-18
Neutral relay 62-18
Magnet switch 62-19
Voltage relay 62-19
Power Generating/Charging Circuit 62-21
Alternator 62-21
ECM (Engine Controller) 62-22
Function of ECM 62-22
Connection diagram 62-22
Monitor lamp test 62-23
Failure diagnosis 62-24
Quantum fault code information 62-29
Power mode change 62-36
Accelerator pedal 62-37
Accelerator pedal 62-39
Transmission Control Circuit (S/N 0101~0153, 9001~) 62-41
Controller 62-41
Controller connection diagram 62-43
Controller function 62-44
Monitor controller 62-61
Transmission Control Circuit (S/N 0154~) 62-62
Machine control unit (MCU) 62-62
Machine control unit (MCU) connection diagram 62-64
Monitor Circuit 62-66
Monitor controller (S/N 0101~0153, 9001~) 62-69
Monitoring sensor and switch 62-71
Instrument Panel and Switch 62-72
Instrument panel 62-72
Instrument panel rear surface 62-73
Gauge circuit 62-74
Fuel gauge circuit 62-75
Tachometer circuit 62-76
Electrical Detent Circuit 62-77
Bucket leveler 62-77
Boom kick-out (option) 62-78
Detent solenoid 62-79
Diode 62-80
Diode check method 62-81
Caution for diode check method 62-81
Surge voltage and surge suppression diodes 62-83
Diagnostic System 62-84
Transmission controller 62-84
Monitor controller 62-88
Diagnostic failure history indication and deletion 62-91
Diagnostic switch 62-93
MODM (S/N 0154~) 62-94
MODM function 62-94
Monitor Changeover 62-94
MODM: input/output monitor – input/output signal correspondence table 62-101
Check & Adjustment Electrical Group 63-1
Cautions Regarding Electric Circuit Check 63-2
Disconnecting or reinstalling connector 63-2
How to attach the probes of the circuit tester 63-4
Electrical Transmission Control System Troubleshooting Flowchart 63-5
Standard troubleshooting flowchart 63-5
Transmission Controller Abnormal Operation Judgment 63-6
Transmission controller check 63-6
Transmission controller LED indicator 63-8
Electrical Circuit Check 63-10
Shift lever input electrical circuit check 63-10
Inching (Declutch) input electrical circuit check 63-12
QUAD switch input electrical circuit check 63-14
Machine speed sensor input electrical circuit check 63-15
Clutch solenoid valve output electrical circuit check 63-16
Modulator valve output electrical circuit check 63-18
Neutral relay electrical circuit check 63-20
Parking brake electrical circuit check 63-21
Auto brake electrical circuit check 63-23
Gauge circuit electrical circuit check 63-25
Fuel level gauge electrical circuit check 63-27
Bucket positioner electrical circuit check 63-29
Function & Structure Operator Station Group 72-1
Cabin 72-2
Glass 72-4
Wiper mount 72-7
Wiper motor 72-8
Operator Seat 72-10
Steering and Transmission Shift Lever 72-11
Tilt case 72-12
Column shaft 72-13
Shift lever 72-13
Air Conditioner 72-14
Air conditioner components 72-14
Air conditioner structure 72-15
Cooling mechanism 72-20
Cooling circuit 72-22
Electrical circuit 72-23
Air conditioner functions of components 72-24
Charge of refrigerant 72-51
Air conditioner troubleshooting 72-66
Check & Adjustment Operator Station Group 73-1
Air Conditioner 73-2
Adjustment of lubricating oil quantity when components of air conditioner are replaced 73-2
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch 73-5
Parts to be replaced periodically 73-6
Cross-section drawing & Diagrams 92-1
Axle Assembly 92-2
Torque Converter and Transmission 92-3
Loading/Steering Hydraulic Line (S/N 0101~0120) 92-4
Loading/Steering Hydraulic Circuit (S/N 0121~) 92-5
Loading/Steering Hydraulic Circuit (S/N 9001~9010) 92-6
Loading/Steering Hydraulic Circuit (S/N 9011~) 92-7
Brake Circuit 92-8
Electrical Wiring Diagram (1/2) (S/N 0101~0120) 92-9
Electrical Wiring Diagram (2/2) (S/N 0101~0120) 92-10
Electrical Wiring Diagram (1/2) (S/N 0121~0124) 92-11
Electrical Wiring Diagram (2/2) (S/N 0121~0124) 92-12
Electrical Wiring Diagram (1/2) (S/N 0125~0153) 92-13
Electrical Wiring Diagram (2/2) (S/N 0125~0153) 92-14
Electrical Wiring Diagram (1/3) (S/N 0154~) 92-15
Electrical Wiring Diagram (2/3) (S/N 0154~) 92-16
Electrical Wiring Diagram (3/3) (S/N 0154~) 92-17
Electrical Wiring Diagram (1/2) (S/N 9001~9010) 92-18
Electrical Wiring Diagram (2/2) (S/N 9001~9010) 92-19
Electrical Wiring Diagram (1/2) (S/N 9011~) 92-20
Electrical Wiring Diagram (2/2) (S/N 9011~) 92-21
Electrical Wiring Diagram Abbreviation Chart (S/N 0101~0153, 9001~) 92-22
Electrical Wiring Diagram Abbreviation Chart (S/N 0154~) 92-23
Electrical Wiring Diagram (CAB) 92-24
Electrical Connection Diagram (S/N 0101~0120) 92-26
Electrical Connection Diagram (S/N 0121~0124) 92-27
Electrical Connection Diagram (S/N 0125~0153) 92-28
Electrical Connection Diagram (S/N 0154~) 92-29
Electrical Connection Diagram (S/N 9001~9010) 92-30
Electrical Connection Diagram (S/N 9011~) 92-31
Electrical Equipment Layout 92-32
Electrical Circuit Diagram (Cabin Air Conditioner) 92-41
Electrical Wiring Diagram (Cabin Air Conditioner) 92-42
Equipment Operation Table (Cabin Air Conditioner) 92-43
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