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

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

Covered Models:
   Zaxis ZW550-G

The manual comprises 3 documents, including the Workshop Manual, Troubleshooting Manual, and Operational Principle Manual

1. Workshop Manual (WNHD-E-00)
Format: PDF, 365 pages
Language: English
Table of Contents:
   General Information
      Symbols
      Weight of Main Components
      Bolt Tightening Torque
      Hose Band Tightening Torque
      Liquid Gasket and Screw Lock Agent
      Cautions Regarding Welding Repair Service
      Cautions Regarding Handling of Bearing
      Applying and Storing Articulation Stopper
   Disassembly and Reassembly Chassis Group
      Deck
      Fuel Tank
      Hydraulic Tank
      Engine Room
      ROPS and Cab
      Floor Board
      Boom
      Center Pin
   Service Standard Chassis Group
      Linkage
      Linkage Pin Standard Clearance Values
      Center Pin
      Bucket Positioner and Boom Kick-Out
   Disassembly and Reassembly Power Group
      Power Line
      Radiator
      Fan
      Engine
      Propeller Shaft
      Air Cleaner
      Muffler
      Front Axle Assembly
      Internal Gear Hub
      Spider Assembly
      Special Tool
      Rear Axle Assembly
      Axle Support
      Differential Assembly
   Service Standard Power Group
      Propeller Shaft Service Standard
      Axle and Differential Service Standard
   Disassembly and Reassembly Torque Converter and Transmission Group
      Torque Converter
      Transmission
      Clutch Assembly
      Clutch Spider Assembly
      Reverse Clutch Spider
      Transmission 1st Clutch Assembly
      Transmission High Clutch Assembly
      Modulator Valve Assembly
      Control Valve Assembly
   Service Standard Torque Converter and Transmission Group
      Transmission Assembly
      Torque Converter Gear Pump
      Gear Train and Number of Teeth
      Clutch Oil Pressure
   Disassembly and Reassembly Hydraulic Group
      Hydraulic Parts Removal and Installation Warning
      Hydraulic Parts Disassembly and Assembly Cautions
      Hydraulic Pump Assembly
      Hydraulic Cylinder
      Pilot Valve
      Multiple Control Valve
      Orbitrol
      Steering Valve
      Stop Valve
      Fan Motor
   Service Standard Hydraulic Group
      Hydraulic Cylinder
      Pilot Valve
      Steering Valve
   Disassembly and Reassembly Brake Group
      Unloader Valve
      Manifold Valve Assembly
      Accumulator
      Brake Valve
      Service Brake
      Parking Brake Actuator
      Parking Brake Assembly
   Service Standard Brake Group
      Brake Valve
      Service Brake
      Parking Brake
   Disassembly and Reassembly Operator Station Group
      Air Conditioner
   Service Standard Operator Station Group
      Air Conditioner

2. Troubleshooting Manual (TTNHD-E-00)
Format: PDF, 90 pages
Language: English
Table of Contents:
   Cautions Regarding Troubleshooting
   How to Use Quick Troubleshooting Table
   Safety Precautions
   Quick Troubleshooting Table
      Torque Converter and Transmission Group
      Hydraulic Group
      Brake Group
      Electrical Group
      Operator Station Group
   MEASUREMENT FOR PERFORMANCE CHECK 03
      Standard Measurement Values for Performance Check
      Preparation for Performance Check
      Measuring Engine Speed
      Measuring Clutch Oil Pressure and Time Lag
      Measuring Cylinder Drift
      Measuring Boom Cycle Time
      Measuring Full Steering Cycle Time
      Measuring Relief Valve Setting Pressures
      Measuring Fan Revolution
      Checking Brake Performance
      Measuring Brake Line Oil Pressure
      Measuring Accumulator Circuit Charging Time
      Measuring Number of Brake Pedal Applications
      Measuring Declutch Engagement

