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Hitachi ZW 550-G, Technical Manual

The Hitachi ZW 550-G Technical Manual is a comprehensive guide designed to assist users in maximizing the performance and functionality of their equipment. Gain access to this invaluable resource for free download at 88.208.23.73:8080, ensuring a smooth operation and hassle-free maintenance of your Hitachi ZW 550-G.

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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  ..................................................................................................................................... 32-6

Planetary gear ............................................................................................................................................. 32-6

Shift lever position ....................................................................................................................................... 32-6

Power up switch operation .......................................................................................................................... 32-6

Gear train and number of teeth ................................................................................................................... 32-7

Clutch Pack ..................................................................................................................................................... 32-10

Power Flow Path in the Transmission ..............................................................................................................32-11

Forward ......................................................................................................................................................32-11

Reverse ..................................................................................................................................................... 32-14

Hydraulic System Diagram  ............................................................................................................................. 32-16

Hydraulic Circuit Diagram  ............................................................................................................................... 32-17

T/C and T/M Oil Circulation ............................................................................................................................. 32-18

Oil flow in the torque converter line ........................................................................................................... 32-19

Oil flow to the clutch .................................................................................................................................. 32-19

Modulator Valve Unit ....................................................................................................................................... 32-20

Interior schematic (not exact representation) ............................................................................................ 32-22

Modulation Mechanism  ................................................................................................................................... 32-23

Modulator valve function ........................................................................................................................... 32-23

Modulator valve operation ......................................................................................................................... 32-25

Clutch Solenoid Valve  ..................................................................................................................................... 32-26

Check & Adjustment Torque Converter and Transmission Group  ........................................................................ 33-1

Clutch Oil Pressure and Time Lag  .................................................................................................................... 33-2

Measuring clutch oil pressure  ..................................................................................................................... 33-2

Measuring clutch time lag  ........................................................................................................................... 33-4

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Summary of Contents for ZW 550-G

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Page 3: ...re 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 meth ods 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 reque...

Page 4: ...l may occur To protect yourself from all accidents be careful when doing service work DANGER This danger symbol identifies special warnings or procedures which if not strictly observed will result in death or serious injury WARNING This warning symbol identifies special warnings or procedures which if not strictly observed could result in death or serious injury CAUTION This caution symbol identif...

Page 5: ...htening torque 00 16 Liquid gasket and screw lock agent 00 17 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 7 D...

Page 6: ...d propeller shaft assembly 22 8 Third propeller shaft assembly 22 10 Axle Assembly 22 11 Axle Support 22 14 Differential Gear 22 20 Function of differential gear 22 24 Operation of differential gear 22 24 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 ...

Page 7: ... the Transmission 32 11 Forward 32 11 Reverse 32 14 Hydraulic System Diagram 32 16 Hydraulic Circuit Diagram 32 17 T C and T M Oil Circulation 32 18 Oil flow in the torque converter line 32 19 Oil flow to the clutch 32 19 Modulator Valve Unit 32 20 Interior schematic not exact representation 32 22 Modulation Mechanism 32 23 Modulator valve function 32 23 Modulator valve operation 32 25 Clutch Sole...

Page 8: ...stem operation outline 42 8 Layout of Hydraulic Units 42 10 Hydraulic Tank 42 11 Hydraulic tank specifications 42 11 Hydraulic oil level check 42 11 Hydraulic tank S N 0101 0200 9001 42 12 Hydraulic tank S N 0201 42 14 Hydraulic Pump 42 16 Loading and pilot and brake pump 42 17 Pump specifications 42 17 Steering pump 42 18 Steering pump specifications 42 18 Hydraulic pump principle 42 19 Hydraulic...

Page 9: ...d relief valve 42 49 Multiple control valve bucket spool 42 52 Multiple control valve boom spool 42 54 Adapter Orifice 42 57 Vibration Damper OPT 42 58 Vibration damper operation 42 59 Vibration damper hydraulic line 42 68 Steering System 42 69 Orbitrol 42 70 Orbitrol structure 42 70 Orbitrol specifications 42 71 Orbitrol operation 42 72 Orbitrol feed back mechanism operation 42 74 Steering speed ...

