Hitachi ZW370 Technical Manual
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Hitachi ZW370 Technical Manual

Wheel loader
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URL:http://www.hitachi-c-m.com
PRINTED IN JAPAN (E) 2018, 03
TO97C5-E-02
PART NO.
Technical Manual
Operational Principle
ZW370
Wheel Loader
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle)
Technical Manual (Troubleshooting)
Workshop Manual
: Vol. No.TO97C5-E
: Vol. No.TT97C5-E
: Vol. No.W97C5-E
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Summary of Contents for Hitachi ZW370

  • Page 1 TO97C5-E-02 PART NO. Technical Manual Operational Principle ZW370 Wheel Loader URL:http://www.hitachi-c-m.com Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TO97C5-E Technical Manual (Troubleshooting) : Vol. No.TT97C5-E PRINTED IN JAPAN (E) 2018, 03 Workshop Manual...
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  • Page 3 October 2016 Foreword To ensure good machine performance, reduce failures or problems, and prolong the service life of each component, it is necessary to operate the machine as is directed in the Operator and Maintenance Manual. To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual. General Information Function and structure For the engine, refer to the engine Shop Manual provided by the engine manufacturer.

  • Page 4: Safety Symbols

    Safety Symbols An accident may occur if you disregard safety rules. In this manual, several expressions are used according to levels of danger for inspection and repair work as shown below. Read the work procedures and cautions described in this manual, and take preventive measures against possible problems before starting service work.
  • Page 5 CONTENTS 00 General Information ............................00-1 How to Use Manual ............................00-2 Safety precautions ............................00-2 Symbols ..............................00-3 Outline ................................00-4 Layout of main components ........................00-4 Inspection and maintenance table ......................00-6 Recommended lubricants ........................... 00-9 Coolant ..............................00-10 Lubrication chart ............................00-11 Weight of main components ........................
  • Page 6 Center Pin ................................. 13-5 Adjusting shim ............................. 13-5 Grease nipple installation direction ......................13-5 Installing bearing outer ring ......................... 13-5 22 Function & Structure Power Group ........................22-1 Power Line ................................ 22-2 Engine / Transmission ............................22-4 Engine / transmission mount ........................22-4 Radiator (S/N 9001~9150) ..........................
  • Page 7 32 Function & Structure Torque Converter and Transmission Group ..............32-1 Torque Converter .............................. 32-2 Torque converter structure .......................... 32-2 Power flow path ............................32-2 Torque multiplication ........................... 32-2 Torque Converter (Lock-up) (Option) ........................ 32-3 Lock-up clutch structure ..........................32-4 Lock-up clutch function (only forward) ......................
  • Page 8 Modulator Valve Unit ............................32-25 Interior schematic (simple explanation) ..................... 32-27 Modulator valve function ........................... 32-28 Modulator valve operation ......................... 32-30 Control Valve Assembly ..........................32-32 Check valve ............................... 32-34 Clutch solenoid valve assembly ........................ 32-35 Clutch valve assembly ..........................32-39 33 Check &...
  • Page 9 Hydraulic Pump ............................... 42-17 Loading and pilot and brake pump/Steering pump ................... 42-17 Loading and pilot and brake pump/Steering pump specifications ............. 42-17 Hydraulic pump principle ........................... 42-18 Hydraulic pump wear plate ........................42-19 Hydraulic pump bushing lubrication ......................42-19 Hydraulic Cylinder ............................
  • Page 10 ® Orbitrol ................................42-63 ® Orbitrol structure ............................. 42-63 ® Orbitrol specifications ..........................42-64 ® Orbitrol operation ............................ 42-65 ® Orbitrol feed-back mechanism operation ....................42-67 Steering speed and flow rate control ......................42-68 Hydraulic pump oil amount and steering force ..................42-68 Orbit rotor operation principle ........................
  • Page 11 Fan Motor Line ..............................42-97 Hydraulic circuit (fan motor normal rotation) ..................... 42-99 Proportional relief valve (S/N 9001~9150) ....................42-101 Proportional relief valve (S/N 9151~) ...................... 42-103 Fan motor ..............................42-105 Reversing Fan Motor Line (OPT) ........................42-108 Reversing fan motor function ........................42-108 Hydraulic circuit (Reverse rotation) ......................42-112 Secondary Steering ............................42-113 Secondary steering operation ........................42-113...
  • Page 12 Service Brake ..............................52-14 Service brake operation ..........................52-14 Service brake friction plate ........................52-15 Service brake steel plate ........................... 52-16 Service brake piston ..........................52-17 Service brake pedal stroke adjusting mechanism (S/N 9001~9014) ............52-18 Brake circuit air bleeding procedure ......................52-20 Parking Brake ..............................
  • Page 13 Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) ............62-5 Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) ..............62-6 Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) ..............62-7 Electrical Cable Color Codes ..........................62-8 Electrical Circuit Symbols ..........................62-9 Sensor Mount ..............................
  • Page 14 Transmission Control Circuit and Monitor Circuit .................... 62-37 Machine control unit (MCU) ........................62-37 Machine control unit (MCU) connection diagram (S/N 9001~9350) ............62-39 Machine control unit (MCU) connection diagram (S/N 9351~) ..............62-41 Machine control unit (MCU) function ......................62-43 Adjustable declutch preset switch ......................
  • Page 15 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 ..............................
  • Page 16 Electrical Wiring Diagram (2/3) (S/N 9049~9250) ................... 92-11 Electrical Wiring Diagram (3/3) (S/N 9049~9250) ................... 92-12 Electrical Wiring Diagram (1/3) (S/N 9251~9350) ................... 92-13 Electrical Wiring Diagram (2/3) (S/N 9251~9350) ................... 92-14 Electrical Wiring Diagram (3/3) (S/N 9251~9350) ................... 92-15 Electrical Wiring Diagram (1/3) (S/N 9351~) ....................

