Hitachi ZW550 Wheel Loader Operational Principle Technical Manual (TO11C5-E-00)
File Details:
Hitachi ZW550 Wheel Loader Operational Principle Technical Manual (TO11C5-E-00)
- Manual Language:English
- Pages: 526
- Size: 21.0 MB
- Downloadable:Yes
- Format:PDF
Video Preview:
Image Preview:
Description:
Hitachi ZW550 Wheel Loader Operational Principle Technical Manual (TO11C5-E-00)
- 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 Technical 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 ZW550 Wheel Loader Operational Principle Technical Manual (TO11C5-E-00)
TO11C5-E-00....................................................................................... 1 Foreword.......................................................................................... 3 Safety Symbols.................................................................................... 4 CONTENTS.......................................................................................... 5 00 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................................................................................... 25 Coolant specification................................................................. 25 Recommended mixture of antifreeze..................................................... 25 Lubrication chart......................................................................... 26 Weight of main components................................................................. 27 Bolt tightening torque.................................................................... 28 Hexagon bolt.......................................................................... 28 Flanged hexagon bolt.................................................................. 31 Hose band tightening torque............................................................... 32 Liquid gasket and screw lock agent........................................................ 33 Cautions regarding parts removal...................................................... 33 Cautions regarding reassembly......................................................... 33 Screw lock agent application procedure................................................ 34 How to wind a seal tape............................................................... 34 Cautions regarding welding repair service................................................. 35 03 Measurement for Performance Check.............................................................. 37 Cautions on Safety............................................................................ 38 Standard Measurement Values for Performance Check............................................. 39 12 Function & Structure Chassis Group............................................................. 43 Front Chassis................................................................................. 44 Loading linkage........................................................................... 44 Loading linkage pin....................................................................... 46 Rear Chassis.................................................................................. 47 Fuel tank................................................................................. 47 Floor board mount......................................................................... 48 Floor board........................................................................... 48 Viscous mount......................................................................... 48 Center Pin.................................................................................... 49 Upper center pin.......................................................................... 49 Lower center pin.......................................................................... 50 Dust seal................................................................................. 51 13 Check & Adjustment Chassis Group............................................................... 53 Linkage Pin................................................................................... 54 Liner..................................................................................... 54 Bucket hinge pin section (#1)......................................................... 55 How to assemble....................................................................... 55 Bucket link pin section (#2).......................................................... 56 How to assemble....................................................................... 56 Adjustment............................................................................ 57 Center Pin.................................................................................... 58 Adjusting shim............................................................................ 58 Installing bearing cover.................................................................. 58 Installing bearing outer ring............................................................. 59 22 Function & Structure Power Group............................................................... 61 Power Line.................................................................................... 62 Engine / Transmission......................................................................... 63 Engine / transmission mount............................................................... 63 Radiator...................................................................................... 64 Radiator mount............................................................................ 65 Propeller Shaft............................................................................... 66 First propeller shaft assembly............................................................ 67 Transmission - Torque converter....................................................... 67 Second propeller shaft assembly........................................................... 68 Front differential - Transmission..................................................... 68 Third propeller shaft assembly............................................................ 69 Transmission - Rear differential...................................................... 69 Axle Assembly................................................................................. 70 Axle Support.................................................................................. 72 Differential Gear............................................................................. 74 Conventional type......................................................................... 74 Function of differential gear............................................................. 77 Power transmission.................................................................... 77 Operation of differential gear............................................................ 77 Straight.............................................................................. 77 Turn.................................................................................. 78 23 Check & Adjustment Power Group................................................................. 79 Engine........................................................................................ 80 Measuring engine speed.................................................................... 80 Measuring engine oil pressure............................................................. 80 Propeller Shaft............................................................................... 81 Propeller shaft phase..................................................................... 81 Second propeller shaft alignment.......................................................... 81 Propeller shaft tightening torque......................................................... 82 Axle.......................................................................................... 83 Axle nut tightening procedure............................................................. 83 Differential gear adjustment procedure.................................................... 84 Preload adjustment.................................................................... 85 Bearing installation.................................................................. 86 Oil seal installation................................................................. 86 Adjusting tooth contact............................................................... 87 32 Function & Structure T/C and T/M Group......................................................... 89 Torque Converter.............................................................................. 90 Torque converter structure................................................................ 91 Power flow path........................................................................... 91 Torque multiplication..................................................................... 91 Torque Converter (Lock-up) (Option)........................................................... 92 Lock-up clutch structure.................................................................. 93 Lock-up clutch function (only forward).................................................... 93 Automatic shift (with lock-up solenoid)............................................... 94 Torque Converter Gear Pump.................................................................... 95 Gear pump specifications.................................................................. 95 Transmission.................................................................................. 96 Clutch combination........................................................................ 97 Planetary gear............................................................................ 97 Shift lever position...................................................................... 