Technical Manual Hitachi ZW330 Wheel Loader | TO92C1-E-01

Technical Manual Hitachi ZW330 Wheel Loader TO92C1-E-01 (Preview)

TO92C1-E-01
Foreword
Safety Symbols
CONTENTS
General Information
How to Use Manual
Safety precautions
Symbols
Outline
Layout of main components
Inspection and maintenance table
Recommended Lubricants
Coolant
Lubrication chart
Weight of main components
Bolt tightening torque
Hose band tightening torque
Liquid gasket and screw lock agent
How to wind a seal tape
Cautions regarding welding repair service
Measurement for Performance Check
Cautions on Safety
Standard Measurement Values for Performance Check
Function & Structure Chassis Group
Front Chassis
Loading linkage
Loading linkage pin
Rear Chassis
Fuel tank
Floor board mount
Center Pin
Upper center pin
Lower center pin
Dust seal
Check & Adjustment Chassis Group
Linkage Pin
Liner
Center Pin
Adjusting shim
Installing bearing cover
Installing bearing outer ring
Function & Structure Power Group
Power Line
Engine / Transmission
Engine / transmission mount
Radiator
Radiator mount
Torque converter oil cooler
Propeller Shaft
Second propeller shaft assembly
Third propeller shaft assembly
Axle Assembly
Axle Support
Torque Proportional Differential Gear (TPD)
Function of T.P.D
Operation of T.P.D
Limited Slip Differential (option)
LSD structure
LSD function
LSD operation
Check & Adjustment Power Group
Engine
Measuring engine speed
Measuring engine oil pressure
Propeller Shaft
Propeller shaft phase
Second propeller shaft alignment
Propeller shaft tightening torque
Axle
Axle nut tightening procedure
Differential gear adjustment procedure
Function & Structure Torque Converter and Transmission Group
Torque Converter
Torque converter structure
Power flow path
Torque multiplication
Torque Converter (Lock-up) (Option)
Lock-up clutch structure
Lock-up clutch function (only forward)
Torque Converter Gear Pump
Gear pump specifications
Transmission
Clutch combination
Shift lever position
Downshift button operation
Gear train and number of teeth
Clutch specifications
Clutch Pack
Forward and 3rd speed clutches
Reverse and 2nd speed clutches
1st speed clutch
4th speed clutch
Power Flow Path in the Transmission
Forward
Reverse
Hydraulic System Diagram
Hydraulic Circuit Diagram
Oil Flow
Oil flow in the torque converter line
Oil flow to the clutch
T/C and T/M Oil Circulation
Control Valve
System diagram
Modulation Mechanism
Clutch control oil pressure curve
Traveling at forward 1st speed
Changing from forward 1st speed to reverse 1st speed
Trimmer engagement
Clutch engagement starting
Clutch Solenoid Valve
For forward/reverse and speed clutches
For trimmer
Lock-up clutch solenoid valve (option)
Check & Adjustment Torque Converter and Transmission Group
Clutch Oil Pressure
Measuring clutch oil pressure
Clutch oil pressure standard value
Function & Structure Hydraulic Group
Flushing Hydraulic Circuit
Purpose of flushing
Cautions on Hydraulic Parts Replacement
Hydraulic Circuit Symbols
Hydraulic lines
Pumps & motors
Cylinders
Operation methods
Pressure control valve
Flow control valve
Directional control valve
Check valve
Miscellaneous hydraulic symbols
Hydraulic System Operation
Hydraulic system operation outline
Layout of Hydraulic Units
Hydraulic Tank
Hydraulic Tank (S/N 9001~9100)
Hydraulic tank breather valve
(tank cap) (S/N 9001~9100)
Hydraulic tank (S/N 9101~)
Hydraulic tank specifications
Hydraulic oil level check
Hydraulic Pump
Main pump
Steering pump
Hydraulic pump principle
Hydraulic pump wear plate
Hydraulic pump bushing lubrication
Hydraulic Cylinder
Boom cylinder
Bucket cylinder
Steering cylinder
Hydraulic cylinder specifications
Loading System
Reducing Valve (for Pilot Pressure)
Pilot valve (S/N 9001~9004)
Pilot valve (S/N 9005~9100)
Pilot valve (S/N 9101~)
Multiple Control Valve (KML35A/2T203)
Multiple control valve specifications
Multiple control valve main relief valve
Multiple control valve overload relief valve (with make-up function)
Multiple control valve make-up valve
Multiple control valve bucket spool
Multiple control valve boom spool
Adapter (Orifice)
Ride Control (OPT)
Ride control hydraulic circuit
Ride control function
Ride control operation
Ride control valve assembly
Accumulator (for ride control)
Steering System
Orbitrol®
Orbitrol® structure
Orbitrol® specifications
Orbitrol® operation
Orbitrol® feed-back mechanism operation
Steering speed and flow rate control
Hydraulic pump oil amount and steering force
Orbit rotor operation principle
Steering Valve (KVS25-A3.0/20)
Steering valve operation
Steering plunger variable throttle
Steering valve flow control plunger
Steering valve main relief valve
Steering valve overload relief valve
Steering pilot circuit and its operation
Stop Valve
Stop valve function
Stop valve operation
Reducing Valve (for Orbitrol®)
