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Hitachi ZW 550-G Technical Manual
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Hitachi ZW 550-G Technical Manual

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Summary of Contents for Hitachi ZW 550-G

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  • Page 3: Machine Specification

    93216-00225 May 2011 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 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 ............................
  • Page 6 Center Pin ................................. 13-6 Adjusting shim ............................. 13-6 Installing bearing cover ..........................13-6 Installing bearing outer ring ......................... 13-6 Function & Structure Power Group ........................22-1 Power Line ................................ 22-2 Engine / Transmission ............................22-3 Engine / transmission mount ........................22-3 Radiator ................................
  • Page 7 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 Gear Pump ........................... 32-4 Gear pump specifications ........................... 32-4 Transmission ..............................32-5 Clutch combination .............................
  • Page 8 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 ............................
  • Page 9 Loading System .............................. 42-23 Reducing Valve (for Pilot Pressure) ........................ 42-24 Pilot Valve (S/N 0101~0140, 9001~9020) ....................... 42-25 Pilot valve operation ..........................42-27 Pilot valve detent magnet solenoid ......................42-29 Detent adjustment procedure ........................42-29 Pilot valve (S/N 0141~0172, 9021~) ....................... 42-30 Pilot valve operation ..........................
  • Page 10 Steering valve overload relief valve ......................42-85 Steering pilot circuit and its operation ....................... 42-87 Stop Valve ............................... 42-89 Stop valve function ............................ 42-91 Stop valve operation ..........................42-92 ® Reducing Valve (for Orbitrol ) ......................... 42-93 Steering Line Filter ............................42-94 Fan Motor System ............................
  • Page 11 Function & Structure Brake Group ........................52-1 Brake System Outline ............................52-2 Service brake .............................. 52-2 Parking brake .............................. 52-2 Auto brake ..............................52-2 Adjustment of axle internal pressure ......................52-2 Brake Units Layout ............................52-3 Unloader Valve ..............................52-4 Unloader valve operation ..........................
  • Page 12 Auto Brake ..............................52-36 Auto brake operation set value ......................... 52-36 Auto brake circuit ............................52-36 Solenoid valve (for auto brake circuit) ....................... 52-37 Shuttle Valve ..............................52-38 Check & Adjustment Brake Group ........................53-1 Brake Circuit Oil Pressure ..........................53-2 Unloader valve setting pressure ........................
  • Page 13 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 ........................ 62-29 Power mode change ..........................62-36 Accelerator pedal ............................
  • Page 14 Caution for diode check method ....................... 62-81 Surge voltage and surge suppression diodes ................... 62-83 Diagnostic System ............................62-84 Transmission controller ..........................62-84 Monitor controller ............................62-88 Diagnostic failure history indication and deletion ..................62-91 Diagnostic switch ............................62-93 MODM (S/N 0154~) ............................62-94 MODM function ............................
  • Page 15 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 ..............................
  • Page 16 Electrical Wiring Diagram (1/2) (S/N 0101~0120) ..................... 92-9 Electrical Wiring Diagram (2/2) (S/N 0101~0120) ................... 92-10 Electrical Wiring Diagram (1/2) (S/N 0121~0124) ................... 92-11 Electrical Wiring Diagram (2/2) (S/N 0121~0124) ................... 92-12 Electrical Wiring Diagram (1/2) (S/N 0125~0153) ................... 92-13 Electrical Wiring Diagram (2/2) (S/N 0125~0153) ...................

  • Page 17: General Information

    00-1 General Information General Information How to Use Manual ..........00-2 Outline ..............00-4...
  • Page 18 00-2 General Information How to Use Manual How to Use Manual Safety precautions - Contact tire manufacturer's local dealer for tire ser- vicing and changing. The most important point in providing repair service is safety. To ensure safety, observe the general cautions - Always store the tools in good condition, and use described below.
  • Page 19 00-3 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

    00-4 General Information Outline Outline Layout of main components 115ZVE00001 1. Engine assembly 9. Air cleaner 17. Front axle assembly (Cummins QSK19-C) 10. Muffler 18. Rear axle assembly 2. Torque converter assy 11. Radiator 19. 1st propeller shaft 3. Transmission 12.

  • Page 21: Inspection And Maintenance Table

    00-5 General Information Outline Inspection and maintenance table : First time replacement or cleaning only Operating hours When Section Item for check Required 1000 2000 Check Engine Oil Level Check Engine Coolant Level Check Warning Lamps Check Exhaust Gas Drain Water and Sediment from Fuel Filter Check Fuel Level Check Drive Belt Check Air Intake System...
  • Page 22 00-6 General Information Outline : First time replacement or cleaning only Operating hours When Section Item for check Required 1000 2000 Check Tire for Damage, Air and Tread Depth Check Tire Air Pressure Greasing (Axle support) Check Differential Gear Oil Check Planetary Gear Oil Axle system Greasing (Pillow block bearing unit)
  • Page 23 00-7 General Information Outline : First time replacement or cleaning only Operating hours When Section Item for check Required 1000 2000 Check Monitor Panel Operation Check Horn Operation Check Back-up Alarm Operation Electrical system Check Wiring Harnesses Check Battery Electrolyte Level Check or Replace Fuses Check and Adjust Air Conditioner Belt Clean Air Conditioner and Heater Filter Element (option)

  • Page 24: Recommended Lubricants

    00-8 General Information Outline Recommended lubricants Ambient Temperature Change Refill capacity Kind of Oil -22ºF Interval (Approximate) -30ºC (Hours) SAE10W Engine oil Engine 65 liter (17.2 gal) SAE10W-30 (CH4 or CG4) SAE15W-40 SAE10W Engine oil (CD) Transmission 85 liter (22.5 gal) 1,000 or ATF ISO VG32...
  • Page 25 00-9 General Information Outline Coolant Coolant specification The machine is originally filled with Long Life Coolant (non-Amin type ethylene glycol) which need not be replaced for the first two years or 3,000 hours. Do not use Amin type Long Life Coolant in cooling sys- tem.