97 Downshift button operation................................................................ 97 Gear train and number of teeth............................................................ 98 Clutch specifications................................................................. 98 Friction plate: mm (in)............................................................... 99 Steel plate: mm (in)..................................................................100 Clutch Pack...................................................................................102 Power Flow Path in the Transmission...........................................................103 Forward 1st speed power flow path.........................................................103 Forward 2nd speed power flow path.........................................................104 Forward 3rd speed power flow path.........................................................104 Forward 4th speed power flow path.........................................................105 Reverse 1st speed power flow path.........................................................105 Reverse 2nd speed power flow path.........................................................106 Reverse 3rd speed power flow path.........................................................106 Hydraulic System Diagram......................................................................107 Hydraulic Circuit Diagram.....................................................................108 Oil Flow......................................................................................110 Oil flow in the torque converter line.....................................................110 Oil flow in the transmission line.........................................................110 T/C and T/M Oil Circulation...................................................................112 Modulator Valve Unit..........................................................................113 Interior schematic (not exact representation).............................................115 Modulation Mechanism......................................................................116 Modulator valve function..............................................................116 Modulator valve operation.................................................................117 Control Valve Assembly........................................................................119 Clutch solenoid valve assembly............................................................121 For high, low, reverse and speed clutches.............................................123 Clutch valve assembly.....................................................................124 Accumulator assembly......................................................................125 Accumulator structure.................................................................125 Direct charge valve.......................................................................126 Lock-up clutch solenoid valve.............................................................127 33 Check & Adjustment T/C and T/M Group...........................................................129 Clutch Oil Pressure and Time Lag..............................................................130 Measuring clutch oil pressure.............................................................130 Clutch oil pressure measurement procedure.............................................131 Time lag measurement procedure........................................................132 42 Function & Structure Hydraulic Group...........................................................133 Flushing Hydraulic Circuit....................................................................134 Purpose of flushing.......................................................................134 Cautions on Hydraulic Parts Replacement.......................................................135 Hydraulic Circuit Symbols.....................................................................136 Hydraulic lines...........................................................................136 Pumps & motors............................................................................136 Cylinders.................................................................................136 Operation methods.........................................................................137 Pressure control valve....................................................................137 Flow control valve........................................................................137 Directional control valve.................................................................138 Check valve...............................................................................138 Miscellaneous hydraulic symbols...........................................................139 Hydraulic System Operation....................................................................140 Hydraulic system operation outline........................................................140 Loading system........................................................................140 Steering system.......................................................................140 Efficient loading system..............................................................141 Fan motor system......................................................................141 Ride control system (OPT).............................................................141 Layout of Hydraulic Units.....................................................................142 Hydraulic Tank................................................................................143 Hydraulic tank breather valve (tank cap)..................................................144 Hydraulic tank specifications.............................................................145 Hydraulic oil level check.................................................................146 Hydraulic Pump................................................................................147 Loading and pilot and brake pump..........................................................147 Pump specifications.......................................................................147 Steering pump.............................................................................148 Steering pump specifications..............................................................148 Hydraulic pump principle..................................................................149 Hydraulic pump wear plate.................................................................150 Hydraulic pump bushing lubrication........................................................150 Hydraulic Cylinder............................................................................151 Boom cylinder.............................................................................151 Bucket cylinder...........................................................................151 Steering cylinder.........................................................................152 Hydraulic cylinder specifications.........................................................153 Loading System................................................................................154 Reducing Valve (for Pilot Pressure)...........................................................155 Pilot Valve...................................................................................156 Pilot valve function......................................................................158 Pilot valve operation (modulated position)................................................158 Pre-detent and detent magnet solenoid.....................................................160 Multiple Control Valve (KML35A/2T103).........................................................161 Multiple control valve specifications.....................................................162 Multiple control valve main relief valve..................................................163 Main relief valve operation...........................................................163 Adjusting set pressure................................................................164 Multiple control valve overload relief valve (with make-up function)......................165 Overload relief valve operation.......................................................165 Make-up valve operation...............................................................166 Multiple control valve make-up valve......................................................166 Make-up valve operation...............................................................166 Multiple control valve bucket spool.......................................................167 Bucket spool operation................................................................167 Multiple control valve boom spool.........................................................169 Boom spool operation..................................................................169 Adapter (Orifice).............................................................................172 Ride Control (OPT)............................................................................173 Ride control hydraulic circuit............................................................173 Ride control function.................................................................173 Ride control operation....................................................................174 Preparation mode (ride control switch is OFF).........................................174 Running mode (ride control switch is ON)..............................................175 Ride control valve assembly (Reducing valve circuit)......................................176 Reducing valve........................................................................177 