Hitachi ZW 550 Wheel Loader Workshop+Operational Principle+Troubleshooting Manual
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This Listing includes all of the manuals mentioned below:
Hitachi ZW 550 Wheel Loader Workshop+Operational Principle+Troubleshooting Manual
1.Hitachi ZW550 Wheel Loader Operational Principle Technical Manual
2.Hitachi ZW550 Wheel Loader Troubleshooting Technical Manual TT11C5-E-00
3.Hitachi ZW550 Wheel Loader Troubleshooting Technical Manual TT11C5-E-01
4.Hitachi ZW550 Wheel Loader Workshop Manual
DESCRIPTION:
Hitachi ZW 550 Wheel Loader Workshop+Operational Principle+Troubleshooting Manual
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.
- Disassembly & Reassembly
- Service Standard
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 methods. Please read this manual to ensure correct troubleshooting and good repair service. This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or requests, please inform us.
TABLE OF CONTENTS:
Hitachi ZW 550 Wheel Loader Workshop+Operational Principle+Troubleshooting Manual
Hitachi ZW550 Wheel Loader Workshop Manual
General Information 00-1
Symbols 00-2
Weight of Main Components 00-3
Bolt Tightening Torque 00-4
Hose Band Tightening Torque 00-8
Liquid Gasket and Screw Lock Agent 00-9
Cautions regarding parts removal 00-9
Cautions regarding reassembly 00-9
Screw lock agent application procedure 00-10
How to wind a seal tape 00-10
Cautions Regarding Welding Repair Service 00-11
Cautions Regarding Handling of Bearing 00-13
Bearing installation cautions 00-13
Interference fits for a bearing 00-13
Bearing removal cautions 00-14
Applying and Storing Articulation Stopper 00-15
Applying articulation stopper 00-15
Storing articulation stopper 00-15
Disassembly & Reassembly Chassis Group 14-1
Deck 14-2
Deck removing and installing 14-2
Fuel Tank 14-4
Fuel tank removing and installing 14-4
Hydraulic Tank 14-5
Hydraulic tank removing and installing 14-5
Engine Room 14-8
Engine room removing and installing 14-8
ROPS and Cab 14-11
ROPS removing and installing 14-11
Cab removing and installing 14-12
Floor Board 14-14
Floor board removing and installing 14-14
Boom 14-17
Boom removing and installing 14-17
Center Pin 14-21
Upper center pin 14-21
Lower center pin 14-22
Center pin removing and installing 14-23
Service Standard Chassis Group 15-1
Linkage 15-2
Linkage Pin Standard Clearance Values 15-3
Liner clearance adjustment 15-3
Center Pin 15-4
Center pin shim adjustment 15-4
Grease nipple installing 15-4
Bearing assy installing 15-4
Attachment Leveler 15-5
Attachment leveler 15-6
Attachment leveler adjustable angle 15-6
Disassembly & Reassembly Power Group 24-1
Power Line 24-2
Power line tightening torque 24-2
Radiator 24-3
Radiator tightening torque 24-3
Radiator removing and installing 24-4
Fan 24-7
Fan removing and installing 24-7
Engine 24-9
Engine removing and installing 24-9
Propeller Shaft 24-11
Propeller shaft removing and installing 24-11
Air Cleaner 24-14
Air cleaner removing and installing 24-14
Muffler 24-16
Muffler removing and installing 24-16
Front Axle Assembly 24-18
Front axle assembly tightening torque 24-18
Front axle assembly removing and installing 24-20
Front axle disassembling and assembling 24-23
Front axle assembly cautions 24-27
Internal Gear Hub 24-33
Internal gear hub disassembling and assembling 24-33
Spider Assembly 24-37
Spider assembly disassembling and assembling 24-37
Special Tool 24-39
Special tool for axle 24-39
Rear Axle Assembly 24-44
Rear axle assembly tightening torque 24-44
Rear axle assembly removing and installing 24-46
Rear axle disassembling and assembling 24-48
Axle Support 24-49
Axle support tightening torque 24-49
Axle support disassembling and assembling 24-50
Differential Assembly 24-53
Differential assembly removing and installing 24-53
Differential assembly disassembling and assembling 24-55
