Technical Manual Hitachi ZW370 Wheel Loader | TO97C5-E-00

Technical Manual Hitachi ZW370 Wheel Loader TO97C5-E-00 (Preview)

TO97C5-E-00
Foreword
Safety Symbols
CONTENTS
00 General Information
How to Use Manual
Safety precautions
Symbols
Outline
Layout of main components
Inspection and maintenance table
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
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
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
Bucket hinge pin section
How to assemble
Adjustment
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 (S/N 9001~9150)
Radiator (S/N 9151~)
Propeller Shaft
Second propeller shaft assembly
Front differential – Transmission
Third propeller shaft assembly
Transmission – Rear differential
Axle Assembly
Axle Support
Differential Gear
Torque proportioning type
Function of T.P.D
Operation of T.P.D
Limited Slip Differential (option)
Structure
LSD function
LSD operation
23 Check & Adjustment Power Group
Engine
Measuring engine speed
Measuring engine oil pressure
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
32 Function & Structure T/C and T/M 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)
Automatic shift (with lock-up solenoid)
Torque Converter Gear Pump
Gear pump specifications
Transmission
Clutch combination
Planetary gear
Shift lever position
Downshift button operation
Gear train and number of teeth
Clutch specifications
Friction plate: mm (in)
Steel plate: mm (in)
Clutch Pack
Power Flow Path in the Transmission
Forward 1st speed power flow path
Forward 2nd speed power flow path
Forward 3rd speed power flow path
Forward 4th speed power flow path
Reverse 1st speed power flow path
Reverse 2nd speed power flow path
Reverse 3rd speed power 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 (not exact representation)
Modulator valve function
Modulator valve 1
Modulator valve 2 (D Solenoid valve)
Pressure sensor
Clutch oil pressure control at the time of engine starting
Modulator valve operation
Control Valve Assembly
Check valve
Clutch solenoid valve assembly
For high/reverse and speed clutches
Clutch valve assembly
33 Check & Adjustment T/C and T/M Group
Clutch Oil Pressure and Time Lag
Measuring clutch oil pressure
Clutch oil pressure measurement procedure
Possible causes for low clutch pressure
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
Efficient loading system
Fan motor system
Ride control system (OPT)
Layout of Hydraulic Units
Hydraulic Tank
Hydraulic tank breather valve (tank cap)
Hydraulic tank specifications
Hydraulic oil level check
Hydraulic Pump
Loading and pilot and brake pump/Steering pump
Loading and pilot and brake pump/Steering 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
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 (with make-up function)
Overload relief valve operation
Make-up valve operation
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)
Ride Control (OPT)
Ride control hydraulic circuit
Ride control function
Ride control operation
Preparation mode (ride control switch is OFF)
Running mode (ride control switch is ON)
Ride control valve assembly (Reducing valve circuit)
Reducing valve
Check valve
Solenoid valve
Ride control valve assembly (Accumulator circuit)
Shuttle valve
Solenoid valve
Check valve
Accumulator (for ride control)
Accumulator function
Steering System
Orbitrol®
Orbitrol® structure
Valve part
Rotor part
Orbitrol® specifications
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-A4.0/20)
Steering valve operation
Neutral position (Steering spool in “Neutral”)
Left turn position
Steering spool variable throttle
Steering valve flow control spool
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
K-Lever (OPT)
Hydraulic circuit
Hydraulic line diagram
Hydraulic line
Solenoid valve mount
Solenoid valve assembly (1/2)
Solenoid valve assembly (2/2)
Adjustment method
Efficient Loading System
Efficient loading system outline
The operation condition of ELS
Mounting of the ELS valve
Mounting of the variable kickout sensor
Efficient loading system operation
While the ELS is not operating
While the ELS is operating
Fan Motor System
Mounting of fan motor
Fan Motor Line
Hydraulic circuit (fan motor normal rotation)
Make-up valve
Proportional relief valve (S/N 9001~9150)
Proportional relief valve operation
Proportional relief valve (S/N 9151~)
Reversing Fan Motor Line (OPT)
Reversing fan motor function
Reversing fan motor (OPT)
Reversing fan control chart
Hydraulic circuit (Reverse rotation)
Secondary Steering
Secondary steering circuit
Secondary steering operation
Secondary steering motor and pump
43 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)
Loading circuit relief valve setting pressures
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)
Measuring ride control circuit reducing 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)
Hydraulic Cylinder
Cylinder natural drift
Stop Valve
Stop valve adjustment procedure
