Hitachi ZW550-G Wheel Loader Operational Principle Technical Service Manual
587 pages · Publication TONHD-E-00
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- Models
- ZW550-G
- Manual type
- Operational Principle Technical Service Manual
- Pages
- 587
- Publication
- TONHD-E-00
- Condition
- Brand new
What's inside
From the manual's own table of contents: 66 sections, 363 entries. See sample pages (PDF, 599 KB)
General31 topics
- General Information
- How to Use Manual
- Safety precautions
- Symbols
- Outline
- Layout of main components
- Inspection and maintenance table
- Recommended lubricants
- Coolant
- Lubrication chart
- Weight of main components
- Bolt tightening torque
- Hose band tightening torque
- Liquid gasket and screw lock agent
- Measurement for Performance Check
- Cautions on Safety
- Standard Measurement Values for Performance Check
- Function & Structure Chassis Group
- Front Chassis
- Loading linkage
- Loading linkage pin
- Rear Chassis
- Fuel tank
- Floor board mount
- Center Pin
- Upper center pin
- Lower center pin
- Dust seal
- Check & Adjustment Chassis Group
- Linkage Pin
- Liner
Center Pin3 topics
- Adjusting shim
- Installing bearing cover
- Installing bearing outer ring
Function & Structure Power Group
Power Line
Engine / Transmission1 topic
- Engine / transmission mount
Radiator1 topic
- Radiator mount
Propeller Shaft3 topics
- First propeller shaft assembly
- Second propeller shaft assembly
- Third propeller shaft assembly
Axle Assembly
Axle Support
Differential Gear2 topics
- Function of differential gear
- Operation of differential gear
Check & Adjustment Power Group
Engine5 topics
- Measuring engine speed
- Measuring engine oil pressure
- Propeller shaft phase
- Second propeller shaft alignment
- Tightening torque
Axle33 topics
- Axle nut tightening procedure
- Function & Structure Torque Converter and Transmission Group
- Torque Converter
- Torque converter structure
- Power flow path
- Torque multiplication
- Torque Converter Gear Pump
- Gear pump specifications
- Transmission
- Clutch combination
- Planetary gear
- Shift lever position
- Power up switch operation
- Gear train and number of teeth
- Clutch Pack
- Power Flow Path in the Transmission
- Forward
- Reverse
- Hydraulic System Diagram
- Hydraulic Circuit Diagram
- T/C and T/M Oil Circulation
- Oil flow in the torque converter line
- Oil flow to the clutch
- Modulator Valve Unit
- Interior schematic (not exact representation)
- Modulation Mechanism
- Modulator valve function
- Modulator valve operation
- Clutch Solenoid Valve
- Check & Adjustment Torque Converter and Transmission Group
- Clutch Oil Pressure and Time Lag
- Measuring clutch oil pressure
- Measuring clutch time lag
Function & Structure Hydraulic Group
Flushing Hydraulic Circuit1 topic
- Purpose of flushing
Cautions on Hydraulic Parts Replacement
Hydraulic Circuit Symbols9 topics
- Hydraulic lines
- Pumps & motors
- Cylinders
- Operation methods
- Pressure control valve
- Flow control valve
- Directional control valve
- Check valve
- Miscellaneous hydraulic symbols
Hydraulic System Operation1 topic
- Hydraulic system operation outline
Layout of Hydraulic Units
Hydraulic Tank3 topics
- Hydraulic tank specifications
- Hydraulic oil level check
- Hydraulic tank (S/N 0201~)
Hydraulic Pump7 topics
- Loading and pilot and brake pump
- Pump specifications
- Steering pump
- Steering pump specifications
- Hydraulic pump principle
- Hydraulic pump wear plate
- Hydraulic pump bushing lubrication
Hydraulic Cylinder37 topics
- Boom cylinder
- Bucket cylinder
- Steering cylinder
- Hydraulic cylinder specifications
- Loading System
- Reducing Valve (for Pilot Pressure)
- Pilot valve operation
- Pilot valve detent magnet solenoid
- Detent adjustment procedure
- Pilot valve operation
- Pre-detent and detent magnet solenoid
- Multiple Control Valve (KML35A/2T103)
- Multiple control valve specifications
- Multiple control valve main relief valve
- Multiple control valve overload relief valve