Service Standard Power Group 25-1
Propeller Shaft Service Standard 25-2
Axle and Differential Service Standard 25-4
Axle group 25-4
Differential 25-5
Disassembly & Reassembly Torque Converter and Transmission Group 34-1
Torque Converter and Transmission Assembly 34-2
Torque converter and transmission assembly tightening torque 34-2
Torque Converter Assembly 34-3
Torque converter removing and installing 34-3
Transmission Assembly 34-12
Transmission assembly removing and installing 34-12
Gear Box Assembly 34-25
Gear box disassembling and assembling 34-25
Transmission Clutch Assembly 34-27
Transmission clutch assy disassembling and assembling 34-27
Clutch Spider Assembly 34-40
Transmission low/3rd speed clutch spider disassembling and assembling 34-40
Transmission 2nd speed clutch spider disassembling and assembling 34-42
Reverse Clutch Spider 34-44
Transmission reverse clutch spider disassembling and assembling 34-44
Transmission 1st Clutch Assembly 34-46
Transmission 1st speed clutch assy disassembling and assembling 34-46
Transmission High Clutch Assembly 34-50
Transmission high clutch assy disassembling and assembling 34-50
Control Valve Assembly 34-55
Control valve removing and installing 34-55
Service Standard Torque Converter and Transmission Group 35-1
Transmission Assembly 35-2
Torque Converter Gear Pump 35-6
Gear pump specifications 35-6
Gear Train and Number of Teeth 35-7
Clutch Oil Pressure 35-9
Disassembly & Reassembly Hydraulic Group 44-1
Hydraulic Parts Removal and Installation Warning 44-2
Hydraulic Parts Disassembly and Assembly Cautions 44-3
Hydraulic parts disassembly cautions 44-3
Hydraulic parts assembly cautions 44-3
Hydraulic Pump Assembly 44-4
Hydraulic pump assy removing and installing 44-4
Hydraulic pump assy disassembling and assembling 44-6
Hydraulic Cylinder 44-14
Boom cylinder removing and installing 44-14
Bucket cylinder removing and installing 44-17
Steering cylinder removing and installing 44-19
Hydraulic cylinder disassembling and assembling 44-21
Pilot Valve 44-27
Pilot valve removing and installing 44-27
Pilot valve disassembling and assembling 44-29
Multiple Control Valve 44-48
Multiple control valve removing and installing 44-48
Multiple control valve disassembling and assembling 44-51
Orbitrol® 44-55
Orbitrol® removing and installing 44-55
Orbitrol® disassembling and assembling 44-57
Steering Valve 44-65
Steering valve removing and installing 44-65
Steering valve disassembling and assembling 44-67
Stop Valve 44-70
Stop valve removing and installing 44-70
Stop valve disassembling and assembling 44-72
Fan Motor 44-74
Fan motor removing and installing 44-74
Service Standard Hydraulic Group 45-1
Hydraulic Cylinder 45-2
Pilot Valve 45-4
Steering Valve 45-6
Disassembly & Reassembly Brake Group 54-1
Unloader Valve 54-2
Unloader valve removing and installing 54-2
Unloader valve disassembling and assembling 54-4
Manifold Valve Assembly 54-8
Valve assembly removing and installing 54-8
Valve assembly disassembling and assembling 54-9
Accumulator 54-11
Accumulator removing and installing 54-11
Accumulator disassembling and assembling 54-13
Nitrogen gas charging 54-15
Brake Valve 54-17
Brake valve removing and installing 54-17
Brake valve disassembling and assembling 54-19
Service Brake 54-25
Service brake disassembling and assembling 54-25
Parking Brake 54-27
Parking brake disassembling and assembling 54-27
Parking Brake Piston 54-33
Parking brake piston assembly disassembling and assembling 54-33
Service Standard Brake Group 55-1
Brake Valve 55-2
Service Brake 55-4
Disassembly & Reassembly Operator Station Group 74-1
Air Conditioner 74-2
Air conditioner removing and installing 74-2
Air conditioner disassembling and assembling 74-4
Compressor V-belt 74-12
Service Standard Operator Station Group 75-1
Air Conditioner 75-2
Periodical Inspection/Servicing 75-2
Tightening Torque 75-2