Check valve...........................................................................177 Solenoid valve........................................................................178 Ride control valve assembly (Accumulator circuit).........................................179 Shuttle valve.........................................................................180 Solenoid valve........................................................................180 Selector valve........................................................................181 Accumulator (for ride control)............................................................182 Accumulator function..................................................................182 Steering System...............................................................................183 Orbitrol®.....................................................................................184 Orbitrol® structure.......................................................................184 Valve part............................................................................184 Rotor part............................................................................185 Orbitrol® specifications..................................................................185 Orbitrol® operation.......................................................................186 Neutral...............................................................................186 Turn..................................................................................187 Orbitrol® feed-back mechanism operation...................................................188 Steering speed and flow rate control......................................................189 Hydraulic pump oil amount and steering force..............................................189 Orbit rotor operation principle...........................................................190 Steering Valve (KVS32-A4.0/21)................................................................191 Steering valve operation..................................................................193 Neutral position (steering spool in "Neutral")........................................193 Left turn position....................................................................194 Steering spool variable throttle..........................................................195 Steering valve flow control spool.........................................................196 Steering valve main relief valve..........................................................197 When the pressure is at the preset value or less......................................197 When the pressure exceeds the preset value............................................198 Steering valve overload relief valve......................................................199 Overload relief valve operation.......................................................200 Make-up valve operation...............................................................200 Steering pilot circuit and its operation..................................................201 Flow amplifier notch and pilot orifice................................................202 Stop Valve....................................................................................203 Stop valve function.......................................................................204 Stop valve operation......................................................................204 Reducing Valve (for Orbitrol®)................................................................205 Steering Line Filter..........................................................................206 Efficient Loading System......................................................................207 Efficient loading system outline..........................................................207 The operation condition of ELS........................................................207 Mounting of the ELS valve.................................................................208 Mounting of the variable kickout sensor...................................................209 Efficient loading system operation........................................................210 While the ELS is not operating........................................................210 While the ELS is operating............................................................210 Fan Motor System..............................................................................211 Mounting of fan motor.....................................................................211 Fan Motor Line................................................................................212 Hydraulic circuit (fan motor normal rotation).............................................214 Make-up valve.........................................................................214 Proportional relief valve (S/N 9001~9050).................................................216 Proportional relief valve operation...................................................216 Proportional relief valve (S/N 9051~).....................................................218 Reversing Fan Motor Line (OPT)................................................................223 Reversing fan motor function..............................................................223 Reversing fan motor (OPT).............................................................224 Fan motor specifications..............................................................224 Reversing fan control chart...........................................................226 Hydraulic circuit (Reverse rotation)......................................................227 Secondary Steering............................................................................228 Secondary steering circuit................................................................228 Secondary steering operation..........................................................229 Secondary steering motor and pump.....................................................230 43 Check & Adjustment Hydraulic Group.............................................................231 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)...............232 Loading circuit relief valve setting pressures............................................232 Measuring loading circuit main relief pressure........................................233 Measuring loading circuit overload relief pressure....................................235 Measuring pilot circuit reducing valve pressure.......................................236 Ride control circuit reducing valve setting pressures (OPT)...............................237 Measuring ride control circuit reducing pressure......................................238 Steering circuit relief valve setting pressures...........................................240 Measuring steering circuit main relief pressure.......................................241 Measuring steering circuit overload relief pressure...................................242 Measuring pilot circuit relief pressure (reducing pressure)...........................243 Hydraulic Cylinder............................................................................245 Cylinder natural drift....................................................................245 Stop Valve....................................................................................247 Stop valve adjustment procedure...........................................................247 52 Function & Structure Brake Group...............................................................249 Brake System Outline..........................................................................250 Service brake.............................................................................250 Parking brake.............................................................................250 Adjustment of axle internal pressure......................................................250 Brake Units Layout............................................................................251 Unloader Valve................................................................................252 Unloader valve operation..................................................................254 Valve Unit....................................................................................255 Accumulator low pressure sensor...........................................................256 Accumulator...................................................................................257 Brake Valve...................................................................................258 Brake valve performance chart.............................................................259 Brake valve outline.......................................................................260 While the valve is not operating......................................................260 Service Brake.................................................................................262 Service brake operation...................................................................262 Service brake friction disc...............................................................263 Service brake steel plate.................................................................264 Service brake piston......................................................................265 Service brake pedal stroke adjusting mechanism............................................266 Tolerance ring........................................................................267 Brake circuit air bleeding procedure......................................................268 Bleeding air from brake pipes and axle housing hubs...................................269 Bleeding air from parking brake housing...............................................269 