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72 Function & Structure Operator Station Group .................................................................................................. 72-1

Cabin ................................................................................................................................................................. 72-2

Glass ........................................................................................................................................................... 72-3

Wiper mount ................................................................................................................................................ 72-6

Wiper motor ................................................................................................................................................ 72-7

Operator Seat ................................................................................................................................................... 72-9

Steering and Transmission Shift Lever ........................................................................................................... 72-10

Tilt case ......................................................................................................................................................72-11

Column shaft ............................................................................................................................................. 72-12

Shift lever .................................................................................................................................................. 72-12

Air Conditioner ................................................................................................................................................ 72-13

Denso air conditioner components ........................................................................................................... 72-13

Denso air conditioner structure ................................................................................................................. 72-14

Function of cooling mechanism ................................................................................................................ 72-19

Cooling circuit ........................................................................................................................................... 72-22

Electrical circuit ......................................................................................................................................... 72-23

Air conditioner functions of components ................................................................................................... 72-24

Charge of refrigerant ................................................................................................................................. 72-52

Air conditioner troubleshooting ................................................................................................................. 72-69

73 Check & Adjustment Operator Station Group .................................................................................................. 73-1

Air Conditioner .................................................................................................................................................. 73-2

Adjustment of lubricating oil quantity when components of air conditioner are replaced ............................ 73-2

Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ......................................... 73-5

Compressor V-belt adjustment .................................................................................................................... 73-6

Parts to be replaced periodically ................................................................................................................. 73-7

92 Drawing & Diagrams ........................................................................................................................................ 92-1

Axle Assembly .................................................................................................................................................. 92-2

Torque Converter and Transmission ................................................................................................................. 92-3

Hydraulic & Brake Circuit (S/N 9001~9250) ...................................................................................................... 92-4

Hydraulic & Brake Circuit (S/N 9251~) .............................................................................................................. 92-5

Brake Circuit ..................................................................................................................................................... 92-6

Electrical Wiring Diagram (1/3) (S/N 9001~9048) ............................................................................................. 92-7

Electrical Wiring Diagram (2/3) (S/N 9001~9048) ............................................................................................. 92-8

Electrical Wiring Diagram (3/3) (S/N 9001~9048) ............................................................................................. 92-9

Electrical Wiring Diagram (1/3) (S/N 9049~9250) ........................................................................................... 92-10

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Summary of Contents for ZW370

Page 1: ...Service Manual consists of the following separate Part No Technical Manual Operational Principle Vol No TO97C5 E Technical Manual Troubleshooting Vol No TT97C5 E Workshop Manual Vol No W97C5 E TO97C5 E 02 PART NO Wheel Loader Technical Manual Operational Principle URL http www hitachi c m com ZW370 ...

Page 2: ...Find manuals at https best manuals com ...

Page 3: ...t in this Shop Manual General Information Function and structure For the engine refer to the engine Shop Manual provided by the engine manufacturer The purpose of this manual is to provide information on the product and the correct maintenance and repair meth ods Please read this manual to ensure correct troubleshooting and good repair service This manual will be periodically reviewed and revised ...

Page 4: ...l may occur To protect yourself from all accidents be careful when doing service work DANGER This danger symbol identifies special warnings or procedures which if not strictly observed will result in death or serious injury WARNING This warning symbol identifies special warnings or procedures which if not strictly observed could result in death or serious injury CAUTION This caution symbol identif...

Page 5: ...d gasket and screw lock agent 00 18 Cautions regarding welding repair service 00 20 03 Measurement for Performance Check 03 1 Cautions on Safety 03 2 Standard Measurement Values for Performance Check 03 3 12 Function Structure Chassis Group 12 1 Front Chassis 12 2 Loading linkage 12 2 Loading linkage pin 12 4 Rear Chassis 12 5 Fuel tank 12 5 Floor board mount 12 6 Center Pin 12 7 Upper center pin ...

