Technical Manual Hitachi ZW330 Wheel Loader | TT92C1-E-00

Technical Manual Hitachi ZW330 Wheel Loader TT92C1-E-00 (Preview)

TT92C1-E-00
Foreword
Safety Precautions
Safety Symbols
Symbols
CONTENTS
01 Troubleshooting
– Cautions Regarding Troubleshooting
– How to Use Quick Troubleshooting Table
– Safety Precautions
– Torque Converter and Transmission Group
— 1. Machine dose not move in any shift lever position.
— 2. Machine dose not move at a certain shift lever position. (OR:Machine moves only in a certain shift lever position.)
— 3. Machine moves at the neutral position. (Example: Machine moves forward at the neutral position.)
— 4. Large shock at starting or changing speed / direction
— 5. Large time lag at starting or changing speed / direction
— 6. Low power of traction / pushing (Defective torque converter or transmission)
— 7. Torque converter oil is overheating.
— 8. Machine moves reverse when starting to climb up on a slope using inching brake.
— 9. Automatic speed change is not possible.
— 10. Downshift button does not work.
– Hydraulic Group
— 1. Boom and/or bucket do not move.
— 2. Boom and/or bucket have low power, or move too slowly.
— 3. Excessive cylinder drift
— 4. Boom and/or bucket are spongy. (Holding bucket against the ground is not possible-front wheels off the ground.)
— 5. Bucket leveler does not work. Boom lift kickout and lower kickout does not work.
— 6. Steering is not possible or hard to steer.
— 7. Machine sways, or has a shock during steering
— 8. ELS (Efficient Loading System) does not work. (Excavating and scooping tractive power does not become up during ELS working condition.)
— 9. Ride control does not work.
— 10. Fan motor rotates abnormally or does not rotate.
— 11. Abnormal noise in hydraulic system.
— 12. Others
– Brake Group
— 1. Brake does not work well. (In the worst case, the brake does not work at all.)
— 2. Brake is dragging when released.
— 3. Stepping on the brake pedal sounds the buzzer.
— 4. Accumulator pressure does not rise, or too slow in rising.
— 5. Parking brake does not work. (or: Releasing the parking brake is not possible.)
– Electrical Group
— 1. Instrument panel does not indicate properly.
— 2. Fuse for controller is blown.
— Error code (for chassis)
— Error code (for engine)
– Operator Station Group
— Air conditioner
03 Measurement for Performance Check
– Cautions on Safety
– Standard Measurement Values for Performance Check
– Preparation for Performance Check
– Engine
— Measuring engine speed
— Measurement instrument
— Standard measurement value (Normal mode)
– Clutch Oil Pressure
— Measuring clutch oil pressure
– Hydraulic Cylinder
— Cylinder natural drift
— Measurement instrument
— Standard measurement value (mm/min) (in/min)
— Measurement procedure
– Boom Rising Time
— Measurement instrument
— Warm-up the engine before measuring boom rising time.
— Standard measurement value (sec)
— Measurement procedure
– Full Steering Cycle Time
— Measurement instrument
— Warm-up the engine before measuring full steering time.