Hitachi ZW550 Wheel Loader Troubleshooting Technical Manual
Cautions Regarding Troubleshooting 01-3
How to Use Quick Troubleshooting Table 01-4
Safety Precautions 01-5
Torque Converter and Transmission Group 01-6
1 Machine dose not move in any shift lever position 01-6
2 Machine dose not move at a certain shift lever position
(OR:Machine moves only in a certain shift lever position) 01-7
3 Machine moves at the neutral position (Example: Machine moves forward at the neutral position) 01-8
4 Large shock at starting or changing speed / direction 01-9
5 Large time lag at starting or changing speed / direction 01-10
6 Low power (Defective torque converter or transmission) 01-11
7 Torque converter oil is overheating 01-12
8 Machine moves reverse when starting to climb up on a slope using inching brake 01-13
9 Automatic speed change is not possible 01-14
10 Downshift button does not work 01-15
Hydraulic Group 01-16
1 Boom and/or bucket do not move 01-16
2 Boom and/or bucket have low power, or move too slowly 01-17
3 Excessive cylinder drift 01-18
4 Boom and/or bucket are spongy
(Holding bucket against the ground is not possible-front wheels off the ground) 01-19
5 Bucket leveler does not work Boom lift kickout and lower kickout does not work 01-20
6 Steering is not possible or hard to steer 01-21
7 Machine sways, or has a shock during steering 01-22
8 ELS (Efficient Loading System) does not work
(Excavating and scooping tractive power does not become up during ELS working condition) 01-23
01-2
9 Ride control does not work 01-24
10 Fan motor rotates abnormally or does not rotate 01-25
11 Abnormal noise in hydraulic system 01-26
12 Others 01-27
Brake Group 01-28
1 Brake does not work well (In the worst case, the brake does not work at all) 01-28
2 Brake is dragging when released 01-29
3 Stepping on the brake pedal sounds the buzzer 01-30
4 Accumulator pressure does not rise, or too slow in rising 01-31
5 Parking brake does not work (or: Releasing the parking brake is not possible) 01-32
Electrical Group 01-33
1 Instrument panel does not indicate properly 01-33
2 Fuse for controller is blown 01-34
Error code (for chassis) 01-35
Error code (for engine) 01-38
Operator Station Group 01-44
Air conditioner 01-44
Hitachi ZW550 Wheel Loader Operational Principle Technical Manual
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 00-5
Recommended lubricants 00-8
Coolant 00-9
Lubrication chart 00-10
Weight of main components 00-11
Bolt tightening torque 00-12
Hose band tightening torque 00-16
Liquid gasket and screw lock agent 00-17
Cautions regarding welding repair service 00-19
Measurement for Performance Check 03-1
Cautions on Safety 03-2
Standard Measurement Values for Performance Check 03-3
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 12-7
Lower center pin 12-8
Dust seal 12-9
Check & Adjustment Chassis Group 13-1
Linkage Pin 13-2
Liner 13-2
Center Pin 13-6
Adjusting shim 13-6
Installing bearing cover 13-6
Installing bearing outer ring 13-7
Function & Structure Power Group 22-1
Power Line 22-2
Engine / Transmission 22-3
Engine / transmission mount 22-3
Radiator 22-4
Radiator mount 22-5
Propeller Shaft 22-6
First propeller shaft assembly 22-7
Second propeller shaft assembly 22-8
Third propeller shaft assembly 22-9
Axle Assembly 22-10
Axle Support 22-12
Differential Gear 22-14
Conventional type 22-14
Function of differential gear 22-17
Operation of differential gear 22-17
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 propeller shaft alignment 23-3
Propeller shaft tightening torque 23-4
Axle 23-5
Axle nut tightening procedure 23-5
Differential gear adjustment procedure 23-6
Function & Structure Torque Converter and Transmission Group 32-1
Torque Converter 32-2
Torque converter structure 32-3
Power flow path 32-3
Torque multiplication 32-3
Torque Converter (Lock-up) (Option) 32-4
Lock-up clutch structure 32-5