  • Page 26: Lubrication Chart

    00-10 General Information Outline Lubrication chart DIFF & GEAR HYD. OIL DIFF & GEAR TANK EVERY 2000Hr DIFF TRANSMISSION DIFF EVERY 1000Hr ENGINE OIL PAN PILLOW UNIT EVERY 250Hr CENTER PIN (UPPER) AXLE SUPPORT EVERY 50Hr BUCKET LINK SYSTEM EVERY DAY CENTER PIN STEERING CYL.
  • Page 27 00-11 General Information Outline Weight of main components Approx. Approx. Item weight weight Remarks Unit name Part name (kg) (lb) Bucket 4,985 10,990 RVT bucket Boom 3,210 7,080 Standard “Z” -Lever 435/pc 960/pc Link (Bucket to Lever) 90/pc 200/pc Screen board Roof Engine room Radiator guard...
  • Page 28 00-12 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) Unified thread: Coarse pitch thread (UNC), fine pitch thread (UNF) (N-m) Bolt size Bolt strength...
  • Page 29 00-13 General Information Outline (kgf-m) Bolt size Bolt strength Type Nominal Nominal Pitch 8.8 (8T) 10.9 (11T) dimension dia. (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 22.5 (C) 2.0 22.0 32.0 (F) 1.5...
  • Page 30 00-14 General Information Outline (lb-ft) Bolt size Bolt strength Type Nominal Nominal Pitch 8.8 (8T) 10.9 (11T) dimension dia. (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 (F) 1.5 Metric thread (C) 2.5...
  • Page 31 00-15 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 (kgf-m) Bolt size Bolt strength Type...
  • Page 32 00-16 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 29.9 69002-03100 19.0 30.0...
  • Page 33 00-17 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 34 00-18 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 To avoid a piece of seal tape left in the circuit, leave 1 or 2 screws from the end of the thread and start threading 65ZV00002 it clockwise.
  • Page 35 00-19 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. Cautions 1. Turn the starter switch OFF. 5.
  • Page 36 00-20 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 damaged by the spatter; hydraulic units, har- nesses, hydraulic hoses, and nylon tubes.
  • Page 37 03-1 Measurement for Performance Check Measurement for Performance Check Cautions on Safety ..............03-2 Standard Measurement Values for Performance Check ..03-3...

  • Page 38: Cautions On Safety

    03-2 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. area while the engine is running may cause severe Therefore, to provide repair service with the engine accidents.
  • Page 39 03-3 Measurement for Performance Check Standard Measurement Values for Performance Check Standard Measurement Values for Performance Check For Asia and Africa (S/N 0101~) 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) Item Standard measurement val-...
  • Page 40 03-4 Measurement for Performance Check Standard Measurement Values for Performance Check 20.6 ± 0.5 (210 ± 5) Loading line main relief pressure (HI) (2,986 ± 71) Run engine at lowest 23.5 ± 0.5 (240 ± 5) Loading line overload relief pressure (LI) possible speed while (3,413 ±...
  • Page 41 03-5 Measurement for Performance Check Standard Measurement Values for Performance Check For Europe (S/N 9001~) 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) Item Standard measurement val- ues for performance check...
  • Page 42 03-6 Measurement for Performance Check Standard Measurement Values for Performance Check 20.6 ± 0.5 (210 ± 5) Loading line main relief pressure (HI) (2,986 ± 71) Run engine at lowest 23.5 ± 0.5 (240 ± 5) Loading line overload relief pressure (LI) possible speed while (3,413 ±...
  • Page 43 12-1 Function & Structure Chassis Group Function & Structure Chassis Group Front Chassis ................12-2 Rear Chassis.................12-5 Center Pin ................12-7...
  • Page 44 12-2 Function & Structure Chassis Group Front Chassis Front Chassis Loading linkage 115ZV12001 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. Bucket stop plate (Design differs by manufacturer of the attachment)
  • Page 45 12-3 Function & Structure Chassis Group Front Chassis Even contact both sides 50º 43º (Hinge pin height at 300 mm bucket on ground) 11.8 (in) Typical bucket dump stopper clearance (Contact attachment supplier for details on non-standard attachments) Typical bucket roll-back stopper adjustment To increase clearance increase height of lever stopper surface (9).
  • Page 46 12-4 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. Lever - Bucket cylinder 8.

  • Page 47: Rear Chassis

    12-5 Function & Structure Chassis Group Rear Chassis Rear Chassis Fuel tank (S/N 0101~0125) 4 (S/N 9001~9020) Torque when installing fuel level (S/N 0126~) sensor (2): 4 (S/N 9021~) 14.7 N-m (1.5 kgf-m) (10.8 lb-ft) 1. Fuel tank 2. Fuel level sensor 3.
  • Page 48 12-6 Function & Structure Chassis Group Rear Chassis Floor board mount Viscous mount Floor board 115ZV12008 1. Floor board 2. Viscous mount 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.
  • Page 49 12-7 Function & Structure Chassis Group Center Pin Center Pin Upper center pin Lower center pin 4 9, 10 Front chassis Front chassis Rear Rear chassis chassis Lower 8, 10 Upper 115ZV12011 115ZV12010 Upper Lower 1. Center pin 1. Center pin 2.
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