Technical Manual Hitachi ZW550-G Wheel Loader | TONHD-E-00

Technical Manual Hitachi ZW550-G Wheel Loader TONHD-E-00 (Preview)

TONHD-E-00
Foreword
Machine Specification
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
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
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 (#1)
How to assemble
Bucket link pin section (#2)
How to assemble
Center Pin
Adjusting shim
Installing bearing cover
Installing bearing outer ring
22 Function & Structure Power Group
Power Line
Engine / Transmission
Engine / transmission mount
Radiator
Radiator mount
Propeller Shaft
First propeller shaft assembly
Second propeller shaft assembly
Third propeller shaft assembly
Axle Assembly
Axle Support
Differential Gear
Function of differential gear
Power transmission
Operation of differential gear
Straight
Turn
23 Check & Adjustment Power Group
Engine
Measuring engine speed
Measurement instrument
Standard measurement value
Measuring engine oil pressure
Measurement instrument
Install position
Propeller Shaft
Propeller shaft phase
Second propeller shaft alignment
Tightening torque
Axle
Axle nut tightening procedure
Planetary gear oil drain and refill
Differential gear adjustment procedure
Preload adjustment
Bearing installation
Oil seal installation
Greasing
Adjusting tooth contact
32 Function & Structure Torque Converter and Transmission Group
Torque Converter
Torque converter structure
Power flow path
Torque multiplication
Torque Converter Gear Pump
Gear pump specifications
Transmission
Clutch combination
Planetary gear
Shift lever position
Power up switch 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
Forward 1st speed
Forward 2nd speed
Forward 3rd speed
Forward 4th speed
Reverse
Reverse 1st speed
Reverse 2nd speed
Reverse 3rd speed
Hydraulic System Diagram
Hydraulic Circuit Diagram
T/C and T/M Oil Circulation
Oil flow in the torque converter line
From torque converter charge pump to torque converter
From torque converter to cooling circuit
From cooler to lubrication circuit
Oil flow to the clutch
Modulator Valve Unit
Interior schematic (not exact representation)
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
After power-off (Clutch disengaged status)
After power-on (Clutch engaged status)
33 Check & Adjustment Torque Converter and Transmission Group
Clutch Oil Pressure and Time Lag
Measuring clutch oil pressure
Measurement instrument
Gauge port
Standard measurement value
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 0101~0200, 9001~)
Hydraulic tank breather valve (tank cap) (S/N 0101~0200, 9001~)
Hydraulic tank (S/N 0201~)
Hydraulic tank breather valve (tank cap)(S/N 0201~)
Hydraulic Pump
Loading and pilot and brake pump
Pump specifications
Steering 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 (S/N 0101~0140, 9001~9020)
Pilot valve operation
Pilot valve detent magnet solenoid
Detent adjustment procedure
Pilot valve (S/N 0141~0172, 9021~)
Pilot valve operation
Pre-detent and detent magnet solenoid
Pilot valve (S/N 0173~0176)
Pilot valve function
Pilot valve operation (modulated position)
Pre-detent and detent magnet solenoid
Pilot valve (S/N 0177~)
Pilot valve function
Pilot valve operation (modulated position)
Pre-detent and detent magnet solenoid
Multiple Control Valve (KML35A/2T103)
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 function
Vibration damper operation
Preparation mode (vibraion damper switch is OFF)
Running mode (vibration damper switch is ON)
Vibration damper valve assembly (Reducing valve circuit)
Reducing valve
Check valve
Solenoid valve
Vibration damper valve assembly (Accumulator circuit)
Shuttle valve
Solenoid valve
Check valve
Accumulator (for vibration damper)
Vibration damper hydraulic line
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-A4.0/21)
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
Fan Motor System
Fan Motor Line (S/N 0101~0120, 9001~9010)
Fan Motor (GM30C)
Fan motor specifications
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
Solenoid valve specifications
Fan Motor Line (S/N 0121~, 9011~)
Fan Motor (GM30W)
Thermo Sensing Valve
Thermo sensing valve specifications
Thermo sensing valve operation
Fan Motor Relief Valve Assembly
Fan motor relief valve
Fan motor check valve (Make-up valve)
Emergency Steering
Emergency steering hydraulic line
Emergency steering oil flow
Emergency steering pump
Emergency steering valve assembly
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 9004~)
Hydraulic Cylinder
Cylinder natural drift
Stop Valve
Stop valve adjustment procedure
Fan Motor Revolution
Fan maximum revolution measurement (S/N 0101~0120, 9001~9010)