  • Page 17: General Information

    ZW370 FS 00-1 00 General Information 00 General Information How to Use Manual ..........00-2 Outline ..............00-4...

  • Page 18: How To Use Manual

    ZW370 FS 00-2 00 General Information How to Use Manual How to Use Manual Safety precautions - Do not start to work in an enclosed area if adequate ventilation is not provided. The most important point in providing repair service is - To remove a heavy unit (20 kg (40 lbs) or more), be safety.
  • Page 19 ZW370 FS 00-3 00 General Information How to Use Manual Symbols For safe and effective service work, the following sym- bols are used for notes and useful information in this manual. Symbol Item Description Shows the condition or procedure that will be useful Reference or efficient in doing service work.

  • Page 20: Layout Of Main Components

    ZW370 FS 00-4 00 General Information Outline Outline Layout of main components (S/N 9001 ~ 9150) 95V2E00002...
  • Page 21 ZW370 FS 00-5 00 General Information Outline 1. Engine assembly (Cummins QSX-15) (S/N 9151~) 2. Transmission/Torque converter assy 3. Hydraulic pump 4. Multiple (loader) control valve 5. Steering valve 6. Pilot valve (for loading) 7. Transmission control valve 8. Air cleaner 9.

  • Page 22: Inspection And Maintenance Table

    ZW370 FS 00-6 00 General Information Outline Inspection and maintenance table IMPORTANT Refer to Operation & Maintenance Manual for mainte- Severe application require more frequent mainte- nance procedures. nance. Severe conditions include heavy dust, extremely abrasive material, caustic chemicals, extremely wet conditions or abnormally hot or cold ambient temper- atures.
  • Page 23 ZW370 FS 00-7 00 General Information Outline : First time replacement or cleaning only Operating hours When Section Item for check Required 1000 1500 2000 Check Transmission Oil Level Transmission & Replace Transmission Oil Filter Cartridge Torque Replace Transmission Oil...
  • Page 24 ZW370 FS 00-8 00 General Information Outline : First time replacement or cleaning only Operating hours When Section Item for check Required 1000 1500 2000 Adjust and Check Rear View Mirrors ROPS (Roll Over Protective Structure) Cab Check Seat Belt Restraint...

  • Page 25: Recommended Lubricants

    ZW370 FS 00-9 00 General Information Outline Recommended lubricants Ambient Temperature (ºC) Refill capacity Change Interval Kind of Oil -20 -10 (Approximate) (Hours) SAE10W-30 2 Engine oil Engine 49.2 liter SAE15W-40 (CH4 or CI4) SAE10W Engine oil (CD) or Transmission...
  • Page 26 ZW370 FS 00-10 00 General Information Outline Diesel Fuel Requirements for diesel fuel Specifications Grade No. 1-D Grade No. 2-D Flash Point ºC. min. Water and Sediment % vol. max. 0.05 0.05 Distillation Temperature ºC. 90% vol. recovered max. min.

