Technical Manual Hitachi ZW370-G Wheel Loader | TONHB-E-00

Technical Manual Hitachi ZW370-G Wheel Loader TONHB-E-00 (Preview)

TONHB-E-00
Foreword
MACHINE SPECIFICATION
Safety Symbols
CONTENTS
00 General Information
How to Use Manual
Safety precautions
Symbols
Outline
Layout of main components
Recommended lubricants
Coolant
Coolant specification
Recommended mixture of antifreeze
Lubrication chart
Weight of main components
Bolt tightening torque
Hexagon bolt
Flanged hexagon bolt
Hose band tightening torque
Liquid gasket and screw lock agent
Cautions regarding parts removal
Cautions regarding reassembly
Screw lock agent application procedure
How to wind a seal tape
Cautions regarding welding repair service
Cautions
03 Measurement for Performance Check
Cautions on Safety
Standard Measurement Values for Performance Check
12 Function & Structure Chassis Group
Front Chassis
Loading linkage
Loading linkage pin
Rear Chassis
Fuel tank (S/N 0101~0262, 9001~9064)
Fuel tank (S/N 0263~, 9065~)
Floor board mount
Floor board
Viscous mount
Center Pin
Upper center pin
Lower center pin
Dust seal
13 Check & Adjustment Chassis Group
Linkage Pin
Liner
Adjustment
Bucket hinge pin section
How to assemble
Center Pin
Adjusting shim
Grease nipple installation direction
Installing bearing outer ring
22 Function & Structure Power Group
Power Line
Engine / Transmission
Engine / transmission mount
Radiator
Radiator mount
Propeller Shaft
Second propeller shaft assembly
Front differential – Transmission
Third propeller shaft assembly
Transmission – Rear differential
Axle Assembly
Axle Support
Differential Gear
Function of T.P.D
Difference in gear shapes
Contact between pinion and side gear
Operation of T.P.D
23 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
Planetary gear oil drain and refill
Differential gear adjustment procedure
Preload adjustment
Bearing installation
Oil seal installation
Adjusting tooth contact
32 Function & Structure T/C and T/M Group
Torque Converter
Torque converter structure
Power flow path
Torque multiplication
Torque Converter Gear Pump
Gear pump specifications
Gear pump specifications
Clutch combination
Planetary gear
Shift lever position
QUAD switch operation
Gear train and number of teeth
Clutch specifications
Friction plate
Steel plate
Clutch Pack
Power Flow Path in the Transmission
Forward 1st speed flow path
Forward 2nd speed flow path
Forward 3rd speed flow path
Forward 4th speed flow path
Reverse 1st speed flow path
Reverse 2nd speed flow path
Reverse 3rd speed flow path
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
Modulator Valve Unit
Interior schematic (example)
Modulation Mechanism
Modulator valve function
Modulator valve 1
Modulator valve 2
Pressure difference sensor
Clutch oil pressure control at the time of engine starting
Modulator valve operation
Clutch Solenoid Valve
For high/reverse and speed clutches
33 Check & Adjustment T/C and T/M
Clutch Oil Pressure and Time Lag
Measuring clutch oil pressure
Clutch oil pressure measurement procedure
Possible causes for low clutch oil pressure
Measuring clutch time lag
Time lag measurement procedure
Possible causes for clutch time lag
42 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
Loading system
Steering system
Fan motor system
Vibration damper system (OPT)
Layout of Hydraulic Units
Hydraulic Tank
Hydraulic tank specifications
Hydraulic oil level check
Hydraulic tank (S/N 0101~0450, 9001~)
Hydraulic tank breather valve (tank cap) (S/N 0101~0450, 9001~)
Hydraulic tank (S/N 0451~)
Hydraulic tank breather valve (tank cap) (S/N 0451~)
Hydraulic Pump