- Multiple control valve bucket spool
- Multiple control valve boom spool
- Adapter (Orifice)
- Vibration Damper (OPT)
- Vibration damper operation
- Vibration damper hydraulic line
- Steering System
- Orbitrol ®
- Orbitrol ® structure
- Orbitrol ® specifications
- Orbitrol ® operation
- Orbitrol ® feed-back mechanism operation
- Steering speed and flow rate control
- Hydraulic pump oil amount and steering force
- Orbit rotor operation principle
- Steering Valve (KVS32-A4.0/21)
- Steering valve operation
- Steering spool variable throttle
- Steering valve flow control spool
- Steering valve main relief valve
- Steering valve overload relief valve
- Steering pilot circuit and its operation
Stop Valve2 topics
- Stop valve function
- Stop valve operation
Reducing Valve (for Orbitrol ® )
Show all 67 sections
Steering Line Filter
Fan Motor System7 topics
- Fan Motor (GM30C)
- Valve Assembly (for Fan Motor)
- Relief Valve (Two-step Relief)
- Solenoid Valve (for Fan Speed Control)
- Fan Motor (GM30W)
- Thermo Sensing Valve
- Fan Motor Relief Valve Assembly
Emergency Steering4 topics
- Emergency steering operation
- Emergency steering hydraulic line
- Emergency steering oil flow
- Emergency steering pump
Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve4 topics
- Loading circuit relief valve setting pressures
- Steering circuit relief valve setting pressures
- Cylinder natural drift
- Stop valve adjustment procedure
Fan Motor Revolution35 topics
- Fan maximum revolution measurement (S/N 0121~, 9011~)
- Function & Structure Brake Group
- Brake System Outline
- Service brake
- Parking brake
- Auto brake
- Adjustment of axle internal pressure
- Brake Units Layout
- Unloader Valve
- Unloader valve operation
- Reducing valve
- Valve Unit (Main Brake Manifold Block)
- Brake Accumulator Line
- Accumulator
- In-Line Filter
- Brake Valve
- Brake main valve (left pedal)
- Brake pilot valve (right pedal)
- Brake valve performance chart
- Brake valve outline
- Stop Lamp Pressure Switch
- Pressure switch (for stop lamp)
- Pressure switch (for Declutch)
- Service Brake
- Service brake operation
- Service brake friction plate
- Service brake steel plate
- Service brake piston
- Service brake pedal stroke adjusting mechanism
- Parking Brake
- Parking brake operation
- Parking brake solenoid valve
- Parking Brake Manual Release
- Parking Brake Spring Chamber
- Brake Circuit Check Valve
Auto Brake3 topics
- Auto brake operation set value
- Auto brake circuit
- Solenoid valve (for auto brake circuit)
Shuttle Valve
Check & Adjustment Brake Group
Brake Circuit Oil Pressure2 topics
- Unloader valve setting pressure
- Brake valve oil pressure
Service Brake2 topics
- Service brake performance check
- Service brake friction plate wear measurement
Parking Brake2 topics
- Parking brake performance check
- Parking brake clearance adjustment
Function & Structure Electrical Group
How to Use Electrical Wiring Diagram
Electrical Cable Color Codes
Electrical Circuit Symbols
Sensor Mount
Fuse2 topics
- Fuse box
- Fusible link
Engine Start Circuit42 topics
- Engine start circuit diagram
- Neutral starter
- Starter switch
- Battery relay
- Alternator I terminal wire
- Diode unit
- Neutral relay
- Magnet switch
- Voltage relay
- Power Generating/Charging Circuit
- Alternator
- ECM (Engine Controller)
- Function of ECM
- Connection diagram
- Monitor lamp test
- Failure diagnosis
- Quantum fault code information
- Power mode change
- Accelerator pedal
- Controller
- Controller connection diagram
- Controller function
- Monitor controller
- Transmission Control Circuit (S/N 0154~)
- Machine control unit (MCU)
- Machine control unit (MCU) connection diagram
- Monitor Circuit
- Monitoring sensor and switch
- Instrument Panel and Switch
- Instrument panel
- Instrument panel rear surface
- Gauge circuit
- Fuel gauge circuit
- Tachometer circuit
- Electrical Detent Circuit
- Bucket leveler
- Boom kick-out (option)
- Detent solenoid
- Diode
- Diode check method
- Caution for diode check method