52 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 low pressure sensor
Accumulator
Brake Valve
Brake valve performance chart
Brake valve outline
While the valve is not operating
While the valve is operating
While the valve is releasing
Service Brake
Service brake operation
Service brake friction plate
Service brake steel plate
Service brake piston
Service brake pedal stroke adjusting mechanism (S/N 9001~9014)
Tolerance ring
Brake circuit air bleeding procedure
Bleeding air from brake pipes and axle housing hubs
Bleeding air from parking brake housing
Parking Brake
Parking brake operation
Operation of parking brake
Parking brake friction plate
Parking brake steel plate
Parking brake solenoid valve
Solenoid valve operation
Solenoid valve specifications
Parking Brake Manual Release
Brake Circuit Check Valve
Auto Brake
Auto brake circuit
Auto brake operation set value
Solenoid valve (for Autobrake circuit)
Solenoid specifications
Pressure Sensor (for stop lamp and declutch)
Pressure sensor (for stop lamp)
Pressure sensor (for Declutch)
53 Check & Adjustment Brake Group
Brake Circuit Oil Pressure
Unloader valve setting pressure
Unloader valve setting pressure measurement
Brake valve oil pressure
Brake valve oil pressure measurement
Brake valve performance
Service Brake
Service brake performance check
Service brake friction plate wear measurement
Measurement procedure
Cautions on installing brake discs
Parking Brake
Parking brake performance check
62 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
Shift lever neutral (N) position
Shift lever forward/reverse (F/R) position
Starter switch
ECM safety features
Battery relay
Battery relay operation
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
Engine diagnostic switch (option)
Failure diagnostic chart
Increment decrement switch (option)
Quantum fault code information
Accelerator pedal
Accelerator pedal installation
Transmission Control Circuit and Monitor Circuit
Machine control unit (MCU)
Connector
Machine control unit (MCU) connection diagram
Machine control unit (MCU) function
Forward/reverse (F/R) shifting and speed change
Automatic shift
Automatic shift (with lock-up solenoid)
Machine speed sensor
Switching from automatic to manual
Downshift button operation
Modulation at clutch switching
Adjustable declutch preset switch
Back-up alarm
Parking brake
Auto brake
Machine control unit (MCU) failure warning
Secondary steering function (OPT)
Monitoring system
Items to be monitored and operation condition
Operation monitor lamps
Instrument Panel and Switch
Instrument panel
Instrument panel rear surface
Gauge circuit
Fuel gauge circuit
MODM
MODM function
Monitor Changeover
Changing display from one function to next
Information Monitor
Information monitor display
Unit conversion and language selection
Replacement Monitor
Replacement time check
Replacement interval set (timer reset)
Replacement interval pop-up
Display language
Fault Log Monitor
Fault log history check
Selection of machine fault log and engine fault log
Machine fault log navigation
Engine fault log navigation
Clear fault log
Clear active fault log (error pop up)
Input/Output Monitor
Input/Output monitor display
Parameter Setting Monitor
Parameter setting monitor display
Parameter change
Specification Setting Monitor
Specification setting monitor display
All setting reset
Electrical Detent Circuit
Bucket leveler
Proximity switch
Detent solenoid
Lift kickout & lower kickout
Lift kickout
Lower kickout
Sensor assy
Detent solenoid
Preset height adjustment
Diode
Diode check method
Caution for diode check method
Continuity check mode
Diode check mode
Resistance check mode
Surge voltage and surge suppression diodes
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
Denso air conditioner components
Air conditioner specifications (system performance)
Denso air conditioner structure
Cooling unit
Heater and accessories
Air distributor (hood & defroster selection box)
Air compressor (with magnetic clutch)
Condenser unit
Control unit
Function of 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
Compressor V-belt adjustment
Belt adjustment procedure
Belt adjustment value
Parts to be replaced periodically
Air filters
Receiver dryer
80 Function & Structure Supplement
Foreword
01 Function & Structure Supplement
Quick Coupler
Hydraulic line and electrical circuit
Solenoid valve
Solenoid valve specifications
Quick coupler cylinder
Quick coupler cylinder specifications
Power boost circuit
Multiple control valve main relief valve (MRV) (2 stage relief)
Multiple control valve main relief valve (MRV) operation
Multiple control valve main relief valve (MRV) adjusting set pressure
Measuring loading circuit overload relief pressure
Adjusting overload relief pressure
Hydraulic line
Electrical cable
Short Boom (OPT)
Bucket cylinder
Bucket cylinder specifications
Steering Cylinder (OPT)
Steering cylinder specifications
Maintenance Log
Notes