Loading and pilot and brake pump
Pump specifications
Steering pump (S/N 0101~0258, 9001~9065)
Pump specifications
Steering pump (S/N 0259~0398, 9066~)
Pump specifications
Steering pump (S/N 0399~)
Pump specifications
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 0101~0290, 9001~9080)
Pilot valve operation
Pilot valve detent magnet solenoid
Detent adjustment procedure
Pilot valve (S/N 0291~0408, 9081~)
Pilot valve operation
Pre-detent and detent magnet solenoid
Pilot valve (S/N 0409~0410)
Pilot valve function
Pilot valve operation (modulated position)
Pre-detent and detent magnet solenoid
Pilot valve (S/N 0411~)
Pilot valve function
Pilot valve operation (modulated position)
Pre-detent and detent magnet solenoid
Multiple Control Valve (KML35A/2T003B)
Multiple control valve specifications
Multiple control valve main relief valve
Main relief valve operation
Adjusting set pressure
Multiple control valve overload relief valve
Overload relief valve operation
Make-up valve operation
Adjusting set pressure
Multiple control valve make-up valve
Make-up valve operation
Multiple control valve bucket spool
Bucket spool operation
Multiple control valve boom spool
Boom spool operation
Adapter (Orifice)
Vibration Damper (OPT)
Vibration damper hydraulic circuit
Vibration damper function
Vibration damper operation
Reducing valve
Check valve
Solenoid valve
Shuttle valve
Solenoid valve
Check valve
Vibration damper hydraulic line
Steering System
Orbitrol®
Orbitrol® specification
Orbitrol® structure
Valve part
Rotor part
Orbitrol® operation
Neutral
Turn
Orbitrol® feed-back mechanism operation
Steering speed and flow rate control
Hydraulic pump oil amount and steering force
Orbit rotor operation principle
Steering Valve (KVS32-A4.0)
Steering valve operation
Neutral position
Left turn position
Steering plunger variable throttle
Steering valve flow control plunger
Steering valve main relief valve
When the pressure is at the preset value or less
When the pressure exceeds the preset value
Steering valve overload relief valve
Overload relief valve operation
Make-up valve operation
Steering pilot circuit and its operation
Flow amplifier notch and pilot orifice
Stop Valve
Stop valve function
Stop valve operation
Reducing Valve (for Orbitrol®)
Steering Line Filter
Fan Motor System
Fan Motor Line (S/N 0101~0230)
Fan motor (GM30C) (S/N 0101~0230)
Valve assembly (for fan motor)
Relief valve (two-step relief)
Relief valve (two-step relief) operation
Make-up valve operation
Solenoid valve (for fan speed control)
Solenoid valve (for fan speed control) operation
Fan Motor Line (S/N 0231~)
Fan motor (GM30C) (S/N 0231~0313)
Fan motor (GM30W) (S/N 0314~0398)
Fan motor (FM30) (S/N 0399~)
Thermo sensing valve
Thermo sensing valve operation
Fan motor relief valve assembly
Fan motor relief valve
Fan motor check valve (make-up valve)
Fan Motor Line (S/N 9001~9010)
Fan motor (GM30C) (S/N 9001~9010)
Valve assembly (for fan motor)
Relief valve (two-step relief)
Relief valve (two-step relief) operation
Make-up valve operation
Solenoid valve (for fan speed control)
Solenoid valve (for fan speed control) operation
Fan Motor Line (S/N 9011~)
Fan motor (GM30C) (S/N 9011~9065)
Fan motor specifications
Fan motor (GM30W) (S/N 9066~)
Thermo sensing valve
Thermo sensing valve operation
Fan motor relief valve assembly
Fan motor relief valve
Fan motor check valve (make-up valve)
Emergency Steering (for Europe)
Emergency steering operation condition
Emergency steering line oil flow
Emergency steering hydraulic diagram
Machine speed signal
Emergency steering motor and pump