Steering Line Filter
Efficient Loading System
Efficient loading system outline
Mounting of the ELS valve
Mounting of the variable kickout sensor
Efficient loading system operation
Fan Motor System
Mounting of fan motor
Fan Motor Line
Hydraulic circuit (fan motor normal rotation)
Reversing Fan Motor Line (OPT)
Reversing fan motor function
Hydraulic circuit (Reverse rotation)
Secondary Steering
Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)
Loading circuit relief valve setting pressures
Ride control circuit reducing valve setting pressures (OPT)
Steering circuit relief valve setting pressures
Hydraulic Cylinder
Cylinder natural drift
Stop Valve
Stop valve adjustment procedure
Function & Structure Brake Group
Brake System Outline
Service brake
Parking brake
Adjustment of axle internal pressure
Brake Units Layout
Unloader Valve
Unloader valve operation
Valve Unit
Accumulator
In-Line Filter
Brake Valve
Brake valve performance chart
Brake valve outline
Service Brake
Service brake operation
Service brake friction plate
Service brake steel plate
Service brake piston
Brake circuit air bleeding procedure
Parking Brake
Parking brake operation
Parking brake friction disc
Parking brake solenoid valve
Parking Brake Manual Release
Brake Circuit Check Valve
Auto Brake
Auto brake circuit
Auto brake operation set value
Solenoid valve (for Autobrake circuit)
Pressure Sensor (for stop lamp and declutch)
Pressure sensor (for stop lamp)
Pressure sensor (for Declutch)
Check & Adjustment Brake Group
Brake Circuit Oil Pressure
Unloader valve setting pressure
Brake valve oil pressure
Service Brake
Service brake performance check
Service brake friction plate wear measurement
Cautions on installing brake discs
Parking Brake
Parking brake performance check
Function & Structure Electrical Group
How to Use Electrical Wiring Diagram
Utilisation des schémas des câblages électriques (FRANÇAIS)
Verwendung des elektrischen Schaltplans (DEUTSCH)
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)
Electrical Cable Color Codes
Electrical Circuit Symbols
Sensor Mount
Fuse
Fuse box
Fusible link
Engine Start Circuit
Engine start circuit diagram
Neutral starter
Starter switch
Battery relay
Alternator I terminal wire
Diode unit
Neutral relay
Magnetic switch
Voltage relay
Power Generating/Charging Circuit
Alternator
ECM (Engine Controller)
Function of ECM
Connection diagram
Monitor lamp test
Failure diagnosis
Quantum fault code information
Accelerator pedal
Transmission Control Circuit and Monitor Circuit
Machine control unit (MCU)
Machine control unit (MCU) connection diagram
Machine control unit (MCU) function
Adjustable declutch preset switch
Monitoring system
Instrument Panel and Switch
Instrument panel
Instrument panel rear surface
Gauge circuit
Fuel level sensor
MODM
MODM function
Monitor Changeover
Information Monitor
Replacement Monitor
Fault Log Monitor
Input/Output Monitor
Parameter Setting Monitor
Specification Setting Monitor
Electrical Detent Circuit
Bucket leveler
Detent solenoid
Lift kickout & lower kickout
Sensor assy
Detent solenoid
Preset height adjustment
Diode
Diode check method
Caution for diode check method
Surge voltage and surge suppression diodes
Function & Structure Operator Station Group
Cabin
Glass
Wiper mount
Wiper motor
Operator Seat
Steering and Transmission Shift Lever
Tilt case
Column shaft
Shift lever
Air Conditioner
Air conditioner components
Denso air conditioner structure
Function of cooling mechanism
Cooling circuit
Electrical circuit
Air conditioner functions of components
Charge of refrigerant
Air conditioner troubleshooting
Check & Adjustment Operator Station Group
Air Conditioner
Adjustment of lubricating oil quantity when components of air conditioner are replaced
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch
Compressor V-belt adjustment
Parts to be replaced periodically
Function & Structure Supplement
Quick Coupler
Short Boom (OPT)
Drawing & Diagrams
Axle Assembly
Torque Converter and Transmission
Hydraulic & Brake Circuit
Brake Circuit
Electrical Wiring Diagram
(1/3)
(2/3)
(3/3)
Electrical Wiring Diagram
Way of looking at connectors
Electrical wiring diagram abbreviation chart
Electrical Connection Diagram
(1/2)
(2/2)
Electrical Wiring Diagram (CAB)
Electrical Wiring Diagram (Cabin Air Conditioner)
Electrical Circuit Diagram (Cabin Air Conditioner)
Equipment Operation Table (Cabin Air Conditioner)
Electrical Equipment Layout
Front chassis
Rear chassis
Floor board
Floor board (control box)
Outline of MODM (Machine Operation Diagnostic Module) Operation
Main Menu
Information Monitor
Replacement Monitor
Fault Log Monitor
Input/Output Monitor
Parameter Setting Monitor
Specification Setting Monitor
MODM: Input/Output Monitor – Input/Output Signal Correspondence Table
Maintenance Log
Notes