  • Page 27: Lubrication Chart

    ZW370 FS 00-11 00 General Information Outline Lubrication chart DIFF & 2ND PROPELLER HYDRAULIC DIFF & EVERY 12000Hr GEAR BOX SHAFT TANK GEAR BOX EVERY 2000Hr DIFF TRANSMISSION DIFF EVERY 1000Hr ENGINE OIL PAN EVERY 500Hr PILLOW UNIT EVERY 250Hr...
  • Page 28 ZW370 FS 00-12 00 General Information Outline Weight of main components Approx. Approx. Item weight weight Remarks Unit name Part name (kg) (lb) Bucket 2,750 6,050 GSC bucket Boom 2,130 4,690 "Z" -Lever 275/pc 605/pc Link (Bucket to Lever) 60/pc...
  • Page 29 ZW370 FS 00-13 00 General Information Outline Bolt tightening torque Hexagon bolt 1. Thread type Metric thread, Unified thread 2. Bolt strength 8.8 (8T) ~ 10.9 (11T) 3. Thread pitch Metric thread: Coarse pitch thread (C), fine pitch thread (F)
  • Page 30 ZW370 FS 00-14 00 General Information Outline (kgf-m) Bolt size Bolt strength Type Nominal Nominal Pitch 8.8 (8T) 10.9 (11T) dimension diameter (C) 1.25 (C) 1.5 (F) 1.25 (C) 1.75 13.5 (F) 1.25 14.5 (C) 2.0 14.5 21.0 (F) 1.5 15.5...
  • Page 31 ZW370 FS 00-15 00 General Information Outline (lb-ft) Bolt size Bolt strength Type Nominal Nominal Pitch 8.8 (8T) 10.9 (11T) dimension diameter (C) 1.25 19.5 (C) 1.5 (F) 1.25 (C) 1.75 (F) 1.25 (C) 2.0 (F) 1.5 (C) 2.0 (F) 1.5 (C) 2.5...
  • Page 32 ZW370 FS 00-16 00 General Information Outline Flanged hexagon bolt 1. Bolt type: Metric thread 2. Bolt strength: 8.8 (8T) 3. Thread pitch: Coarse pitch thread (C) (N-m) Bolt size Bolt strength Type Nominal Pitch 8.8 (8T) dimension 1.25 Metric thread 1.75...
  • Page 33 ZW370 FS 00-17 00 General Information Outline Hose band tightening torque Low pressure hose Tightening torque Tightening torque Tightening torque (heat resisting hose) Hose band (N-m) (kgf-cm) (lb-ft) Inner dia. (mm) Outer dia. (mm) 16.5 18.5 69002-02200 20.5 12.7 24.5 69002-02700 15.9...
  • Page 34 ZW370 FS 00-18 00 General Information Outline Liquid gasket and screw lock Cautions regarding reassembly agent To reassemble a screw Completely remove the hardened lock agent from the To reassemble the disassembled parts, be sure to use screw and the threaded hole before reassembling the the specified liquid gasket or screw lock agent or the screw.
  • Page 35 ZW370 FS 00-19 00 General Information Outline Screw lock agent application procedure How to wind a seal tape Through-hole Apply screw lock agent one or two lines on the male threads. Seal tape Screw lock agent Leave 1~2 screw 65ZV00004...
  • Page 36 ZW370 FS 00-20 00 General Information Outline Cautions regarding welding repair service If welding is needed to repair the chassis, observe the following precautions to protect the hydraulic cylinders, hydraulic units, gear sets, and electrical units from pos- sible damage.
  • Page 37 ZW370 FS 00-21 00 General Information Outline 7. The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylin- ders and pins. There are other parts that may be Heat-resistant damaged by the spatter; hydraulic units, har- cloth nesses, hydraulic hoses, and nylon tubes.
  • 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: Cautions On Safety

    ZW370 FS 03-2 03 Measurement for Performance Check Cautions on Safety Cautions on Safety WARNING CAUTION Unexpected movement of the machine may cause an Touching the fan or the V belt of the engine or the hot accident resulting in injury or death.
  • Page 41 ZW370 FS 03-3 03 Measurement for Performance Check Standard Measurement Values for Performance Check Standard Measurement Values for Performance Check Measurement conditions Temperature of torque converter oil: 50~80°C (120~180°F) Temperature of hydraulic oil: 50~80°C (120~180°F) Temperature of engine coolant: 50~80°C (120~180°F)
  • Page 42 ZW370 FS 03-4 03 Measurement for Performance Check Standard Measurement Values for Performance Check Standard measurement Item values for performance check Remarks Fuel efficient Measurement item Normal System mode Cylinder drift Boom cylinder 3 (1/8) or less (when boom and...
  • Page 43 ZW370 FS 03-5 03 Measurement for Performance Check Standard Measurement Values for Performance Check Standard measurement Item values for performance check Remarks Fuel efficient Measurement item Normal System mode Shift lever position 2nd speed reverse Performance of service brake Engine speed...
  • 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 ZW370 FS 12-2 12 Function & Structure Chassis Group Front Chassis Front Chassis Loading linkage 95ZV12001 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.
  • Page 47 ZW370 FS 12-3 12 Function & Structure Chassis Group Front Chassis Even contact both sides 45 º 40 º Hinge pin height at 270 mm (10.6 in) bucket on ground Typical bucket dump stopper clearance (Contact attachment supplier for details on...
  • Page 48 ZW370 FS 12-4 12 Function & Structure Chassis Group Front Chassis Loading linkage pin mm (in) 1. Bucket - Boom 2. Boom - Lever 3. Boom - Boom cylinder 4. Front chassis - Boom 5. Bucket - Rod 6. Lever - Rod 7.

  • Page 49: Rear Chassis

    ZW370 FS 12-5 12 Function & Structure Chassis Group Rear Chassis Rear Chassis Fuel tank A-Detail (S/N 9151~) (S/N ~9150) 1. Fuel tank 2. Fuel level sensor 3. Fuel tank filler assembly 4. Filter 5. Drain plug 6. Inspection hole cover 7.
  • Page 50 ZW370 FS 12-6 12 Function & Structure Chassis Group Rear Chassis Floor board mount Viscous mount Floor board 95ZV12007 1. Floor board 2. Rubber cushion The floor board is installed on the rear chassis by the rubber cushion. The instrument panel, control box, operator's seat and the air conditioner unit are on the floor board.
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