Page 10: ... 106 Thermo Sensing Valve 42 107 Fan Motor Relief Valve Assembly 42 109 Emergency Steering 42 111 Emergency steering operation 42 112 Emergency steering hydraulic line 42 112 Emergency steering oil flow 42 113 Emergency steering pump 42 115 Check Adjustment Hydraulic Group 43 1 Loading Steering Circuit Relief Valve 43 2 Loading circuit relief valve setting pressures 43 2 Steering circuit relief va...

Page 11: ...ft pedal 52 12 Brake pilot valve right pedal 52 13 Brake valve performance chart 52 14 Brake valve outline 52 15 Stop Lamp Pressure Switch 52 18 Pressure switch for stop lamp 52 18 Pressure switch for Declutch 52 19 Service Brake 52 20 Service brake operation 52 20 Service brake friction plate 52 21 Service brake steel plate 52 22 Service brake piston 52 23 Service brake pedal stroke adjusting mec...

Page 12: ...r measurement 53 9 Parking Brake 53 12 Parking brake performance check 53 12 Parking brake clearance adjustment 53 14 Function Structure Electrical Group 62 1 How to Use Electrical Wiring Diagram 62 2 Electrical Cable Color Codes 62 8 Electrical Circuit Symbols 62 9 Sensor Mount 62 10 Fuse 62 11 Fuse box 62 12 Fusible link 62 13 Engine Start Circuit 62 14 Engine start circuit diagram 62 14 Neutral...

Page 13: ...ram 62 43 Controller function 62 44 Monitor controller 62 61 Transmission Control Circuit S N 0154 62 62 Machine control unit MCU 62 62 Machine control unit MCU connection diagram 62 64 Monitor Circuit 62 66 Monitor controller S N 0101 0153 9001 62 69 Monitoring sensor and switch 62 71 Instrument Panel and Switch 62 72 Instrument panel 62 72 Instrument panel rear surface 62 73 Gauge circuit 62 74 ...

Page 14: ...ng Flowchart 63 5 Standard troubleshooting flowchart 63 5 Transmission Controller Abnormal Operation Judgment 63 6 Transmission controller check 63 6 Transmission controller LED indicator 63 8 Electrical Circuit Check 63 10 Shift lever input electrical circuit check 63 10 Inching Declutch input electrical circuit check 63 12 QUAD switch input electrical circuit check 63 14 Machine speed sensor inp...

Page 15: ...erant 72 51 Air conditioner troubleshooting 72 66 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 Parts to be replaced periodically 73 6 Cross section drawing Diagrams 92 1 Axle Assembly 92 2 Torque Converter an...

Page 16: ...ctrical Wiring Diagram 1 2 S N 9011 92 20 Electrical Wiring Diagram 2 2 S N 9011 92 21 Electrical Wiring Diagram Abbreviation Chart S N 0101 0153 9001 92 22 Electrical Wiring Diagram Abbreviation Chart S N 0154 92 23 Electrical Wiring Diagram CAB 92 24 Electrical Connection Diagram S N 0101 0120 92 26 Electrical Connection Diagram S N 0121 0124 92 27 Electrical Connection Diagram S N 0125 0153 92 ...

Page 17: ...00 1 General Information General Information How to Use Manual 00 2 Outline 00 4 ...

Page 18: ...ch as the hydraulic oil air or engine coolant pipe Be sure to apply the articulation stopper before start ing work While supporting the bottom of the chassis using a jack be sure to support the chassis using the blocks When the boom or bucket is raised or when a unit is lifted by a crane be sure to place a stand or ade quate cribbing under the unit to prevent unexpected dropping Do not start to wo...

Page 19: ...ue of a section that should be carefully tightened during assembly work Coating Shows the type of coating or adhesive and the coat ing section Oil or water supply Shows the oil or water supply port and the refill amount Drainage Shows the oil or water drain port and the drain amount IMPORTANT If the specified conditions are not satisfied or the specified procedure is not observed there is a strong...

Page 20: ...le loader control valve 6 Steering valve 7 Pilot valve for loading right side 8 Transmission control valve 9 Air cleaner 10 Muffler 11 Radiator 12 Hydraulic oil cooler air to oil type 13 T C oil cooler lower tank of radiator 14 T C oil cooler installed on E G 15 Charge air cooler 16 Fuel cooler 17 Front axle assembly 18 Rear axle assembly 19 1st propeller shaft 20 2nd propeller shaft 21 3rd propel...