Lock-up clutch function (only forward) 32-5
Torque Converter Gear Pump 32-7
Gear pump specifications 32-7
Transmission 32-8
Clutch combination 32-9
Planetary gear 32-9
Shift lever position 32-9
Downshift button operation 32-9
Gear train and number of teeth 32-10
Clutch Pack 32-14
Power Flow Path in the Transmission 32-15
Hydraulic System Diagram 32-19
Hydraulic Circuit Diagram 32-20
Oil Flow 32-22
Oil flow in the torque converter line 32-22
Oil flow in the transmission line 32-22
T/C and T/M Oil Circulation 32-24
Modulator Valve Unit 32-25
Interior schematic (not exact representation) 32-27
Modulation Mechanism 32-28
Modulator valve operation 32-29
Control Valve Assembly 32-31
Clutch solenoid valve assembly 32-33
Clutch valve assembly 32-36
Accumulator assembly 32-37
Direct charge valve 32-38
Lock-up clutch solenoid valve 32-39
Check & Adjustment Torque Converter and Transmission Group 33-1
Clutch Oil Pressure and Time Lag 33-2
Measuring clutch oil pressure 33-2
Function & Structure Hydraulic Group 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 system operation outline 42-8
Layout of Hydraulic Units 42-10
Hydraulic Tank 42-11
Hydraulic tank breather valve (tank cap) 42-12
Hydraulic tank specifications 42-13
Hydraulic oil level check 42-14
Hydraulic Pump 42-15
Loading and pilot and brake pump 42-15
Pump specifications 42-15
Steering pump 42-16
Steering pump specifications 42-16
Hydraulic pump principle 42-17
Hydraulic pump wear plate 42-18
Hydraulic pump bushing lubrication 42-18
Hydraulic Cylinder 42-19
Boom cylinder 42-19
Bucket cylinder 42-19
Steering cylinder 42-20
Hydraulic cylinder specifications 42-21
Loading System 42-22
Reducing Valve (for Pilot Pressure) 42-23
Pilot Valve 42-24
Pilot valve function 42-26
Pilot valve operation (modulated position) 42-26
Pre-detent and detent magnet solenoid 42-28
Multiple Control Valve (KML35A/2T103) 42-29
Multiple control valve specifications 42-30
Multiple control valve main relief valve 42-31
Multiple control valve overload relief valve (with make-up function) 42-33
Multiple control valve make-up valve 42-34
Multiple control valve bucket spool 42-35
Multiple control valve boom spool 42-37
Adapter (Orifice) 42-40
Ride Control (OPT) 42-41
Ride control hydraulic circuit 42-41
Ride control operation 42-42
Ride control valve assembly (Reducing valve circuit) 42-44
Ride control valve assembly (Accumulator circuit) 42-47
Accumulator (for ride control) 42-50
Steering System 42-51
Orbitrol® 42-52
Orbitrol® structure 42-52
Orbitrol® specifications 42-53
Orbitrol® operation 42-54
Orbitrol® feed-back mechanism operation 42-56
Steering speed and flow rate control 42-57
Hydraulic pump oil amount and steering force 42-57
Orbit rotor operation principle 42-58
Steering Valve (KVS32-A40/21) 42-59
Steering valve operation 42-61
Steering spool variable throttle 42-63
Steering valve flow control spool 42-64
Steering valve main relief valve 42-65
Steering valve overload relief valve 42-67
Steering pilot circuit and its operation 42-69
Stop Valve 42-71
Stop valve function 42-72
Stop valve operation 42-72
Reducing Valve (for Orbitrol®) 42-73
Steering Line Filter 42-74
Efficient Loading System 42-75
Efficient loading system outline 42-75
Mounting of the ELS valve 42-76
Mounting of the variable kickout sensor 42-77
Efficient loading system operation 42-78
Fan Motor System 42-79
Mounting of fan motor 42-79
Fan Motor Line 42-80
Hydraulic circuit (fan motor normal rotation) 42-82
Proportional relief valve (S/N 9001~9050) 42-84
Proportional relief valve (S/N 9051~) 42-86
Reversing Fan Motor Line (OPT) 42-91
Reversing fan motor function 42-91
Hydraulic circuit (Reverse rotation) 42-95
Secondary Steering 42-96
Secondary steering circuit 42-96
Check & Adjustment Hydraulic Group 43-1
Loading/Steering Circuit Relief 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 43-10
Hydraulic Cylinder 43-15