Page 6: ...1 Axle Support 22 12 Torque Proportioning Type Differential Gear TPD 22 14 Function of T P D 22 17 Operation of T P D 22 18 Limited Slip Differential LSD option 22 19 LSD structure 22 19 LSD function 22 23 LSD operation 22 23 23 Check Adjustment Power Group 23 1 Engine 23 2 Measuring engine speed 23 2 Measuring engine oil pressure 23 2 Propeller Shaft 23 3 Propeller shaft phase 23 3 Second propell...

Page 7: ...position 32 8 Downshift button operation 32 8 Gear train and number of teeth 32 9 Clutch Pack 32 12 Power Flow Path in the Transmission 32 13 Forward 1st speed power flow path 32 13 Forward 2nd speed power flow path 32 14 Forward 3rd speed power flow path 32 14 Forward 4th speed power flow path 32 15 Reverse 1st speed power flow path 32 16 Reverse 2nd speed power flow path 32 16 Reverse 3rd speed ...

Page 8: ...up 42 1 Flushing Hydraulic Circuit 42 2 Purpose of flushing 42 2 Cautions on Hydraulic Parts Replacement 42 3 Hydraulic Circuit Symbols 42 4 Hydraulic lines 42 4 Pumps motors 42 4 Cylinders 42 4 Operation methods 42 5 Pressure control valve 42 5 Flow control valve 42 5 Directional control valve 42 6 Check valve 42 6 Miscellaneous hydraulic symbols 42 7 Hydraulic System Operation 42 8 Hydraulic sys...

Page 9: ...51 9255 42 30 Pilot valve S N 9256 42 35 Multiple Control Valve KML35A 2T003B 42 40 Multiple control valve specifications 42 41 Multiple control valve main relief valve 42 42 Multiple control valve overload relief valve with make up function 42 44 Multiple control valve make up valve 42 45 Multiple control valve bucket spool 42 46 Multiple control valve boom spool 42 48 Adapter Orifice 42 51 Ride ...

Page 10: ... overload relief valve 42 78 Steering pilot circuit and its operation 42 80 Stop Valve 42 82 Stop valve function 42 83 Stop valve operation 42 83 Reducing Valve for Orbitrol 42 84 Steering Line Filter 42 85 K Lever OPT 42 86 Hydraulic circuit 42 86 Hydraulic line diagram 42 87 Hydraulic line 42 88 Solenoid valve mount 42 89 Solenoid valve assembly 1 2 42 90 Solenoid valve assembly 2 2 42 91 Effici...

Page 11: ...lief Valve Ride Control Circuit Reducing Valve OPT 43 2 Loading circuit relief valve setting pressures 43 2 Ride control circuit reducing valve setting pressures OPT 43 7 Steering circuit relief valve setting pressures 43 9 Hydraulic Cylinder 43 14 Cylinder natural drift 43 14 Stop Valve 43 17 Stop valve adjustment procedure 43 17 52 Function Structure Brake Group 52 1 Brake System Outline 52 2 Se...

Page 12: ...eration set value 52 32 Solenoid valve for Autobrake circuit 52 33 Pressure Sensor for stop lamp and declutch 52 34 Pressure sensor for declutch 52 34 Pressure sensor for stop lamp 52 34 53 Check Adjustment Brake Group 53 1 Brake Circuit Oil Pressure 53 2 Unloader valve setting pressure 53 2 Brake valve oil pressure 53 4 Service Brake 53 6 Service brake performance check 53 6 Service brake frictio...

Page 13: ...x 62 11 Fusible link 62 13 Engine Start Circuit 62 14 Engine start circuit diagram 62 14 Neutral starter 62 15 Starter switch 62 16 Battery relay 62 17 Alternator I terminal wire 62 18 Diode unit 62 18 Neutral relay 62 19 Magnetic switch 62 20 Voltage relay 62 21 Power Generating Charging Circuit 62 22 Alternator 62 22 ECM Engine Controller 62 23 Function of ECM 62 23 Connection diagram 62 23 Moni...

