All-Inclusive Factory Service Technical manual for Hitachi Wheel Loaders Models Zaxis ZW550-6.

This manual will assist you in diagnosing, repairing, troubleshooting, and operating for your wheel loader.

Covered Models:
   Zaxis ZW550-6

The manual comprises 9 documents, including two Workshop Manuals, two Troubleshooting Manuals, two Operational Principle Manuals, and three Wiring Diagrams

1. Workshop Manual (WNHK70-EN-00)
Format: PDF, 828 pages
Language: English
Table of Contents:
   GENERAL
      Precautions for Disassembling and Assembling
      Tightening
      Painting
      Bleeding Air
      Pressure Release Procedure
      Preparation
   MAINTENANCE STANDARD
      Body
      Front Attachment
   BODY
      Cab
      Counterweight
      Center Hinge
      Engine
      Radiator Assembly
      Hydraulic Oil Tank
      Fuel Tank
      Pump Device
      Control Valve
      Pilot Valve
      Brake Charge Valve
      Combination Valve
      DEF Tank
      Flow Regulator Valve
      Cooling Fan System
      Aftertreatment Device
      Ride Control Valve and Accumulator
      Battery Disconnect Switch
   TRAVEL SYSTEM
      Tire
      Drive Unit
      Axle
      Propeller Shaft
      Brake Valve
      Steering Valve
      Steering Cylinder
      Emergency Steering Device
      Reducing Valve
      Stop Valve
      Main Pressure Block
      Priority Hammer Valve and Shuttle Valve
      Check Valve
      Joystick Steering
      Axle Oil Cooler
   FRONT ATTACHMENT
      Front Attachment
      Cylinder

2. Workshop Manual (WNHK40-EN-00(20180806))
Format: PDF, 781 pages
Language: English
Table of Contents:
   GENERAL
      Precautions for Disassembling and Assembling
      Tightening
      Painting
      Bleeding Air
      Pressure Release Procedure
      Preparation
   MAINTENANCE STANDARD
      Body
      Front Attachment
   BODY
      Cab
      Counterweight
      Center Hinge
      Engine
      Radiator Assembly
      Hydraulic Oil Tank
      Fuel Tank
      Pump Device
      Control Valve
      Pilot Valve
      Brake Charge Valve
      Combination Valve
      DEF Tank
      Flow Regulator Valve
      Cooling Fan System
      Aftertreatment Device
      Ride Control Valve and Accumulator
      Battery Disconnect Switch
   TRAVEL SYSTEM
      Tire
      Drive Unit
      Axle
      Propeller Shaft
      Brake Valve
      Steering Pilot Valve
      Steering Valve
      Steering Cylinder
      Emergency Steering Device
      Reducing Valve
      Stop Valve
      Main Pressure Block
      Priority Hammer Valve and Shuttle Valve
      Check Valve
   FRONT ATTACHMENT
      Front Attachment
      Cylinder

3. Troubleshooting Manual (TTNHK70-EN-00)
Format: PDF, 504 pages
Language: English
Table of Contents:
   OPERATIONALPERFORMANCE TEST
      Introduction
      Standard
      Engine Test
      Machine Performance Test
      Component Test
      Adjustment
   TROUBLESHOOTING
      Diagnosing Procedure
      Monitor
      e-Service
      Component Layout
      Troubleshooting A
      Troubleshooting B
      Air Conditioner
   SERVICE MANUAL REVISION REQUEST FORM
   The Attached Diagram List

4. Troubleshooting Manual (TTNHK40-EN-00(20170510))
Format: PDF, 542 pages
Language: English
Table of Contents:
   OPERATIONAL PERFORMANCE TEST
      Introduction
      Standard
      Engine Test
      Machine Performance Test
      Component Test
      Adjustment
   TROUBLESHOOTING
      Diagnosing Procedure
      Monitor
      e-Service
      Component Layout
      Troubleshooting A
      Troubleshooting B
      Air Conditioner
      Joystick Steering System

