Hitachi ZW550-6 Wheel Loader Repair Manual PDF

Service Repair Manual (Troubleshooting) – 504 Pages
Operation Manual – 489 Pages
Workshop Manual – 828 Pages
Circuit diagram: 17 Pages
Hitachi ZW550-6 Wheel Loader Service Manual
The manual is applicable for the Hitachi ZW550-6 Wheel Loader Model
Service Manual consists of the following:
For Model ZW550-6 as mentioned above:
Service Manual (Troubleshooting) – 504 Pages

Table of Content of the Workshop Manual

SECTION 1 GENERAL INFORMATION

Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
Group 5 Pressure Release Procedure
Group 6 Preparation

SECTION 2 MAINTENANCE STANDARD

Group 1 Body
Group 2 Front Attachment

SECTION 3 BODY

Group 1 Cab
Group 2 Counterweight
Group 3 Center Hinge
Group 4 Engine
Group 5 Radiator Assembly
Group 6 Hydraulic Oil Tank
Group 7 Fuel Tank
Group 8 Pump Device
Group 9 Control Valve
Group 10 Pilot Valve
Group 11 Brake Charge Valve
Group 12 Manifold Valve
Group 13 Solenoid Valve
Group 14 Flow Regulator Valve
Group 15 Cooling Fan System
Group 16 Muffler Filter
Group 17 Ride Control Accumulator
Group 18 Battery Disconnect Switch

Table of Content of the Technical Manual

SECTION 4 OPERATIONAL

PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
Group 5 Component Test
Group 6 Adjustment

SECTION 5 TROUBLESHOOTING

Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Air Conditioner

Table of Content of the Operation Manual

SECTION 1 GENERAL

Group 1 Specifications
Group 2 Component Layout
Group 3 Component Specifications

SECTION 2 SYSTEM

Group 1 Controller
Group 2 Control System
Group 3 Engine System
Group 4 Hydraulic System
Group 5 Electrical System

SECTION 3 COMPONENT OPERATION

Group 1 Pump Device
Group 2 Control Valve
Group 3 Cooling Fan System
Group 4 Steering Pilot Valve
Group 5 Steering Valve
Group 6 Pilot Valve
Group 7 Charging Circuit
Group 8 Drive Unit
Group 9 Axle
Group 10 Brake Valve
Group 11 DEF Supply System
Group 12 Others
Hitachi ZAXIS ZW550-6 service manual consists of the Troubleshooting and the Workshop Manual.

Information included in the Service Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.

Actuator speed of front attachment and steering are slow in the Wheel Loader ZW550-6
Preparation
– The pump flow rate is minimized due to some reasons.
– Even if speed is satisfactory, in case power is weak, refer to the troubleshooting for faulty main relief valve (F-1/S-1).
– If actuator speed of only front attachment is slow, the pilot system may be faulty (A-1) or the circuit after the pilot valve may be faulty (F-2).
– If actuator speed of only steering is slow, the circuit after the steering pilot valve may be faulty (S-3).
– Refer to SYSTEM / Hydraulic System.
| Procedure
| Inspection Method
| Condition
| Evaluation
| Cause
| 1
| Monitor Main Pump Delivery Pressure
| No steering or loading operation Engine: High idling
| The measured value exceeds 3.5 ~ 5.0 MPa
(508 ~ 725 psi)
| Faulty bleed-off compensation spool (stuck)
| 2
| Measure steering time (full turn) and lift arm raising time (fully up)
| Disconnect the connector of torque control solenoid valve
| Both of the measured times are out of normal range
(Full turn: 4.70.5 sec Lift arm fully up:
8.00.3 sec)
| Faulty torque control solenoid valve
Faulty main pump
Faulty main pump regulator
| Only the steering time is out of normal range: 4.70.5 sec (full turn)
| Faulty steering valve
Problem in the circuit after the Orbitrol (steering pilot valve)
| Only the lift arm raising time is out of normal range: 8.0
0.3 sec (fully up)
| Faulty multiple control valve Problem in the pilot circuit after the pilot valve
| Both of the measured times are within the normal range.
| Faulty torque control solenoid valve
Faulty Main Controller (SC)