Page 14: ...N 9351 62 66 Instrument panel rear surface 62 67 Gauge circuit 62 69 Fuel gauge circuit 62 71 MODM 62 72 MODM function 62 72 Monitor Changeover 62 72 Information Monitor 62 75 Replacement Monitor 62 79 Fault Log Monitor 62 85 Input Output Monitor 62 92 Parameter Setting Monitor 62 96 Specification Setting Monitor 62 105 Electrical Detent Circuit 62 111 Bucket leveler 62 111 Detent solenoid 62 112 ...

Page 15: ...ooting 72 69 73 Check Adjustment Operator Station Group 73 1 Air Conditioner 73 2 Adjustment of lubricating oil quantity when components of air conditioner are replaced 73 2 Adjustment of air gap between hub and rotor in compressor magnetic clutch 73 5 Compressor V belt adjustment 73 6 Parts to be replaced periodically 73 7 92 Drawing Diagrams 92 1 Axle Assembly 92 2 Torque Converter and Transmiss...

Page 16: ...iring Diagram CAB 92 23 Electrical Connection Diagram 1 2 S N 9001 9250 92 26 Electrical Connection Diagram 2 2 S N 9001 9250 92 27 Electrical Connection Diagram 1 2 S N 9251 9350 92 28 Electrical Connection Diagram 2 2 S N 9251 9350 92 29 Electrical Connection Diagram 1 2 S N 9351 92 30 Electrical Connection Diagram 2 2 S N 9351 92 31 Electrical Wiring Diagram Cabin Air Conditioner 92 32 Electric...

Page 17: ...ZW370 FS 00 1 00 General Information 00 General Information How to Use Manual 00 2 Outline 00 4 ...

Page 18: ... a unit is lifted by a crane be sure to place a stand or ade quate cribbing under the unit to prevent unexpected dropping Do not start to work in an enclosed area if adequate ventilation is not provided To remove a heavy unit 20 kg 40 lbs or more be sure to use a crane or other lifting device Just after stopping operation be careful not to directly touch a hot component You may get burned Contact ...

Page 19: ...at should be carefully tightened during assembly work Coating Shows the type of coating or adhesive and the coat ing section Oil or water supply Shows the oil or water supply port and the refill amount Drainage Shows the oil or water drain port and the drain amount IMPORTANT If the specified conditions are not satisfied or the specified procedure is not observed there is a strong possibility that ...

Page 20: ...ZW370 FS 00 4 00 General Information Outline Outline Layout of main components 95V2E00002 5 6 7 8 10 22 18 11 16 17 20 14 2 15 13 1 19 12 3 8 9 4 21 3 4 S N 9001 9150 ...

Page 21: ... 6 Pilot valve for loading 7 Transmission control valve 8 Air cleaner 9 ELS valve 10 Muffler 11 Radiator 12 Front axle assembly 13 Rear axle assembly 14 2nd propeller shaft 15 3rd propeller shaft 16 Hydraulic oil cooler air to oil type 17 T C oil cooler 18 Air charge cooler 19 Fuel cooler 20 Parking brake 21 Combination valve 22 Fan motor K95V2U00001 11 11 18 22 17 19 16 S N 9151 ...

Page 22: ...m Fuel Filter Check Fuel Level Check Drive Belt Check Crankcase Breather Tube Check Air Intake System Check Cooling Fan Drain Water and Sediment from Fuel Tank Replace Fuel Filter Cartridge Replace Engine Oil and Oil Filter Cartridge Add DCA4 Coolant Additive Inspect Automatic Belt Tensioner Pulley Replace Fuel Tank Breather Replace Coolant Filter Cartridge One year or 1500 hours whichever comes f...

Page 23: ...y 12000 hours Greasing 3rd Propeller Shaft Every 12000 hours Steering system Check Steering Wheel Operation Greasing Steering Cylinder Clean Filter for Orbitrol Brake system Check Service Brake Operation Check Parking Brake Operation Check Parking Brake Gear Oil Replace Parking Brake Gear Oil Check Service Brake Disk Wear Check Brake Accumulator Clean Filter for Brake Line Loading system Check Hyd...