Cylinder natural drift 43-15
Stop Valve 43-17
Stop valve adjustment procedure 43-17
Function & Structure Brake Group 52-1
Brake System Outline 52-2
Service brake 52-2
Parking brake 52-2
Adjustment of axle internal pressure 52-2
Brake Units Layout 52-3
Unloader Valve 52-4
Unloader valve operation 52-6
Valve Unit 52-7
Accumulator 52-9
Brake Valve 52-10
Brake valve performance chart 52-11
Brake valve outline 52-12
Service Brake 52-14
Service brake operation 52-14
Service brake friction disc 52-15
Service brake steel plate 52-16
Service brake piston 52-17
Service brake pedal stroke adjusting mechanism 52-18
Brake circuit air bleeding procedure 52-20
Parking Brake 52-22
Parking brake operation 52-25
Parking brake friction disc 52-28
Parking brake steel plate 52-28
Parking brake solenoid valve 52-29
Parking Brake Manual Release 52-30
Brake Circuit Check Valve 52-32
Auto Brake 52-33
Auto brake circuit 52-33
Auto brake operation set value 52-33
Reducing valve (for Autobrake circuit) 52-34
Solenoid valve (for Autobrake circuit) 52-35
Pressure Sensor (for stop lamp and declutch) 52-36
Pressure sensor (for stop lamp) 52-36
Pressure sensor (for Declutch) 52-37
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 friction plate wear measurement 53-7
Cautions on installing brake discs 53-8
Parking Brake 53-9
Parking brake performance check 53-9
Function & Structure Electrical Group 62-1
How to Use Electrical Wiring Diagram 62-2
Utilisation des schémas des câblages électriques (FRANÇAIS) 62-3
Verwendung des elektrischen Schaltplans (DEUTSCH) 62-4
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 62-10
Fuse 62-11
Fuse box 62-11
Fusible link 62-12
Engine Start Circuit 62-13
Engine start circuit diagram 62-13
Neutral starter 62-14
Starter switch 62-15
Battery relay 62-16
Alternator I terminal wire 62-17
Diode unit 62-17
Neutral relay 62-18
Magnetic switch 62-19
Voltage relay 62-20
Power Generating/Charging Circuit 62-21
Alternator 62-21
ECM (Engine Controller) 62-22
Function of ECM 62-22
Connection diagram 62-22
Monitor lamp test 62-23
Failure diagnosis 62-24
Quantum fault code information 62-27
Accelerator pedal 62-33
Transmission Control Circuit and Monitor Circuit 62-35
Machine control unit (MCU) 62-35
MCU connection diagram 62-37
Machine control unit (MCU) function 62-39
Modulator valve operation 62-46
Adjustable declutch preset switch 62-47
Monitoring system 62-57
Operation monitor lamps 62-59
Instrument Panel and Switch 62-60
Instrument panel 62-60
Instrument panel rear surface 62-61
Gauge circuit 62-62
Fuel gauge circuit 62-64
MODM 62-65
MODM function 62-65
Monitor Changeover 62-65
Information Monitor 62-68
Replacement Monitor 62-72
Fault Log Monitor 62-78
Input/Output Monitor 62-85
Parameter Setting Monitor 62-89
Specification Setting Monitor 62-98
Electrical Detent Circuit 62-104
Bucket leveler 62-104
Detent solenoid 62-105
Lift kickout & lower kickout 62-106
Sensor assy 62-107
Detent solenoid 62-109
Preset height adjustment 62-109
Diode 62-110
Diode check method 62-111
Caution for diode check method 62-111
Surge voltage and surge suppression diodes 62-113
Function & Structure Operator Station Group 72-1
Cabin 72-2
Glass 72-4
Wiper mount 72-7
Wiper motor 72-8
Operator Seat 72-10
Steering and Transmission Shift Lever 72-11
Tilt case 72-12
Column shaft 72-13
Shift lever 72-13
Air Conditioner 72-14
Air conditioner components 72-14
Denso air conditioner structure 72-15
Function of cooling mechanism 72-20
Cooling circuit 72-23
Electrical circuit 72-24
Air conditioner functions of components 72-25
Charge of refrigerant 72-53
Troubleshooting 72-70
Air conditioner 72-70
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
Function & Structure Supplement 80-1
Foreword 80-2
Quick Coupler 80-3
Power Boost Circuit 80-7
Short Boom (OPT) 80-15
Limited Slip Differential (LSD) 80-17
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