Technical Manual Hitachi ZW330-6 Wheel Loader | TONGE40-EN-00

Technical Manual Hitachi ZW330-6 Wheel Loader TONGE40-EN-00 (Preview)

TONGE40-EN-00
CONTENTS
INTRODUCTION
SYMBOL AND ABBREVIATION
SECTION AND GROUP CONTENTS
SECTION 1 GENERAL
Group 1 Specifications
Specifications
Weight of Main Components
Group 2 Component Layout
Main Component
Electric Component Layout (Overview)
Electrical System (Cab)
Controller and Relays
Right Console
Monitor and Switches
Monitor Panel
Electrical System (Relays)
Electrical System (Around Hydraulic Oil Tank)
Electrical System (Around Fuel Tank)
Engine
Aftertreatment Device
Air Cleaner
Hydraulic Pump
Main Pump
Accessory Pump
Drive Unit
Control Valve
Brake Charge Valve/Combination Valve
Flow Regulator Valve
Brake Valve
Ride Control Valve
Emergency Steering Group
Steering Valve
Emergency Steering Pump
Joystick Steering System (Option)
Joystick Steering Valve
2-Spool Solenoid Valve Unit and Pressure Sensor
Control Unit (JSS)
Operator’s Seat (JSS)
DEF Tank and DEF Supply Module
Group 3 Component Specifications
Engine
Engine Accessories
Hydraulic Component
Electrical Component
SECTION 2 SYSTEM
Group 1 Controller
Outline
CAN Circuit
Group 2 Control System
Outline
Engine Control
Accelerator Pedal Control
Auto-Warm Up Control
Engine Load Idle Speed Control
Forward/Reverse Idle Speed Limiter
Forward/Reverse Operation Engine Speed Limiter
Load-free Engine High Idle Limiter
Engine Speed Regulator For Digging
Speed Limit Control with Power Mode OFF
Driving Load Idle Speed Control
Aftertreatment Device Manual Regeneration Control
Pump Control
Base Torque Control
Torque Decrease Control While Dumping Bucket
Lift Arm Speed Multiplication Control
Transmission Control
Neutral Control
Forward/Reverse Lever Priority Control
Manual Speed Shift Control
Automatic Speed Shift Control
Downshift Control
Speed Shift Delay Control
Declutch Control
Shift Holding Control
Lock Up Control
Fan Control, Valve Control
Fan Speed Control
Fan Reverse Rotation Control
Lift Arm and Bucket Selection Circuit Control
Ride Control
JSS Control System (Option)
JSS: Joystick Steering Control
Joystick Steering Lever Control
Forward/Reverse Switch Control
JSS Alarm Control
Other Controls
Transmission Alarm Control
Parking Brake Operation Indicator Control
Low Brake Oil Pressure Indicator Control
Low Steering Oil Pressure Indicator Control
Overrun Alarm Control
Lift Arm Auto Leveler Height Kickout Control
Lift Arm Auto Leveler Lower Kickout Control
Quick Power Mode Control
Auto Shut-Down Control
Emergency Steering Control
Combined Electric and Hydraulic Control Circuit
Bucket Auto Leveler Control
Lift Arm Float Control
Group 3 Engine System
Outline
Engine Sensors
Fuel Injection Control
Operation of Fuel Injection
Fuel Injection Volume Control
Fuel Injection Pressure Control
Fuel Injection Timing Control
Fuel Injection Rate and Frequency Control
EGR Control
Preheating Control
Variable Turbocharger Control
Urea SCR System
DEF Dosing Control
DEF Priming Control
DEF Defrosting/Heat-Retention Control
DEF Purging Control
Engine Output Restriction (Inducement)
Insufficient DEF Level
Malfunction of Urea SCR System
Aftertreatment Device
Outline
Operation
Aftertreatment Device Regeneration Control
Aftertreatment Device Regeneration Operation
Auto Regeneration (Automatic Cleaning)
Manual Regeneration
Regeneration Inhibit Setting
Engine Output Restriction (Inducement) Due To Aftertreatment Device Regeneration Inhibit
Group 4 Hydraulic System
Outline
Pilot Circuit
Brake Priority Circuit
Service Brake Circuit
Parking Brake Circuit
Lift Arm / Bucket Operation Control Circuit
Fan Circuit
Main Circuit
Steering Priority Circuit
Steering Operation Control Circuit
Neutral Circuit
Flow Rate Control Circuit
Relief Circuit
Other Circuits
Pump Control Circuit
Parallel Circuit Flow Rate Control
Single Operation Circuit
Combined Operation Circuit
Ride Control Circuit
Emergency Steering Circuit
JSS Hydraulic System (Option)
Joystick Steering Operation Control Circuit
Group 5 Electrical System
Outline
Main Circuit
Electric Power Circuit (Key Switch: OFF)
CAN Circuit
Accessory Circuit (Key Switch: ACC)
Starting Circuit (Key Switch: START)
Neutral Engine Start Circuit
Charging Circuit (Key Switch: ON)
Alternator Operation
Regulator Operation
Surge Voltage Prevention Circuit
Pilot Shut-Off Circuit (Key Switch: ON)
Auto Shut-Down Circuit
Engine Stop Circuit
Monitor Circuit
Air Conditioner Circuit
Steering Column Monitor Circuit
Head Light Circuit
Clearance Light, License Light, Tail Light Circuit (Light Switch: Clearance Light Position)
Head Light Circuit
High-Beam Circuit
Hazard Light Circuit (Key Switch: OFF)
Turn Signal Light Circuit
Horn Circuit (Key Switch: OFF)
Reverse Light/Buzzer Circuit
Brake Light Circuit
Parking Brake Circuit
Accessory Circuit
Work Light Circuit
Wiper Circuit
Front Wiper Circuit
Rear Wiper Circuit
Washer Circuit
Cab Dome Light Circuit
JSS Electrical System (Option)
Outline
Joystick Steering Electrical Circuit
Forward/Reverse Switch Electrical Circuit
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Hydraulic Pump Outline
Main Hydraulic Pump
Main Pump Hydraulic Diagram
Main Pump Cross Section
Increasing and Decreasing Flow Rate
Main Pump Regulator
Regulator Control Function
Accessory Pump
Accessory Pump Structure
Pump Operation
Pump Delivery Pressure Sensor
Pressure Sensor Specifications (Pump Delivery Pressure)
Group 2 Control Valve
Outline
Multiple Control Valve Location
Multiple Control Valve Hydraulic Circuit
Control Valve Overview
Control Valve Cross Section Views
Hydraulic Circuit
Main Circuit
Pilot Operation Control Circuit
Main Relief Valve
Relief Operation
Overload Relief Valve (with Make-Up Function)
Relief Operation
Overload Relief Valve Make-Up Operation
Bleed-Off Compensation Spool
Bucket Spool
Bucket Roll Back Operation
Bucket Dump Operation
Lift Arm Spool
Lift Arm Raise Operation
Lift Arm Down Operation
Lift Arm Float Operation
Lift Arm Flow Rate Control Valve
Flow Rate Control Operation
Ride Control
Ride Control Selector Valve
Pump Control Valve (Negative Control Relief Valve)
Group 3 Cooling Fan System
Fan Pump (Accessory Pump)
Fan Motor
Fan Motor Specifications
Fan Valve
Pressure Sensor (Fan Circuit Pressure)
Operation
Reverse Rotation
Fan Speed Control
Make-Up Function
Group 4 Steering Pilot Valve
Outline
Unit Location
Overview
Structure
Operation
Steering (Left)
Steering (Right)
Neutral
Group 5 Steering Valve
Outline
Steering Valve Main Component
Steering Valve Cross Section View
Operation
Neutral Position
Steering (Left Turn Position)
Steering Valve Meter-In Compensator
Steering Main Relief Valve
Normal Operation
Relief Operation
Steering Overload Relief Valve
Overload Relief Function
Makeup Function
Overload Relief Valve Operation
Make-Up Valve Operation
Steering Spool Variable Orifice
Steering Pilot Circuit and Its Operation
Flow Amplifier Notch and Pilot Orifice
Group 6 Pilot Valve