Page 24: ...peration Check Horn Operation Check Back up Alarm Operation Check Wiring Harnesses Check Battery Electrolyte Level Check or Replace Fuses Air Conditioner Check Drive Belt Clean Air Conditioner Filter Element Check Air Conditioner Refrigerant Replace Air Conditioner Filter Elements Clean Air Conditioner Condenser Replace Air Conditioner Receiver Dryer Every 3 years or 6000 hours Others Walk Around ...

Page 25: ... A T F Hydraulic System Use industrial type hydraulic oils which are certified by suppliers having anti wear anti foam anti rust and anti oxidation additive properties for heavy duty use Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure 3 In a case that fire resistant fluid is used in the hydraulic circuit replace hydraulic pumps every ...

Page 26: ... for diesel fuel Grade No 1 D Grade No 2 D Flash Point ºC min 38 52 Water and Sediment vol max 0 05 0 05 Distillation Temperature ºC 90 vol recovered max 288 338 Kinematic Viscosity mm2 s at 40ºC min 1 3 1 9 max 2 4 4 1 Ash mass max 0 01 0 01 Sulfur mass max 0 50 0 50 Cetane Number min 40 40 Carbon residue on 10 distillation residue mass max 0 15 0 35 Expected minimum ambient temperature 35ºC 31ºF...

Page 27: ...ANK DIFF GEAR BOX TRANSMISSION PILLOW UNIT LINK SYSTEM ENGINE OIL PAN BUCKET 2ND PROPELLER SHAFT STEERING CYL EVERY 2000Hr EVERY 1000Hr EVERY 500Hr EVERY 250Hr EVERY 50Hr EVERY DAY AXLE SUPPORT EVERY 12000Hr 2ND PROPELLER SHAFT DIFF DIFF CENTER PIN Grease point Check and add if necessary Oil replacement G Multipurpose grease GO Gear oil EO Engine oil HO Hydraulic oil TO Engine oil ...

Page 28: ...unter weight 1 920 4 230 Power line Engine 1 600 3 520 Excluding oil Radiator assembly 570 1 260 Excluding water and oil Transmission 1 570 3 460 Excluding oil Second propeller shaft 90 200 Third propeller shaft 20 45 Front axle assembly 2 000 4 400 Excluding tires and oil Rear axle assembly 2 030 4 470 Excluding tires and oil Including axle support Differential Front 550 1 210 Rear 370 820 Hydrau...

Page 29: ...11T Metric thread M8 8 C 1 25 26 38 M10 10 C 1 5 53 76 F 1 25 55 80 M12 12 C 1 75 90 132 F 1 25 96 142 M14 14 C 2 0 142 206 F 1 5 152 221 M16 16 C 2 0 216 314 F 1 5 226 330 M18 18 C 2 5 299 436 F 1 5 324 476 M20 20 C 2 5 417 608 F 1 5 451 662 M22 22 C 2 5 559 814 F 1 5 598 878 M24 24 C 3 0 721 1 030 F 2 0 770 1 128 M27 27 C 3 0 1 030 1 520 F 2 0 1 128 1 618 M30 30 C 3 5 1 422 2 109 F 2 0 1 569 2 2...

Page 30: ...5 22 5 M16 16 C 2 0 22 0 32 0 F 1 5 23 0 33 7 M18 18 C 2 5 30 5 44 5 F 1 5 33 0 48 5 M20 20 C 2 5 42 5 62 0 F 1 5 46 0 67 5 M22 22 C 2 5 57 0 83 0 F 1 5 61 0 89 5 M24 24 C 3 0 73 5 105 0 F 2 0 78 5 115 0 M27 27 C 3 0 105 0 155 0 F 2 0 115 0 165 0 M30 30 C 3 5 145 0 215 0 F 2 0 160 0 230 0 M33 33 C 3 5 195 0 290 0 F 2 0 210 0 310 0 Unified thread 5 16 05 18 UNC 2 5 3 6 3 8 06 16 UNC 4 5 6 6 7 16 07...