3. Operational Principle Manual (TONHD-E-00)
Format: PDF, 587 pages
Language: English
Table of Contents:
   Measurement for Performance Check
      Cautions on Safety
      Standard Measurement Values for Performance Check
   Function and Structure Chassis Group
      Front Chassis
      Rear Chassis
      Center Pin
   Check and Adjustment Chassis Group
      Linkage Pin
      Center Pin
   Function and Structure Power Group
      Power Line
      Engine / Transmission
      Radiator
      Propeller Shaft
      Axle Assembly
      Axle Support
      Differential Gear
   Check and Adjustment Power Group
      Engine
      Propeller Shaft
      Axle
   Function and Structure Torque Converter and Transmission Group
      Torque Converter
      Torque Converter Gear Pump
      Transmission
      Clutch Pack
      Power Flow Path in the Transmission
      Hydraulic System Diagram
      Hydraulic Circuit Diagram
      T/C and T/M Oil Circulation
      Modulator Valve Unit
      Modulation Mechanism
      Clutch Solenoid Valve
   Check and Adjustment Torque Converter and Transmission Group
      Clutch Oil Pressure and Time Lag
   Function and Structure Hydraulic Group
      Flushing Hydraulic Circuit
      Cautions on Hydraulic Parts Replacement
      Hydraulic Circuit Symbols
      Hydraulic System Operation
      Layout of Hydraulic Units
      Hydraulic Tank
      Hydraulic Pump
      Hydraulic Cylinder
      Loading System
      Reducing Valve (for Pilot Pressure)
      Pilot Valve (S/N 0101~0140, 9001~9020)
      Pilot valve (S/N 0141~0172, 9021~)
      Pilot valve (S/N 0173~0176)
      Pilot valve (S/N 0177~)
      Multiple Control Valve (KML35A/2T103)
      Adapter (Orifice)
      Vibration Damper (OPT)
      Steering System
      Orbitrol
      Steering Valve (KVS32-A4.0/21)
      Stop Valve
      Reducing Valve (for Orbitrol)
      Steering Line Filter
      Fan Motor System
      Fan Motor Line (S/N 0101~0120, 9001~9010)
      Fan Motor Line (S/N 0121~, 9011~)
      Emergency Steering
   Check and Adjustment Hydraulic Group
      Loading/Steering Circuit Relief Valve
      Hydraulic Cylinder
      Stop Valve
      Fan Motor Revolution
   Function and Structure Brake Group
      Brake System Outline
      Brake Units Layout
      Unloader Valve
      Reducing valve
      Valve Unit (Main Brake Manifold Block)
      Brake Accumulator Line
      Brake Valve
      Stop Lamp Pressure Switch
      Service Brake
      Parking Brake
      Parking Brake Manual Release
      Parking Brake Spring Chamber
      Brake Circuit Check Valve
      Auto Brake
      Shuttle Valve
   Check and Adjustment Brake Group
      Brake Circuit Oil Pressure
      Service Brake
      Parking Brake
   Function and Structure Electrical Group
      How to Use Electrical Wiring Diagram
      Electrical Cable Color Codes
      Electrical Circuit Symbols
      Sensor Mount
      Fuse
      Engine Start Circuit
      Power Generating/Charging Circuit
      ECM (Engine Controller)
      Transmission Control Circuit (S/N 0101~0153, 9001~)
      Transmission Control Circuit (S/N 0154~)
      Monitor Circuit
      Instrument Panel and Switch
      Electrical Detent Circuit
      Diode
      Diagnostic System
      MODM (S/N 0154~)
   Check and Adjustment Electrical Group
      Cautions Regarding Electric Circuit Check
      Electrical Transmission Control System Troubleshooting Flowchart
      Transmission Controller Abnormal Operation Judgment
      Electrical Circuit Check
   Function and Structure Operator Station Group
      Cabin
      Operator Seat
      Steering and Transmission Shift Lever
      Air Conditioner
   Check and Adjustment Operator Station Group
      Air Conditioner
   Cross-section drawing and 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 (1/2) (S/N 0101~0120)
      Electrical Wiring Diagram (2/2) (S/N 0101~0120)
      Electrical Wiring Diagram (1/2) (S/N 0121~0124)
      Electrical Wiring Diagram (2/2) (S/N 0121~0124)
      Electrical Wiring Diagram (1/2) (S/N 0125~0153)
      Electrical Wiring Diagram (2/2) (S/N 0125~0153)
      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 9001~9010)
      Electrical Wiring Diagram (2/2) (S/N 9001~9010)
      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)