Outline
Operation
Electromagnetic Detent

Outline
Operation
Electromagnetic Detent
Group 7 Charging Circuit
Outline
Brake Charge Valve
Operation
Pressure Sensor (Brake Pressure Alarm) (17)
Combination Valve (Manifold Valve)
Reducing Valve
Pressure Sensor Specifications (Loading Pilot Pressure)
Combination Valve (Parallel / Tandem Switching Solenoid Valve)
Proportional Solenoid Valve
Service Brake Accumulator
Group 8 Drive Unit
Outline
Main Component
Transmission Pressure Sensor Port
Front View of Transmission
Cross Section View of Transmission
Number of Gear Teeth
Torque Converter (Lock-Up)
Lock-Up Clutch Function
Transmission
Operation of Transmission
Transmission Control Valve
Transmission Control Valve Assembly
Exploded View of Transmission Control Valve
Lock-Up Clutch Control Valve
Transmission Regulator Valve
Transmission Regulator Valve Operation
Safety Valve
Safety Valve Function
Safety Valve Operation
Torque Converter Safety Valve
Torque Converter Safety Valve Function
Torque Converter Safety Valve Operation
Parking Brake
Parking Brake Operation
Parking Brake Manual Release
Drive Unit Circuit
Lubrication Lines
Group 9 Axle
Outline
Differential
Purpose of Differential
Principle of Differential
Operation of Differential
Torque Proportioning Differential (TPD)
Limited Slip Differential (LSD)
Service Brake
Final Drive Planetary / Axle Shaft
Group 10 Brake Valve
Outline
Brake Valve Component Layout
Operation
Neutral
During Metering or Decompressing
Full Stroke
Pressure Switch (for Stop Lamp)
Pressure Sensor (for Declutch)
Group 11 DEF Supply System
System Overview
DEF
DEF Tank
Hose Urea
DEF Sensor Unit
DEF Sensor Head Unit
Sensor Harness Connector
Level Sensor
Quality Sensor
Temperature Sensor
Coolant Heater Tube
DEF Suction Tube (7) with Suction Filter
DEF Supply Module
Harness Connector (5) Pin Assignment
Supply Module Main Filter
Coolant Line
Group 12 Others
Steering Accumulator
Parking Brake Accumulator
Propeller Shaft
1st Propeller Shaft
2nd Propeller Shaft
3rd Propeller Shaft
Flow Regulator Valve
Ride Control Valve
Ride Control Circuit Diagram
Ride Control Operation
Ride Control Accumulator
Priority Hammer Valve
Emergency Steering Pump
Axle Oil Cooler (Option)
Axle Oil Cooler Hydraulic System
Axle Oil Cooler Hydraulic Circuit Diagram
Axle Oil Cooler Major Components
Oil Cooler Fan
Oil Filter Assembly
Oil Pump Assembly
Axle Oil Cooler Electrical System
SERVICE MANUAL REVISION REQUEST FORM