Page 31: ... 105 150 F 1 5 110 160 M16 16 C 2 0 160 230 F 1 5 165 245 M18 18 C 2 5 220 320 F 1 5 235 350 M20 20 C 2 5 305 450 F 1 5 330 490 M22 22 C 2 5 410 600 F 1 5 440 650 M24 24 C 3 0 530 760 F 2 0 565 830 M27 27 C 3 0 760 1 120 F 2 0 830 1 190 M30 30 C 3 5 1 050 1 550 F 2 0 1 160 1 660 M33 33 C 3 5 1 410 2 100 F 2 0 1 520 2 240 Unified thread 5 16 05 18 UNC 18 0 26 3 8 06 16 UNC 32 47 7 16 07 14 UNC 52 7...

Page 32: ...M5 0 8 7 M6 1 12 M8 1 25 28 M10 1 5 53 M12 1 75 94 M16 2 231 M20 2 5 441 M24 3 765 kgf m Type Bolt size Bolt strength Nominal dimension Pitch 8 8 8T Metric thread M5 0 8 0 7 M6 1 1 2 M8 1 25 2 9 M10 1 5 5 4 M12 1 75 9 6 M16 2 23 5 M20 2 5 45 0 M24 3 78 0 lb ft Type Bolt size Bolt strength Nominal dimension Pitch 8 8 8T Metric thread M5 0 8 5 0 M6 1 8 6 M8 1 25 20 9 M10 1 5 38 9 M12 1 75 69 1 M16 2...

Page 33: ...9 0 30 0 25 4 38 0 69002 04400 31 8 45 8 69002 05200 38 1 52 1 69002 05700 50 8 67 8 69002 07100 60 5 76 0 69002 08200 75 5 93 0 69002 09500 Low pressure hose Hose band Tightening torque N m Tightening torque kgf cm Tightening torque lb ft Inner dia mm Outer dia mm 6 16 5 69002 02200 1 6 16 1 2 8 18 5 9 20 5 9 22 0 69002 02300 4 40 2 9 12 24 5 69002 02700 12 26 0 15 29 0 69002 03100 15 30 5 19 32 ...

Page 34: ...w bolt should be used during reassembly Cautions regarding reassembly To reassemble a screw Completely remove the hardened lock agent from the screw and the threaded hole before reassembling the screw Note A piece of hardened lock agent may be peeled off and remain in the component The remaining piece may cause malfunction during fastener installation To bond a plane or to fit a shaft Remove the h...

Page 35: ...hrough hole Apply screw lock agent one or two lines on the male threads How to wind a seal tape To avoid a piece of seal tape left in the circuit leave 1 or 2 screws from the end of the thread and start threading it clockwise 65ZV00002 Screw lock agent 65ZV00004 Seal tape Leave 1 2 screw ...

Page 36: ...low conductive metal that will cause spark if the welding current flows The spark may damage the cylinder rod 6 Calibrate throttle pedal to ECM a Turn the starter switch to ON b Fully depress and release the throttle pedal three times c Turn the starter switch to OFF IMPORTANT If a battery terminal is removed from a machine in less than 30 seconds after the key is put into the OFF position it can ...

Page 37: ... Cover the hydraulic units electrical units har nesses hydraulic hoses nylon tubes etc with heat resistant cloth glass wool or canvas or scrap material to protect them from spatter c Hydraulic hoses nylon tubes or harnesses are easily damaged by the heat during welding To pro tect them from the heat remove them from the sec tion to be welded to make enough clearance 35C00003 Hydraulic cylinder Pla...

Page 38: ...ZW370 FS 00 22 00 General Information MEMO ...

Page 39: ...ZW370 FS 03 1 03 Measurement for Performance Check 03 Measurement for Performance Check Cautions on Safety 03 2 Standard Measurement Values for Performance Check 03 3 ...