Page 21: ...rankcase Breather Adjust Belt Tension Replace Fuel Filter Cartridge Replace DCA4 Coolant Filter Cartridge Check Engine Compression Pressure Check Injection Pressure Check and Adjust Injection Timing Clean Fuel Tank Check and Adjust Valve Lash Clearance Check Vibration Damper Clean Crankcase Breather Tube Replace Ether Cylinder Clean or Replace Air Cleaner Element Clean Radiator Air Cooler Fuel Coo...

Page 22: ...haft Adjust Parking Brake Lining Check Service Brake Disk Wear Check Brake Accumulators Clean Filter for Brake Line Loading system Check Hydraulic Oil Level Greasing Replace Hydraulic Oil Return Filter Replace Hydraulic Oil Clean Filter Replace Filter in the Hydraulic Tank Cap S N 0101 0200 9001 Replace Filter in the Hydraulic Tank Breather Valve S N 0201 Replace Bucket Teeth option Replace Cuttin...

Page 23: ...ck and Adjust Air Conditioner Belt Clean Air Conditioner and Heater Filter Element option Check Air Conditioner Refrigerant Replace Air Conditioner Filter Elements option Clean Air Conditioner Condenser option Replace Air Conditioner Receiver Dryer option Every 3 years or 6000 hours Others Walk Around Inspection First time replacement or cleaning only Section Item for check Operating hours When Re...

Page 24: ...T F Hydraulic System Use industrial type hydraulic oils which are certified by suppliers having anti wear anti foam anti rust and anti oxidation additive properties for heavy duty use Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure Differential Planetary Use class API CD engine oil with 5 Antichatter additive or friction modifier Lubr...

Page 25: ...use engine overheating Keep 33 antifreeze mixture same as the mixture for a minimum ambient temperature of 15 C 5 F if the engine overheats in a high ambient temperature Do not use hard water or water with high levels of calcium and magnesium ions as the coolant water Expected Minimum Ambient Temperature 35ºC 31ºF 30ºC 22ºF 25ºC 13ºF 20ºC 4ºF 15ºC 5ºF Pure Water liter gal 58 6 15 5 63 4 16 7 69 5 ...

Page 26: ...SMISSION PILLOW UNIT LINK SYSTEM CENTER PIN UPPER ENGINE OIL PAN AXLE SUPPORT PARKING BRAKE STEERING CYL PROPELLER SHAFT EVERY 2000Hr EVERY 1000Hr EVERY 50Hr EVERY DAY DIFF BUCKET CENTER PIN LOWER PROPELLER SHAFT DIFF EVERY 250Hr Grease point Check and add if necessary Oil replacement G Multipurpose grease GO Gear oil EO Engine oil HO Hydraulic oil TO Engine oil ...

Page 27: ... line Engine 1 900 4 190 Excluding water and oil Radiator 730 1 610 Excluding water and oil Torque converter 350 775 Excluding oil Transmission 1 100 2 425 Excluding oil First propeller shaft 14 35 Second propeller shaft 180 400 Third propeller shaft 27 60 Front axle assembly 2 780 6 130 Excluding tires and oil Rear axle assembly 2 940 6 485 Excluding tires and oil Including axle support Different...

Page 28: ...ic thread M8 8 C 1 25 26 38 M10 10 C 1 5 53 76 F 1 25 55 80 M12 12 C 1 75 90 132 F 1 25 96 142 M14 14 C 2 0 142 206 F 1 5 152 221 M16 16 C 2 0 216 314 F 1 5 226 330 M18 18 C 2 5 299 436 F 1 5 324 476 M20 20 C 2 5 417 608 F 1 5 451 662 M22 22 C 2 5 559 814 F 1 5 598 878 M24 24 C 3 0 721 1 030 F 2 0 770 1 128 M27 27 C 3 0 1 030 1 520 F 2 0 1 128 1 618 M30 30 C 3 5 1 422 2 109 F 2 0 1 569 2 256 M33 3...