43 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve
Loading circuit relief valve setting pressures
Measuring loading circuit main relief pressure
Measuring loading circuit overload relief pressure
Measuring pilot circuit relief pressure
Steering circuit relief valve setting pressures
Measuring steering circuit main relief pressure
Measuring steering circuit overload relief pressure
Measuring pilot circuit relief pressure (reducing pressure) (S/N 0107~, 9004~)
Hydraulic Cylinder
Cylinder natural drift
Cylinder natural drift measurement procedure
Stop Valve
Stop valve adjustment procedure
Fan Revolution (S/N 0101~)
Fan maximum revolution measurement (S/N 0101~0230)
Fan maximum revolution measurement (S/N 0231~)
Fan Revolution (S/N 9001~)
Fan maximum revolution measurement (S/N 9001~9010)
Fan maximum revolution measurement (S/N 9011~)
52 Function & Structure Brake Group
Brake System Outline
Service brake
Parking brake
Auto brake
Adjustment of axle internal pressure
Brake Units Layout
Unloader Valve
Unloader valve operation
Valve Unit
Reducing Valve
Brake Accumulator Line
Accumulator
In-line filter
Brake circuit check valve
Brake Valve
Brake main valve (left pedal)
Brake pilot valve (right pedal)
Brake valve performance chart
Brake valve outline
Main valve (tandem type) operation
Pilot valve operation
Stop Lamp Pressure Switch
Pressure switch (for stop lamp)
Pressure switch (for declutch)
Service Brake
Service brake operation
Service brake friction plate
Service brake steel plate
Service brake piston
Service brake pedal stroke adjusting mechanism (S/N 0101~0311, 9001~9095)
Tolerance ring
Brake circuit air bleeding procedure
Bleeding air from the brake valves
Bleeding air from brake pipes and axle housing hubs
Parking Brake
Parking brake operation chart
Parking Brake (Rear)
Rear parking brake operation
Parking brake solenoid valve (rear)
Parking solenoid valve operation (rear)
Parking brake manual release procedure (rear)
Parking brake spring chamber
Parking Brake (Front) (for Europe only)
Front parking brake operation
Parking brake solenoid valve (front)
Parking solenoid valve operation (front)
Front parking brake auto adjuster mechanism
Parking brake line air bleeding procedure (front parking)
Parking brake manual release procedure (front)
Auto Brake
Auto brake circuit
Auto brake operation set value
Solenoid valve (for autobrake circuit)
Shuttle valve
53 Check & Adjustment Brake Group
Brake Circuit Oil Pressure
Unloader valve setting pressure
Measuring unloader valve setting pressure
Adjusting unloader valve setting pressure
Accumulator circuit pressure
Measuring reducing valve setting pressure
Adjusting reducing valve setting pressure
Brake valve oil pressure
Measuring brake valve oil pressure
Brake valve performance
Service Brake
Service brake performance check
Method 1
Method 2
Service brake friction plate wear measurement
Cautions when installing brake discs (S/N 0101~0311, 9001~9095 only)
Parking Brake
Parking brake performance check
Method 1
Method 2
Parking brake clearance adjustment
Brake lining abrasion check
62 Function & Structure Electrical Group
How to Use Electrical Wiring Diagram
Electrical Cable Color Codes
Electrical Circuit Symbols
Sensor Mount
Fuse
Fuse box location
Fuse box
Fusible link
Engine Start Circuit
Engine start circuit diagram (S/N 0101~0360, 9001~)
Neutral starter
Shift lever neutral (N) position
Shift lever forward/reverse (F/R) position
Engine start circuit diagram (S/N 0361~)
Neutral starter
Shift lever neutral (N) position
Shift lever forward/reverse (F/R) position
Starter switch
Battery relay