Fan revolution adjustment procedure
Fan maximum revolution measurement (S/N 0121~, 9011~)
Fan revolution adjustment procedure
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
Reducing valve
Valve Unit (Main Brake Manifold Block)
Brake Accumulator Line
Accumulator
In-Line Filter
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 structure
Pressure switch specifications
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
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
Parking brake solenoid valve
Solenoid valve operation
Solenoid valve specifications
Parking Brake Manual Release
Parking Brake Spring Chamber
Brake Circuit Check Valve
Auto Brake
Auto brake operation set value
Auto brake circuit
Solenoid valve (for auto brake circuit)
Solenoid specifications
Shuttle Valve
53 Check & Adjustment Brake Group
Brake Circuit Oil Pressure
Unloader valve setting pressure
Measurement procedure
Adjusting unloader valve setting pressure
Accumulator circuit pressure measurement and adjusting
Measuring reducing valve setting pressure
Measurement procedure
Adjusting reducing valve setting pressure
Brake valve oil pressure
Measurement instrument
Brake valve performance
Measurement procedure
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
Parking brake clearance adjustment
Adjustment procedure
Brake lining wear 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 location
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
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
Diag. Inc/Dec switch assembly (option)
Engine diagnostic switch (option)
Failure diagnostic chart
Increment decrement switch (option)
Quantum fault code information
Power mode change
Accelerator pedal
Accelerator pedal installation
Accelerator pedal
Accelerator pedal installation
Transmission Control Circuit (S/N 0101~0153, 9001~)
Controller
LED inspection windows
Controller connection diagram
Controller function
Forward/reverse (F/R) shifting and speed change
Automatic shift
Machine speed sensor/Engine speed sensor
Switching from automatic to manual
QUAD (shift) 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
Emergency steering function
Monitor controller
Transmission Control Circuit (S/N 0154~)
Machine control unit (MCU)
Connector
Machine control unit (MCU) connection diagram
Machine control unit (MCU) failure warning
Monitor Circuit
Items to be monitored and operation condition
Operation monitor lamps
Monitor controller (S/N 0101~0153, 9001~)
Monitoring sensor and switch
Instrument Panel and Switch
Instrument panel
Instrument panel rear surface
Gauge circuit
Temperature sensor
Fuel gauge circuit
Tachometer 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
Transmission controller
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 0154~)
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
Neutral relay electrical circuit check
Parking brake electrical circuit check
Auto brake electrical circuit check
Gauge circuit electrical circuit check
Fuel level gauge electrical circuit check
Bucket positioner electrical circuit check
72 Function & Structure Operator Station Group
Cabin
Glass
1. Part number 32011-21690
2. Part number 32011-21700
3. Part number 32011-21500
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 0101~0120)
Loading/Steering Hydraulic Circuit (S/N 0121~)
Loading/Steering Hydraulic Circuit (S/N 9001~9010)
Loading/Steering Hydraulic Circuit (S/N 9011~)
Brake Circuit
Electrical Wiring Diagram (1/2) (S/N 0101~0120)
Electrical Wiring Diagram (2/2) (S/N 0101~0120)
Electrical Wiring Diagram (1/2) (S/N 0121~0124)
Electrical Wiring Diagram (2/2) (S/N 0121~0124)
Electrical Wiring Diagram (1/2) (S/N 0125~0153)
Electrical Wiring Diagram (2/2) (S/N 0125~0153)
Electrical Wiring Diagram (1/3) (S/N 0154~)
Electrical Wiring Diagram (2/3) (S/N 0154~)
Electrical Wiring Diagram (3/3) (S/N 0154~)
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~)
Electrical Wiring Diagram (2/2) (S/N 9011~)
Electrical Wiring Diagram Abbreviation Chart (S/N 0101~0153, 9001~)
Electrical Wiring Diagram Abbreviation Chart (S/N 0154~)
Electrical Wiring Diagram (CAB)
Electrical Connection Diagram (S/N 0101~0120)
Electrical Connection Diagram (S/N 0121~0124)
Electrical Connection Diagram (S/N 0125~0153)
Electrical Connection Diagram (S/N 0154~)
Electrical Connection Diagram (S/N 9001~9010)
Electrical Connection Diagram (S/N 9011~)
Electrical Equipment Layout
Front chassis
Rear chassis
Floor board
Electrical Circuit Diagram (Cabin Air Conditioner)
Electrical Wiring Diagram (Cabin Air Conditioner)
Equipment Operation Table (Cabin Air Conditioner)
INDEX
Maintenance Log
Notes