Hitachi ZW550 & ZW550-G Wheel Loader Repair Manual PDF

For Model ZW550 as mentioned above:
Service Repair Manual (Troubleshooting) : Vol. No.TT11C5-E-01 (116 Pages)
Operation Manual : Vol. No.TO11C5-E-01 (526 Pages)
Workshop Manual : Vol. No.W11C5-E-01 (353 Pages)
For Model ZW550-G as mentioned above:
Service Repair Manual (Troubleshooting) : Vol. No.TTNHD-E-EN0 (90 Pages)
Operation Manual : Vol. No.TONHD-E (587 Pages)
Workshop Manual : Vol. No.WNHD-E (365 Pages)
Hitachi ZW550, ZW550-G Wheel Loader Service Manual
The manual is applicable for the Hitachi ZW550, ZW550-G Wheel Loader Model
Service Manual consists of the following:
Service Manual (Troubleshooting) : Vol. No.TT11C5-E-01 (116 Pages)
Service Manual (Troubleshooting) : Vol. No.TTNHD-E-EN0 (90 Pages)

Table of Content of the Workshop Manual

Clutch Assembly …………………………………………………………………………………………………………………………… 34-26
Clutch assembly disassembling and assembling ………………………………………………………………………….. 34-26
Clutch Spider Assembly …………………………………………………………………………………………………………………. 34-38
Transmission low/3rd speed clutch spider disassembling and assembling ………………………………………. 34-38
Transmission 1st and 2nd speed clutch spider disassembling and assembling ………………………………… 34-39
Reverse Clutch Spider …………………………………………………………………………………………………………………… 34-41
Transmission reverse clutch spider disassembling and assembling ………………………………………………… 34-41
Transmission 1st Clutch Assembly ………………………………………………………………………………………………….. 34-43
Transmission 1st speed clutch assy disassembling and assembling ………………………………………………. 34-43
Transmission High Clutch Assembly ………………………………………………………………………………………………… 34-47
Transmission high clutch assy disassembling and assembling ………………………………………………………. 34-47
Modulator Valve Assembly ……………………………………………………………………………………………………………… 34-50
Removing and reinstalling modulator valve …………………………………………………………………………………. 34-50
Control Valve Assembly …………………………………………………………………………………………………………………. 34-52
Control valve removing and installing …………………………………………………………………………………………. 34-52
Service Standard Torque Converter and Transmission Group …………………………………………………………………. 35-1
Transmission Assembly …………………………………………………………………………………………………………………… 35-2
Torque Converter Gear Pump …………………………………………………………………………………………………………… 35-5
Gear pump specifications ……………………………………………………………………………………………………………. 35-5
Gear Train and Number of Teeth ……………………………………………………………………………………………………….. 35-6
Clutch Oil Pressure …………………………………………………………………………………………………………………………. 35-7
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

This is only an extract of the Table of content and not the whole table.

Hitachi ZAXIS ZW550, ZW550-G 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.

Time lag measurement procedure:
1) Lower the boom to the lowest limit, and fully roll back the bucket until the bucket contacts to the stopper.
2) Set the parking brake switch to the “OFF” position.
Do not apply the service brakes.
3) Set the transmission shift lever to the neutral 1st speed.
4) Keep the engine speed at 1,500 min-1 (rpm).
5) Move the shift lever to the forward position. At the same time, start the stop watch to measure the time required before the machine moves.
Clutch Oil Pressure
| Possible cause
| Solution
| Malfunctioning modulator valve (1) operation
| Inspection & repair
| Malfunctioning modulator valve (2) operation
| Inspection & repair
| Defective controller
| Replacement
| Oil leakage from clutch
| Disassembly & repair
Clutch time lag
| Possible cause
| Solution
| Defective pressure difference sensor
| Replacement
| Malfunctioning modulator valve (1) operation
| Inspection & repair
| Malfunctioning modulator valve (2) operation
| Inspection & repair
| Defective controller
| Replacement
| Defective clutch
| Disassembly & repair