Battery relay operation
Alternator I terminal wire
Diode unit
Neutral relay
Magnet switch
Voltage relay
Power Generating/Charging Circuit
Alternator
ECM (Engine Controller)
Function of ECM
Connection diagram
Monitor lamp test
Failure diagnosis
Engine diagnostic switch (option)
Engine diagnostic switch (option)
Failure diagnostic chart
Increment decrement switch (option)
Quantum fault code information
Accelerator pedal
Accelerator pedal installation
Accelerator pedal
Accelerator pedal installation
Transmission Control Circuit and Monitor Circuit (S/N 0101~0358, 9001~)
Controller
LED inspection windows
Controller connection diagram
Controller function
Forward/reverse (F/R) shifting and speed change
Automatic shift
Machine speed sensor
Switching from automatic to manual
QUAD (downshift) switch operation
Modulation at clutch switching
Transmission cut off (Declutch)
Pressure switch for inching (declutch)
Back-up alarm
Parking brake
Auto brake
Transmission controller failure warning
Transmission Control Circuit and Monitor Circuit (S/N 0359~)
Machine control unit (MCU)
Connector
Machine control unit (MCU) connection diagram
Machine control unit (MCU) failure warning
Emergency steering function (for Europe only)
Monitoring System
Monitor controller
Monitor controller connection diagram
Monitor controller function
Items to be monitored and operation condition
Operation monitor lamps
Instrument Panel and Switch
Instrument panel
Instrument panel rear surface
Gauge circuit
Temperature sensor
Tachometer circuit
Tachometer
Fuel gauge circuit
Electrical Detent Circuit
Bucket leveler
Boom kick-out (option)
Float
Proximity switch
Detent solenoid
Diode
Diode check method
Caution for diode check method
Continuity check mode
Diode check mode
Resistance check mode
Surge voltage and surge suppression diodes
Diagnostic System
Diagnostic system flow
Diagnostic system flow
Failure code (T/M controller)
Diagnostic (T/M controller) failure code detection condition
Fault diagnostic result storage condition
Monitor controller
Diagnostic system flow
Alarm monitor actuation and data storage
Diagnostic failure history indication and deletion
Failure history indication
Failure history deletion
Diagnostic switch
MODM (S/N 97C4-0361~)
MODM function
Monitor Changeover
Changing display from one function to next
MODM: Input/output monitor – Input/output signal correspondence table
63 Check & Adjustment Electrical Group
Cautions Regarding Electric Circuit Check
Disconnecting or reinstalling connector
How to attach the probes of the circuit tester
Electrical Transmission Control System Troubleshooting Flowchart
Standard troubleshooting flowchart
Transmission Controller Abnormal Operation Judgment
Transmission controller check
When the “controller failure” monitor lamp lights:
When the output units (solenoid valve, etc.) do not operate properly:
If the input units or circuit are not defective
Transmission controller LED indicator
Electrical Circuit Check
Shift lever input electrical circuit check
Inching (declutch) input electrical circuit check
QUAD switch input electrical circuit check
Machine speed sensor input electrical circuit check
Clutch solenoid valve output electrical circuit check
Modulator valve output electrical circuit check
Check output circuit wiring
Neutral relay electrical circuit check
Parking brake electrical circuit check
Solenoid valve on the front side
Auto brake electrical circuit check
Gauge circuit electrical circuit check
Fuel level gauge electrical circuit check
Shift Lever
Operation force measurement
Changeover between forward and reverse