Parking Brake.................................................................................270 Parking brake operation...................................................................273 Operation of parking brake............................................................273 Parking brake friction disc...............................................................276 Parking brake steel plate.................................................................276 Parking brake solenoid valve..............................................................277 Solenoid valve operation..............................................................277 Solenoid valve specifications.........................................................277 Parking Brake Manual Release..................................................................278 Brake Circuit Check Valve.....................................................................280 Auto Brake....................................................................................281 Auto brake circuit........................................................................281 Auto brake operation set value............................................................281 Reducing valve (for Autobrake circuit)....................................................282 Solenoid valve (for Autobrake circuit)....................................................283 Solenoid specifications...............................................................283 Pressure Sensor (for stop lamp and declutch)..................................................284 Pressure sensor (for stop lamp)...........................................................284 Pressure sensor (for Declutch)............................................................285 53 Check & Adjustment Brake Group.................................................................287 Brake Circuit Oil Pressure....................................................................288 Unloader valve setting pressure...........................................................288 Unloader valve setting pressure measurement...........................................289 Brake valve oil pressure..................................................................290 Brake valve oil pressure measurement..................................................290 Brake valve performance...............................................................291 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 62 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..............................................................................308 Engine Start Circuit..........................................................................309 Engine start circuit diagram..............................................................309 Neutral starter...........................................................................310 Shift lever neutral (N) position......................................................310 Shift lever forward/reverse (F/R) position............................................310 Starter switch............................................................................311 ECM safety features...................................................................312 Battery relay.............................................................................312 Battery relay operation...............................................................312 Alternator I terminal wire................................................................313 Diode unit................................................................................313 Neutral relay.............................................................................314 Magnetic switch...........................................................................315 Voltage relay.............................................................................316 Power Generating/Charging Circuit.............................................................317 Alternator................................................................................317 ECM (Engine Controller).......................................................................318 Function of ECM...........................................................................318 Connection diagram........................................................................318 Monitor lamp test.........................................................................319 Failure diagnosis.........................................................................320 Engine diagnostic switch (option).....................................................320 Failure diagnostic chart..............................................................321 Increment decrement switch (option)...................................................322 Quantum fault code information............................................................323 Accelerator pedal.........................................................................329 Accelerator pedal installation........................................................330 Transmission Control Circuit and Monitor Circuit..............................................331 Machine control unit (MCU)................................................................331 Connector.............................................................................332 MCU connection diagram....................................................................333 Machine control unit (MCU) function.......................................................335 Forward/reverse (F/R) shifting and speed change.......................................335 Automatic shift.......................................................................337 Automatic shift (with lock-up solenoid)...............................................338 Machine speed sensor..................................................................339 Downshift button operation............................................................340 Modulation at clutch switching........................................................341 Modulator valve operation.................................................................342 Adjustable declutch preset switch.........................................................343 Back-up alarm.........................................................................344 Parking brake.........................................................................345 Auto brake............................................................................347 Machine control unit (MCU) failure warning............................................350 Secondary steering function (OPT).....................................................351 Monitoring system.........................................................................353 Items to be monitored and operation condition.........................................353 Operation monitor lamps...................................................................355 Instrument Panel and Switch...................................................................356 Instrument panel..........................................................................356 Instrument panel rear surface.............................................................357 Gauge circuit.............................................................................358 Fuel gauge circuit........................................................................360 MODM..........................................................................................361 MODM function.............................................................................361 Monitor Changeover........................................................................361 Changing display from one function to next............................................362 Information Monitor.......................................................................364 Information monitor display...........................................................364 Unit conversion and language selection................................................367 Replacement Monitor.......................................................................368 Replacement time check................................................................368 Replacement interval set (timer reset)................................................372 Replacement interval pop-up...........................................................373 Display language......................................................................374 Fault Log Monitor.........................................................................374 Fault log history check...............................................................374 Selection of machine fault log and engine fault log...................................375 Machine fault log navigation..........................................................376 Engine fault log navigation...........................................................376 Clear fault log.......................................................................376 Clear active fault log (error pop up).................................................377 Input/Output Monitor......................................................................381 Input/Output monitor display..........................................................381 Parameter Setting Monitor.................................................................385 Parameter setting monitor display.....................................................385 Parameter change......................................................................393 Specification Setting Monitor.............................................................394 Specification setting monitor display.................................................394 All setting