5. Operational Principle Manual (TONHK70-EN-00)
Format: PDF, 489 pages
Language: English
Table of Contents:
   Specifications
      Specifications
      Weight of Main Components
   Component Layout
      Main Component (Overview)
      Main Component
      Main Component
      Electric Component Layout (Front Chassis)
      Electric Component Layout (Rear Grill)
      Electrical System (Cab)
      Electrical System (Around Battery Box)
      Electrical System (Around Hydraulic Tank)
      Electrical System (Around Fuel Tank)
      Electrical System (Rear Chassis Center Frame)
      Engine
      Aftertreatment Device
      Hydraulic Pump
      Transmission and Torque Converter Assembly
      Multiple Control Valve
      Unloader Valve (Brake Charge Valve) and Combination Valve (Brake Manifold Valve)
      Steering Valve
      Flow Regulator Valve
      Ride Control Valve (Option)
      Fuel Priming Pump (us Option)
      Secondary Steering Pump (Option)
   Component Specifications
      Engine
      Engine Accessories
      Hydraulic Component
      Electrical Component
   1 Controller
      Outline
      CAN Circuit
   Control System
      Outline
      Engine Control
      Pump Control
      Transmission Control
      Fan Control, Valve Control
      Other Controls
      Combined Electric and Hydraulic ControlCircuit
   Engine System
      Outline
      Engine Sensors
      Fuel Injection Control
      EGR Control
      Preheating Control
      Variable Turbocharger Control
      Urea SCR System
      Engine Output Restriction (Inducement)
      Aftertreatment Device
      Aftertreatment Device Regeneration Control
   Hydraulic System
      Outline
      Pilot Circuit
      Brake Priority Circuit
      Service Brake Circuit
      Parking Brake Circuit
      Auto Brake Circuit
      Lift Arm (Boom) / Bucket Operation ControlCircuit
      Fan Circuit
      Main Circuit
      Steering Priority Circuit
      Steering Operation Control Circuit
      Neutral Circuit
      Flow Rate Control Circuit
      Relief Circuit
      Other Circuits
      Pump Control Circuit
      Parallel Circuit Flow Rate Control
      Single Operation Circuit
      Combined Operation Circuit
      Ride Control Circuit
      Emergency (Secondary) Steering Circuit(Option)
   Electrical System
      Outline
      Main Circuit
      Electric Power Circuit (Key Switch: OFF)
      CAN Circuit
      Accessory Circuit (Key Switch: ACC)
      Starting Circuit (Key Switch: START)
      Neutral Engine Start Circuit
      Charging Circuit (Key Switch: ON)
      Surge Voltage Prevention Circuit
      Pilot Shut-Off Circuit (Key Switch: ON)
      Auto Shut-Down (Idling Stop) Circuit
      Engine Stop Circuit
      Monitor Circuit
      Air Conditioner Circuit
      Steering Column Monitor Circuit
      Head Light Circuit
      Hazard Light Circuit (Key Switch: OFF)
      Turn Signal Light Circuit
      Horn Circuit (Key Switch: OFF)
      Reverse Light/Buzzer Circuit
      Brake Light Circuit
      Parking Brake Circuit
      Accessory Circuit
      Work Light Circuit
      Wiper Circuit
      Cab Light Circuit
   COMPONENT OPERATION
   Pump Device
      Hydraulic Pump Outline
      Main Hydraulic Pump
      Regulator
      Accessory Pump
      Pump Delivery Pressure Sensor
   Control Valve
      Outline
      Hydraulic Circuit
      Main Relief Valve
      Main Relief Valve Operation
      Overload Relief Valve (with Make-UpFunction)
      Bleed-Off Compensation Spool
      Bucket Spool
      Lift Arm (Boom) Spool
      Lift Arm Flow Rate Control Valve
      Ride Control (Option)
      Pump Control Valve (Negative Control ReliefValve)
   Cooling Fan System
      Cooling Fan System Layout
      Fan Pump (Accessory Pump)
      Fan Motor
      Fan Control Valve
   Steering Pilot Valve
      Steering Pilot Line
      Unit Location
      Steering Pilot Valve
      Joystick Steering Control Valve
   Steering Valve
      Outline
      Operation
      Steering Valve Meter-In Compensator
      Steering Main Relief Valve
      Steering Overload Relief Valve
      Steering Spool Variable Orifice
      Steering Pilot Circuit and Its Operation
      Flow Amplifier Notch and Pilot Orifice
   Pilot Valve
      Outline (Fingertip Control Type Pilot Valvefor Front Attachment)
      Operation
      Electromagnetic Detent
      Outline (Joystick Type Pilot Valve for FrontAttachment)
      Operation
      Electromagnetic Detent
   Charging Circuit
      Outline
      Brake Charge Valve
      Combination Valve (Manifold Block)
      Combination Valve (Solenoid Valve Block)
      Service Brake Accumulator
   Drive Unit
      Outline
      Transmission and Torque Converter Assembly
      Drive Unit Hydraulic Circuit Diagram
      Torque Converter (Lock-Up)
      Transmission
      Operation of Transmission
      Clutch Pack
      Power Flow Path in the Transmission
      Transmission Control Valve
      Lock-Up Clutch Valve Assy
   Axle
      Outline
      Front Axle Assembly
      Rear Axle Assembly
      Differential Gear (Conventional Type)
      Limited Slip Differential (LSD) (Option)
      Service Brake
      Parking Brake
      Parking Brake Manual Release
   Brake Valve
      Outline
      Service Brake Operation
      Bleed Air from Service Brake Circuit
      Pressure Switch (for Stop Lamp)
      Pressure Sensor (for Declutch)
      Auto Brake Operation
      Bleed Air from Auto Brake Circuit
   DEF Supply System
      System Overview
      DEF
      DEF Tank
      Hose Urea
      DEF Sensor Unit
      DEF Supply Module
      Coolant Line
      Coolant Control Valve Air Bleeding Procedure
   Others
      Propeller Shaft
      Emergency (Secondary) Steering Pump(Option)
      Flow Regulator Valve
      Ride Control Valve (Option)
      Ride Control Accumulator
      Steering Accumulator
      Priority Hammer Valve
      Axle Oil Cooler
   