Page 29: ...16 16 C 2 0 22 0 32 0 F 1 5 23 0 33 7 M18 18 C 2 5 30 5 44 5 F 1 5 33 0 48 5 M20 20 C 2 5 42 5 62 0 F 1 5 46 0 67 5 M22 22 C 2 5 57 0 83 0 F 1 5 61 0 89 5 M24 24 C 3 0 73 5 105 0 F 2 0 78 5 115 0 M27 27 C 3 0 105 0 155 0 F 2 0 115 0 165 0 M30 30 C 3 5 145 0 215 0 F 2 0 160 0 230 0 M33 33 C 3 5 195 0 290 0 F 2 0 210 0 310 0 Unified thread 5 16 05 18 UNC 2 5 3 6 3 8 06 16 UNC 4 5 6 6 7 16 07 14 UNC ...

Page 30: ... F 1 5 110 160 M16 16 C 2 0 160 230 F 1 5 165 245 M18 18 C 2 5 220 320 F 1 5 235 350 M20 20 C 2 5 305 450 F 1 5 330 490 M22 22 C 2 5 410 600 F 1 5 440 650 M24 24 C 3 0 530 760 F 2 0 565 830 M27 27 C 3 0 760 1 120 F 2 0 830 1 190 M30 30 C 3 5 1 050 1 550 F 2 0 1 160 1 660 M33 33 C 3 5 1 410 2 100 F 2 0 1 520 2 240 Unified thread 5 16 05 18 UNC 18 0 26 3 8 06 16 UNC 32 47 7 16 07 14 UNC 52 76 1 2 08...

Page 31: ... 7 M6 1 12 M8 1 25 28 M10 1 5 53 M12 1 75 94 M16 2 231 M20 2 5 441 M24 3 765 kgf m Type Bolt size Bolt strength Nominal dimension Pitch 8 8 8T Metric thread M5 0 8 0 7 M6 1 1 2 M8 1 25 2 9 M10 1 5 5 4 M12 1 75 9 6 M16 2 23 5 M20 2 5 45 0 M24 3 78 0 lb ft Type Bolt size Bolt strength Nominal dimension Pitch 8 8 8T Metric thread M5 0 8 5 0 M6 1 8 6 M8 1 25 20 9 M10 1 5 38 9 M12 1 75 69 1 M16 2 169 2...

Page 32: ...19 0 30 0 25 4 38 0 69002 04400 31 8 45 8 69002 05200 38 1 52 1 69002 05700 50 8 67 8 69002 07100 60 5 76 0 69002 08200 75 5 93 0 69002 09500 Low pressure hose Hose band Tightening torque N m Tightening torque kgf cm Tightening torque lb ft Inner dia mm Outer dia mm 6 16 5 69002 02200 1 6 16 1 2 8 18 5 9 20 5 9 22 0 69002 02300 4 40 2 9 12 24 5 69002 02700 12 26 0 15 29 0 69002 03100 15 30 5 19 32...

Page 33: ...lt a new bolt should be used during reassembly Cautions regarding reassembly To reassemble a screw Completely remove the hardened lock agent from the screw and the threaded hole before reassembling the screw Note A piece of hardened lock agent may be peeled off and remain in the component The remaining piece may cause malfunction during fastener installation To bond a plane or to fit a shaft Remov...

Page 34: ...d hole Apply screw lock agent all round on the female threads at 1 3 of the female thread length from the bottom How to wind a seal tape 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 it clockwise 65ZV00002 Screw lock agent 65ZV00003 H About 1 3H 65ZV00004 Seal tape Leave 1 2 screw ...

Page 35: ...e section to be welded 5 To ground the welder check that the electric current will not flow through the cylinders Cylinder head covers for some models have a low conductive metal that will cause spark if the welding current flows through it The spark may damage the cylinder rod or other parts 6 Calibrate throttle pedal to ECM a Turn the starter switch to ON b Fully depress and release the throttle...

Page 36: ...on b Cover the hydraulic units electrical units har nesses hydraulic hoses nylon tubes etc with heat resistant cloth glass wool or canvas or scrap material to protect them from spatter c Hydraulic hoses nylon tubes or harnesses are easily damaged by the heat during welding To pro tect them from the heat remove them from the sec tion to be welded to make enough clearance 35C00003 Hydraulic cylinder...