— Standard measurement value (sec)
— Measurement procedure
– Loading/Steering Circuit Relief Valve
— Loading circuit relief valve setting pressures
— Measurement instruments
— Gauge port
— Standard measurement value MPa (kgf/cm2) (psi)
— Measuring loading circuit main relief pressure
— Measuring loading circuit overload relief pressure
— Measuring pilot circuit relief pressure
— Steering circuit relief valve setting pressures
— Measurement instruments
— Gauge port
— Standard measurement value MPa (kgf/cm2) (psi)
— Measuring steering circuit main relief pressure
— Measuring steering circuit overload relief pressure
— Measuring pilot circuit relief pressure (reducing pressure)
– Service Brake
— Service brake performance check
— Condition
— Standard measurement value
– Parking Brake
— Parking brake performance check
— Condition
— Standard measurement value
– Brake Circuit Oil Pressure
— Unloader valve setting pressure
— Measurement instrument
— Gauge port
— Standard measurement value
— Measurement procedure
— Brake valve oil pressure
— Measurement instrument
— Gauge port
— Measurement procedure
— Brake valve performance
– Accumulator Circuit Charging Time
— Measurement instrument
— Gauge installation position
— Standard measurement valve (sec)
— Measurement procedure
– Number of Brake Pedal Applications
— Standard measurement value
— Measurement procedure
— Possible causes of extremely low measurement value and solution
– Declutch Engagement
— Measurement instrument
— Warm-up the engine before measuring declutch engagement
— Standard measurement value
— Cause of extremely high measurement value and solution
— Measurement procedure
– MEMO
Check & Adjustment
– 13 Check & Adjustment Chassis Group
— Linkage Pin
— Liner
—- Adjustment
—- Bucket hinge pin section
—- How to assemble
— Center Pin
— Adjusting shim
— Installing bearing cover
— Installing bearing outer ring
– 23 Check & Adjustment Power Group
— Engine
— Measuring engine speed
—- Measurement instrument
—- Standard measurement value
— Measuring engine oil pressure
—- Measurement instrument
—- Install position
—- Standard measurement value
— Propeller Shaft
— Propeller shaft phase
— Second propeller shaft alignment
— Tightening torque
— Axle
— Axle nut tightening procedure
— Differential gear adjustment procedure
—- Preload adjustment
—- Bearing installation
—- Oil seal installation
—- Adjusting tooth contact
— MEMO
– 33 Check & Adjustment Torque Converter and Transmission Group
— Clutch Oil Pressure
— Measuring clutch oil pressure
– 43 Check & Adjustment Hydraulic Group
— Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)
— Loading circuit relief valve setting pressures
—- Measurement instruments
—- Gauge port
—- Standard measurement value MPa (kgf/cm2) (psi)
—- Measuring loading circuit main relief pressure
—- Measuring loading circuit overload relief pressure
—- Measuring pilot circuit relief pressure
— Ride control circuit reducing valve setting pressures (OPT)
—- Measurement instruments
—- Gauge port
—- Standard measurement value MPa (kgf/cm2) (psi)
—- Measuring ride control circuit reducing pressure
— Steering circuit relief valve setting pressures
—- Measurement instruments
—- Gauge port
—- Standard measurement value MPa (kgf/cm2) (psi)
—- Measuring steering circuit main relief pressure
—- Measuring steering circuit overload relief pressure
—- Measuring pilot circuit relief pressure (reducing pressure)
— Hydraulic Cylinder
— Cylinder natural drift
—- Measurement instrument
—- Standard measurement value (mm/min) (in/min)
—- Measurement procedure
— Stop Valve
— Stop valve adjustment procedure
— MEMO
– 53 Check & Adjustment Brake Group
— Brake Circuit Oil Pressure
— Unloader valve setting pressure
—- Measurement instrument
—- Gauge port
—- Standard measurement value
—- Measurement procedure
— Brake valve oil pressure
—- Measurement instrument
—- Gauge port
—- Measurement procedure
—- Brake valve performance
— Service Brake
— Service brake performance check
—- Condition
—- Standard measurement value
— Service brake friction plate wear measurement
—- Measurement procedure
— Cautions on installing brake discs
— Parking Brake
— Parking brake performance check
—- Condition
—- Standard measurement value
Drawing & Diagrams
– Axle Assembly
– Torque Converter and Transmission
– Hydraulic & Brake Circuit
– Brake Circuit
– Electrical Wiring Diagram (1/3)
– Electrical Wiring Diagram (2/3)
– Electrical Wiring Diagram (3/3)
– Electrical Wiring Diagram
— Way of looking at connectors
— Electrical wiring diagram abbreviation chart
– Electrical Wiring Diagram (CAB)
– Electrical Wiring Diagram (Cabin Air Conditioner)
– Electrical Connection Diagram (1/2)
– Electrical Connection Diagram (2/2)
– Electrical Circuit Diagram (Cabin Air Conditioner)
– Electrical Equipment Layout
– Equipment Operation Table (Cabin Air Conditioner)
– Outline of MODM (Machine Operation Diagnostic Module) Operation
– MODM: Input/Output Monitor – Input/Output Signal Correspondence Table
Maintenance Log
Notes