Transmission gear changeover
72 Function & Structure Operator Station Group
Cabin
Glass
Wiper mount
Front wiper
Rear wiper
Wiper motor
Operator Seat
Steering and Transmission Shift Lever
Tilt case
Column shaft
Shift lever
Air Conditioner
Air conditioner components
Air conditioner specifications (system performance)
Air conditioner structure
Cooling unit
Heater and accessories
Air distributor (hood & defroster selection box)
Air compressor (with magnetic clutch)
Condenser unit
Control unit
Cooling mechanism
Principle of cooling
Refrigerant
Refrigerant characteristics
Cooling circuit
Electrical circuit
Control schematic drawing
Air conditioner functions of components
Control panel
Air conditioner unit
Compressor and magnetic clutch
Condenser unit
Receiver dryer
Sight glass
Pressure switches
Pressure relief valve
Relay A
Relay B
Refrigerant hose
Charge of refrigerant
Work procedure
Refrigerant charging tools
Refrigerant charging procedure
Troubleshooting using the gauge manifold
Air conditioner troubleshooting
Fault diagnosis procedure
73 Check & Adjustment Operator Station Group
Air Conditioner
Adjustment of lubricating oil quantity when components of air conditioner are replaced
When the compressor is replaced
When the evaporator is replaced
When the condenser is replaced
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch
Parts to be replaced periodically
Air filters
Receiver dryer
92 Cross-Section Drawing & Diagrams
Axle Assembly
Torque Converter and Transmission
Loading/Steering Hydraulic Line (S/N 0101~0230)
Loading/Steering Hydraulic Line (S/N 0231~)
Loading/Steering Hydraulic Circuit (S/N 9001~9010)
Loading/Steering Hydraulic Circuit (S/N 9011~)
Brake Circuit
Electrical Wiring Diagram (1/2) (S/N 0101~0237)
Electrical Wiring Diagram (2/2) (S/N 0101~0237)
Electrical Wiring Diagram (1/2) (S/N 0238~0242)
Electrical Wiring Diagram (2/2) (S/N 0238~0242)
Electrical Wiring Diagram (1/2) (S/N 0243~0358)
Electrical Wiring Diagram (2/2) (S/N 0243~0358)
Electrical Wiring Diagram (1/3) (S/N 0359~)
Electrical Wiring Diagram (2/3) (S/N 0359~)
Electrical Wiring Diagram (3/3) (S/N 0359~)
Electrical Wiring Diagram (1/2) (S/N 9001~9010)
Electrical Wiring Diagram (2/2) (S/N 9001~9010)
Electrical Wiring Diagram (1/2) (S/N 9011~9064)
Electrical Wiring Diagram (2/2) (S/N 9011~9064)
Electrical Wiring Diagram (1/2) (S/N 9065~9080)
Electrical Wiring Diagram (2/2) (S/N 9065~9080)
Electrical Wiring Diagram (1/2) (S/N 9081~)
Electrical Wiring Diagram (2/2) (S/N 9081~)
Electrical wiring diagram abbreviation chart (S/N 0101~0360, 9001~)
Electrical wiring diagram abbreviation chart (S/N 0361~)
Electrical Wiring Diagram (CAB)
Electrical Connection Diagram (S/N 0101~0237)
Electrical Connection Diagram (S/N 0238~0252)
Electrical Connection Diagram (S/N 0253~0360)
Electrical Connection Diagram (S/N 0361~)
Electrical Connection Diagram (S/N 9001~9064)
Electrical Connection Diagram (S/N 9065~)
Electrical Equipment Layout
Front chassis (S/N 0101~)
Front chassis (S/N 9001~)
Front chassis (S/N 0101~)
Rear chassis (S/N 0101~0268)
Rear chassis (S/N 0269~)
Rear chassis (S/N 0101~)
Rear chassis (S/N 0101~)
Rear chassis (S/N 0101~)
Rear chassis (S/N 9001~9010)
Rear chassis (S/N 9011~)
Rear chassis (S/N 9001~)
Rear chassis (S/N 9001~)
Rear chassis (S/N 9001~)
Floor board (S/N 0101~)
Floor board (S/N 0101~)
Floor board (S/N 0101~)
Floor board (S/N 9001~)
Floor board (S/N ~9080)
Floor board (S/N 9001~)
Electrical Circuit Diagram (Cabin Air Conditioner)
Electrical Wiring Diagram (Cabin Air Conditioner)
Equipment Operation Table (Cabin Air Conditioner)
INDEX
Maintenance Log
Notes