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: ...of the boom and the bucket control lever provided in the cab remove the starter key and attach a DO NOT OPERATE tag to the cab CAUTION Be careful not to be burnt by bursting high pressure oil Release the pressure remaining inside the circuit and open the cap of the hydraulic oil tank before removing the plug from the pressure measurement port so that the internal pressure of the hydraulic oil tank...

Page 39: ...multiple control valve relief mode 2 140 100 Maximum speed in torque converter stall plus multiple control valve relief mode 1 520 150 100 1 650 150 100 Transmission Clutch pressure MPa kgf cm2 psi Engine speed Low idle 1st speed 2 2 2 3 22 23 313 327 Except 1st speed 2 5 2 6 25 26 356 370 High idle 1st speed 2 5 2 6 25 26 356 370 Except 1st speed 2 6 2 9 27 30 384 427 Clutch time lag sec Neutral ...

Page 40: ...lowly increase the engine speed and check that the machine does not move at the maximum engine speed Engine speed Maximum HI Performance of park ing brake Shift lever position 3rd speed reverse Before brake check be sure to discon nect the cable con nector of parking brake solenoid valve Engine speed Maximum HI Brake line setting pressure MPa kgf cm2 psi Unloader valve setting pressure LI Off Cut ...

Page 41: ... mode 2 140 100 Maximum speed in torque converter stall plus multiple control valve relief mode 1 520 150 100 1 650 150 100 Transmission Clutch pressure MPa kgf cm2 psi Engine speed Low idle 1st speed 2 2 2 3 22 23 313 327 Except 1st speed 2 5 2 6 25 26 356 370 High idle 1st speed 2 5 2 6 25 26 356 370 Except 1st speed 2 6 2 9 27 30 384 427 Clutch time lag sec Neutral Forward 1st speed engine spee...

Page 42: ...lowly increase the engine speed and check that the machine does not move at the maximum engine speed Engine speed Maximum HI Performance of park ing brake Shift lever position 3rd speed reverse Before brake check be sure to discon nect the cable con nector of parking brake solenoid valve Engine speed Maximum HI Brake line setting pressure MPa kgf cm2 psi Unloader valve setting pressure LI Off Cut ...

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: ...ssis Loading linkage 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 115ZV12001 7 6 1 10 2 8 3 9 4 5 ...

Page 45: ...per adjustment Contact attachment supplier for details on non standard attachments 300 mm 11 8 in Typical bucket dump stopper clearance Contact attachment supplier for details on non standard attachments To increase clearance increase height of lever stopper surface 9 To reduce clearance decrease height of lever stopper surface 9 5 040 mm 16 5 ft 50º 43º ...

Page 46: ...5V2E12002 7 6 1 10 11 2 8 3 9 4 5 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 Bucket cylinder Front chassis 9 Boom cylinder Front chassis 10 Front chassis Steering cylinder 11 Steering cylinder Rear chassis ...

Page 47: ...1 8 E 5 6 8 A A 4 S N 9001 9020 A A B B 1 Fuel tank 2 Fuel level sensor 3 Fuel tank filler assembly 4 Filter 5 Drain cock 6 Inspection hole cover 7 Gasket Rubber seal type 8 Suction pipe 9 Pipe for vacuum prevention 10 Fuel return pipe Torque when installing fuel level sensor 2 14 7 N m 1 5 kgf m 10 8 lb ft FM S N 0101 0125 S N 0126 ...

Page 48: ...r board Note The access hole for floor servicing is provided on S N 9004 Europe and S N 0108 other area Viscous mount 1 Stud 2 Cushion rubber 3 Case 4 Cap 5 Damping plate 6 Plain washer 7 Head bolt 8 Silicon oil 9 Plug The floor board is supported by a viscous mount in four positions so that vibrations impacts and sounds gener ated in the chassis are not transmitted to the inside of cabin 115ZV120...

Page 49: ...4 Washer 5 Shim 6 Bearing assembly 7 Dust seal 8 Bolt 9 Bolt 10 Washer 11 Bushing Lower center pin Lower 1 Center pin 2 Bearing retainer 3 Bearing assembly 4 Dust seal 5 Bushing 6 Bolt 7 Plate 115ZV12010 1 4 9 10 3 5 6 7 8 10 2 11 Front chassis Rear chassis Upper 115ZV12011 1 4 2 6 7 5 3 Front chassis Rear chassis Lower ...

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