Page 40: ...ety lock of the boom and the bucket control lever provided in the cab remove the starter key and attach a DO NOT OPERATE tag to the cab CAUTION Be careful not to be burnt by bursting high pressure oil Release the pressure remaining inside the circuit and open the cap of the hydraulic tank before removing the plug from the pressure measurement port so that the internal pressure of the hydraulic tan...

Page 41: ...1 670 100 Maximum speed in torque converter stall plus multiple control valve relief mode 1 460 150 100 1 250 150 100 Engine speed min 1 rpm S N 9251 Minimum no load speed Low Idle LI 850 50 725 in hibernate mode Maximum no load speed High Idle HI 2 040 50 1 800 50 Maximum speed in torque converter stall mode 2 020 100 1 800 100 Maximum speed in multiple control valve relief mode 2 010 100 2 010 1...

Page 42: ...ief pressure LI 23 5 0 5 240 5 3 413 71 Run engine at lowest possible speed while setting Steering line main relief pressure HI 20 6 0 5 210 5 2 986 71 Steering line overload relief pressure LI 24 5 1 0 0 250 10 0 3 555 142 0 Run engine at lowest possible speed while setting Pilot line reducing pressure LI 3 5 36 512 Run engine at lowest possible speed while setting Fan maximum revolution HI min 1...

Page 43: ... 5 120 5 1 706 71 On Cut in 6 9 1 0 70 10 995 142 Low pressure alarm switch setting pressure For brake accumulator circuit 3 9 0 5 40 5 569 71 Accumulator charge time sec Engine speed LI The time from the low pressure alarm is turned off till the unloading valve cuts off pressure 16 Number of brake pedal applications Run engine 1 minute high idle then stop the engine Turn key switch ON with engine...

Page 44: ...ZW370 FS 03 6 03 Measurement for Performance Check MEMO ...

Page 45: ...ZW370 FS 12 1 12 Function Structure Chassis Group 12 Function Structure Chassis Group Front Chassis 12 2 Rear Chassis 12 5 Center Pin 12 7 ...

Page 46: ...ont Chassis Loading linkage 1 Bucket 2 Link 3 Lever 4 Boom 5 Bucket cylinder 6 Boom cylinder 7 Dump stopper surface 8 Roll back stopper surface 9 Lever stopper surface 10 Bucket stop plate Design differs by manufacturer of the attachment 95ZV12001 1 10 7 2 8 9 4 3 5 6 ...

Page 47: ...clearance Contact attachment supplier for details on non standard attachments To increase clearance increase height of 9 To reduce clearance decrease height of 9 Typical bucket roll back stopper adjustment Contact attachment supplier for details on non standard attachments Even contact both sides 4 490 mm 14 8 13 16 40 º 45 º 270 mm 10 6 in ...

Page 48: ... in K95ZV12003 5 2 3 8 4 7 10 11 9 6 1 1 Bucket Boom 2 Boom Lever 3 Boom Boom cylinder 4 Front chassis Boom 5 Bucket Rod 6 Lever Rod 7 Lever Bucket cylinder 8 Bucket cylinder Front chassis 9 Boom cylinder Front chassis 10 Front chassis Steering cylinder 11 Steering cylinder Rear chassis ...

Page 49: ...A 7 11 8 2 4 1 6 5 8 B 2 10 10 9 1 Fuel tank 2 Fuel level sensor 3 Fuel tank filler assembly 4 Filter 5 Drain plug 6 Inspection hole cover 7 Gasket Rubber seal type 8 Suction pipe 9 Pipe for vacuum prevention S N 9150 10 Breather valve S N 9151 11 Fuel return pipe A Detail B Detail S N 9150 S N 9151 ...

Page 50: ...s seat and the air conditioner unit are on the floor board Viscous mount 1 Stud bolt 2 Stud 3 Cushion rubber S N 9182 HS62 S N 9183 HS70 4 Case 5 Seal plate 6 Damping plate 7 Silicone oil 8 Plain washer 9 Hexagon head bolt The floor board is supported by a viscous mount in four positions so that vibrations impacts and sounds gener ated in the chassis are not transmitted to the inside of cabin 95ZV...

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