reset.....................................................................397 Electrical Detent Circuit.....................................................................400 Bucket leveler............................................................................400 Proximity switch......................................................................400 Detent solenoid...........................................................................401 Lift kickout & lower kickout..............................................................402 Location..............................................................................402 Lift kickout..........................................................................402 Lower kickout.........................................................................402 Sensor assy...............................................................................403 Detent solenoid...........................................................................405 Preset height adjustment..................................................................405 Diode.........................................................................................406 Diode check method........................................................................407 Caution for diode check method............................................................407 Continuity check mode.................................................................407 Diode check mode......................................................................407 Resistance check mode.................................................................408 Surge voltage and surge suppression diodes................................................409 72 Function & Structure Operator Station Group....................................................411 Cabin.........................................................................................412 Glass.....................................................................................414 1. Part number 32011-21690............................................................415 2. Part number 32011-21700............................................................415 3. Part number 32011-21500............................................................416 Wiper mount...............................................................................417 Front wiper...........................................................................417 Rear wiper............................................................................417 Wiper motor...............................................................................418 Operator Seat.................................................................................420 Steering and Transmission Shift Lever.........................................................421 Tilt case.................................................................................422 Column shaft..............................................................................423 Shift lever...............................................................................423 Air Conditioner...............................................................................424 Air conditioner components................................................................424 Air conditioner specifications (system performance)...................................424 Denso air conditioner structure...........................................................425 Cooling unit..........................................................................425 Heater and accessories................................................................427 Air distributor (hood & defroster selection box)......................................427 Air compressor (with magnetic clutch).................................................428 Condenser unit........................................................................428 Control unit..........................................................................429 Function of cooling mechanism.............................................................430 Principle of cooling..................................................................430 Refrigerant...........................................................................431 Refrigerant characteristics...........................................................432 Cooling circuit...........................................................................433 Electrical circuit........................................................................434 Control schematic drawing.............................................................434 Air conditioner functions of components...................................................435 Control panel.........................................................................435 Air conditioner unit..................................................................442 Compressor and magnetic clutch........................................................451 Condenser unit........................................................................454 Receiver dryer........................................................................456 Sight glass...........................................................................458 Pressure switches.....................................................................458 Pressure relief valve.................................................................460 Relay A...............................................................................461 Relay B...............................................................................461 Refrigerant hose......................................................................462 Charge of refrigerant.....................................................................463 Work procedure........................................................................464 Refrigerant charging tools............................................................466 Refrigerant charging procedure........................................................469 Troubleshooting using the gauge manifold..............................................475 Troubleshooting...............................................................................480 Air conditioner...........................................................................480 73 Check & Adjustment Operator Station Group......................................................489 Air Conditioner...............................................................................490 Adjustment of lubricating oil quantity when components of air conditioner are replaced....490 When the compressor is replaced.......................................................491 When the evaporator is replaced.......................................................492 When the condenser is replaced........................................................492 Adjustment of air gap (between hub and rotor) in compressor magnetic clutch...............493 Compressor V-belt adjustment..............................................................494 Belt adjustment procedure.............................................................494 Belt adjustment value.................................................................494 Parts to be replaced periodically.........................................................495 Air filters...........................................................................495 Receiver dryer........................................................................495 Function & Structure Supplement...................................................................497 Foreword......................................................................................498 01 Function & Structure Supplement............................................................497 Quick Coupler.............................................................................499 Hydraulic line and electrical circuit.................................................499 Solenoid valve........................................................................501 Solenoid valve specifications.....................................................502 Power boost circuit.......................................................................503 Multiple control valve main relief valve (MRV) (2 stage relief).......................505 Multiple control valve main relief valve(MRV) operation...........................506 Multiple control valve main relief valve(MRV) adjusting set pressure..............506 Measuring loading circuit overload reliefpressure.................................507 Adjusting overload relief pressure................................................507 Hydraulic line........................................................................508 Electrical cable......................................................................509 Electrical connection diagram.....................................................510 Short Boom (OPT)..........................................................................511 Bucket cylinder.......................................................................512 Bucket cylinder specifications....................................................512 Limited Slip Differential (LSD)...........................................................513 LSD gear structure....................................................................513 LSD function..........................................................................517 LSD operation.........................................................................517 Maintenance Log...................................................................................519 Notes.............................................................................................523
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]