- Surge voltage and surge suppression diodes
Diagnostic System7 topics
- Transmission controller
- Monitor controller
- Diagnostic failure history indication and deletion
- Diagnostic switch
- MODM function
- Monitor Changeover
- MODM: input/output monitor - input/output signal correspondence table
Check & Adjustment Electrical Group
Cautions Regarding Electric Circuit Check2 topics
- Disconnecting or reinstalling connector
- How to attach the probes of the circuit tester
Electrical Transmission Control System Troubleshooting Flowchart1 topic
- Standard troubleshooting flowchart
Transmission Controller Abnormal Operation Judgment2 topics
- Transmission controller check
- Transmission controller LED indicator
Electrical Circuit Check43 topics
- Shift lever input electrical circuit check
- Inching (Declutch) input electrical circuit check
- QUAD switch input electrical circuit check
- Machine speed sensor input electrical circuit check
- Clutch solenoid valve output electrical circuit check
- Modulator valve output electrical circuit check
- Neutral relay electrical circuit check
- Parking brake electrical circuit check
- Auto brake electrical circuit check
- Gauge circuit electrical circuit check
- Fuel level gauge electrical circuit check
- Bucket positioner electrical circuit check
- Function & Structure Operator Station Group
- Cabin
- Glass
- Wiper mount
- Wiper motor
- Operator Seat
- Steering and Transmission Shift Lever
- Tilt case
- Column shaft
- Shift lever
- Air Conditioner
- Air conditioner components
- Air conditioner structure
- Cooling mechanism
- Cooling circuit
- Electrical circuit
- Air conditioner functions of components
- Charge of refrigerant
- Air conditioner troubleshooting
- Check & Adjustment Operator Station Group
- Adjustment of lubricating oil quantity when components of air conditioner are replaced
- Adjustment of air gap (between hub and rotor) in compressor magnetic clutch
- Parts to be replaced periodically
- Cross-section drawing & Diagrams
- Axle Assembly
- Torque Converter and Transmission
- Loading/Steering Hydraulic Line (S/N 0101~0120)
- Loading/Steering Hydraulic Circuit (S/N 0121~)
- Loading/Steering Hydraulic Circuit (S/N 9001~9010)
- Loading/Steering Hydraulic Circuit (S/N 9011~)
- Brake Circuit
Electrical Wiring Diagram (1/3) (S/N 0154~)
Electrical Wiring Diagram (2/3) (S/N 0154~)
Electrical Wiring Diagram (3/3) (S/N 0154~)
Electrical Wiring Diagram (1/2) (S/N 9011~)
Electrical Wiring Diagram (2/2) (S/N 9011~)
Electrical Wiring Diagram Abbreviation Chart (S/N 0101~0153, 9001~)
Electrical Wiring Diagram Abbreviation Chart (S/N 0154~)
Electrical Wiring Diagram (CAB)
Electrical Connection Diagram (S/N 0101~0120)
Electrical Connection Diagram (S/N 0121~0124)
Electrical Connection Diagram (S/N 0125~0153)
Electrical Connection Diagram (S/N 0154~)
Electrical Connection Diagram (S/N 9001~9010)
Electrical Connection Diagram (S/N 9011~)
Electrical Equipment Layout
Electrical Circuit Diagram (Cabin Air Conditioner)
Electrical Wiring Diagram (Cabin Air Conditioner)
Equipment Operation Table (Cabin Air Conditioner)
Inside this manual
Real pages from this operational principle technical service manual (587 pages). Open the sample pages (PDF, 599 KB)
- Specifications, page 116: Function & Structure Torque Converter and Transmission Group
- Diagram, page 323: Function & Structure Electrical Group
- Troubleshooting, page 485: Function & Structure Operator Station Group
- Foldout diagram, page 551: Cross-section drawing & Diagrams
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the ZW550-G are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Operational Principle Technical Service Manual TONHD-E-00$69.65
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Manual types
This manual is a operational principle technical service manual. For reference, the three main manual types:
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 587 pages
Quantity one is the manual described above.
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