6. Operational Principle Manual (TONHK40-EN-00)
Format: PDF, 497 pages
Language: English
Table of Contents:
   GENERAL
      Specifications
      Component Layout
      Component Specifications
   SYSTEM
      Controller
      Control System
      Engine System
      Hydraulic System
      Electrical System
   COMPONENT OPERATION
      Pump Device
      Control Valve
      Cooling Fan System
      Steering Pilot Valve
      Steering Valve
      Pilot Valve
      Charging Circuit
      Drive Unit
      Axle
      Brake Valve
      DEF Supply System
      Others
   SERVICE MANUAL REVISION REQUEST FORM

7. Wiring Diagram (TTNHK70-EN-00_Circuit)
Format: PDF, 17 pages
Language: English
Table of Contents:
   HYDRAULIC CIRCUIT DIAGRAM
   FAN, PILOT AND BRAKE CIRCUIT DIAGRAM
   ELECTRICAL CONNECTION DIAGRAM (1/4)
   ELECTRICAL CONNECTION DIAGRAM (2/4)
   ELECTRICAL CONNECTION DIAGRAM (3/4)
   ELECTRICAL CONNECTION DIAGRAM (4/4)
   FRONT CHASSIS CABLE LAYOUT AND WIRING DIAGRAM
   REAR CHASSIS WIRING DIAGRAM (1/3)
   REAR CHASSIS WIRING DIAGRAM (2/3)
   REAR CHASSIS WIRING DIAGRAM (3/3)
   FLOOR WIRING DIAGRAM (REAR CONSOLE) (1/3)
   FLOOR WIRING DIAGRAM (REAR CONSOLE) (2/3)
   FLOOR WIRING DIAGRAM (REAR CONSOLE) (3/3)
   FLOOR WIRING DIAGRAM (SIDE CONSOLE)
   JOYSTICK STEERING SYSTEM (USA)
   FLOOR WIRING DIAGRAM (FRONT CONSOLE)
   CAB WIRING DIAGRAM

8. Wiring Diagram (TTNHK40-EN-00_Circuit_2)
Format: PDF, 15 pages
Language: English
Table of Contents:
   FLOOR CABLE LAYOUT (REAR AND SIDE CONSOLES)
   FLOOR WIRING DIAGRAM (REAR CONSOLE) (1/3)
   FLOOR WIRING DIAGRAM (REAR CONSOLE) (2/3)
   FLOOR WIRING DIAGRAM (REAR CONSOLE) (3/3)
   FLOOR WIRING DIAGRAM (SIDE CONSOLE)
   FLOOR WIRING DIAGRAM (STEERING POST)
   FLOOR CABLE LAYOUT (FRONT CONSOLE)
   FLOOR WIRING DIAGRAM (FRONT CONSOLE)
   CAB CABLE LAYOUT
   CAB WIRING DIAGRAM
   HYDRAULIC CIRCUIT DIAGRAM OF OPTIONAL SYSTEM
   JOYSTICK STEERING ELECTRICAL CONNECTION DIAGRAM
   JOYSTICK STEERING CABLE LAYOUT (REAR AND SIDE CONSOLE) (OPTION)
   JOYSTICK STEERING WIRING DIAGRAM (REAR & SIDE CONSOLES)
   JOYSTICK STEERING WIRING DIAGRAM (ARMREST HARNESS)

9. Wiring Diagram (TTNHK40-EN-00_Circuit_1)
Format: PDF, 14 pages
Language: English
Table of Contents:
   HYDRAULIC CIRCUIT DIAGRAM
   FAN, PILOT AND BRAKE CIRCUIT DIAGRAM
   ELECTRICAL CONNECTION DIAGRAM (1/4)
   ELECTRICAL CONNECTION DIAGRAM (2/4)
   ELECTRICAL CONNECTION DIAGRAM (3/4)
   ELECTRICAL CONNECTION DIAGRAM (4/4)
   FRONT CHASSIS CABLE LAYOUT AND WIRING DIAGRAM
   REAR CHASSIS CABLE LAYOUT(1/3)
   REAR CHASSIS CABLE LAYOUT (2/3)
   REAR CHASSIS CABLE LAYOUT (3/3)
   REAR CHASSIS WIRING DIAGRAM (1/3)
   REAR CHASSIS WIRING DIAGRAM (2/3)
   REAR CHASSIS WIRING DIAGRAM (3/3)
   FLOOR CABLE LAYOUT