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Hitachi ZW550 Wheel Loader Troubleshooting Technical Manual (TT11C5-E-00) – PDF Download
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- Hitachi ZW550 Wheel Loader Troubleshooting Technical Manual
- Part No:TT11C5-E-00
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Description
Hitachi ZW550 Wheel Loader Troubleshooting Technical Manual (TT11C5-E-00)
File Details:
Hitachi ZW550 Wheel Loader Troubleshooting Technical Manual (TT11C5-E-00)
- Manual Language:English
- Pages: 166
- Size: 8.39 MB
- Downloadable:Yes
- Format:PDF
HITACHI ZW550 WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL (TT11C5-E-00) – PDF DOWNLOAD:
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Description:
Hitachi ZW550 Wheel Loader Troubleshooting Technical Manual (TT11C5-E-00)
- 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 Operation and Maintenance Manual.
- To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Technical Manual.
- 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 methods. 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 requests, please inform us.
Table Of Contents:
Hitachi ZW550 Wheel Loader Troubleshooting Technical Manual (TT11C5-E-00)
TT11C5-E-00.......................................................................................................................................... 1 Foreword............................................................................................................................................. 3 Safety Precautions................................................................................................................................... 4 Safety Symbols....................................................................................................................................... 5 Symbols.............................................................................................................................................. 6 01 Troubleshooting .................................................................................................................................. 9 Cautions Regarding Troubleshooting............................................................................................................... 11 How to Use Quick Troubleshooting Table........................................................................................................... 12 Safety Precautions............................................................................................................................... 13 Torque Converter and Transmission Group.......................................................................................................... 14 1. Machine dose not move in any shift lever position......................................................................................... 14 2. Machine dose not move at a certain shift lever position. (OR:Machine moves only in a certain shift lever position.)....................... 15 3. Machine moves at the neutral position. (Example: Machine moves forward at the neutral position.).......................................... 16 4. Large shock at starting or changing speed / direction..................................................................................... 17 5. Large time lag at starting or changing speed / direction.................................................................................. 18 6. Low power (Defective torque converter or transmission).................................................................................... 19 7. Torque converter oil is overheating....................................................................................................... 20 8. Machine moves reverse when starting to climb up on a slope using inching brake............................................................ 21 9. Automatic speed change is not possible.................................................................................................... 22 10. Downshift button does not work........................................................................................................... 23 Hydraulic Group.................................................................................................................................. 24 1. Boom and/or bucket do not move............................................................................................................ 24 2. Boom and/or bucket have low power, or move too slowly..................................................................................... 25 3. Excessive cylinder drift.................................................................................................................. 26 4. Boom and/or bucket are spongy. (Holding bucket against the ground is not possible-front wheels off the ground.)........................... 27 5. Bucket leveler does not work. Boom lift kickout and lower kickout does not work........................................................... 28 6. Steering is not possible or hard to steer................................................................................................. 29 7. Machine sways, or has a shock during steering............................................................................................. 30 8. ELS (Efficient Loading System) does not work. (Excavating and scooping tractive power does not become up during ELS working condition).... 31 9. Ride control does not work................................................................................................................ 32 10. Fan motor rotates abnormally or does not rotate.......................................................................................... 33 11. Abnormal noise in hydraulic system....................................................................................................... 34 12. Others................................................................................................................................... 35 Brake Group...................................................................................................................................... 36 1. Brake does not work well. (In the worst case, the brake does not work at all.)............................................................ 36 2. Brake is dragging when released........................................................................................................... 37 3. Stepping on the brake pedal sounds the buzzer............................................................................................. 38 4. Accumulator pressure does not rise, or too slow in rising................................................................................. 39 5. Parking brake does not work. (or: Releasing the parking brake is not possible.)........................................................... 40 Electrical Group................................................................................................................................. 41 1. Instrument panel does not indicate properly............................................................................................... 41 2. Fuse for controller is blown.............................................................................................................. 42 Error code (for chassis)..................................................................................................................... 43 Error code (for engine)...................................................................................................................... 46 Operator Station Group........................................................................................................................... 52 Air conditioner.............................................................................................................................. 52 03 Measurement for Performance Check................................................................................................................. 61 Cautions on Safety............................................................................................................................... 62 Standard Measurement Values for Performance Check................................................................................................ 63 Preparation for Performance Check................................................................................................................ 66 Engine........................................................................................................................................... 68 Measuring engine speed....................................................................................................................... 68 Measurement instrument................................................................................................................... 68 Standard measurement value............................................................................................................... 68 Clutch Oil Pressure and Time Lag................................................................................................................. 72 Measuring clutch oil pressure................................................................................................................ 72 Measurement instrument................................................................................................................... 72 Gauge port............................................................................................................................... 72 Standard measurement value............................................................................................................... 73 Clutch oil pressure measurement procedure................................................................................................ 73 Time lag measurement procedure........................................................................................................... 74 Possible causes for low clutch pressure and clutch time lag.............................................................................. 75 Hydraulic Cylinder............................................................................................................................... 76 Cylinder natural drift....................................................................................................................... 76 Measurement instrument................................................................................................................... 76 Standard measurement value (mm/min) (in/min)............................................................................................. 76 Measurement procedure.................................................................................................................... 76 Boom Rising Time................................................................................................................................. 77 Measurement instrument....................................................................................................................... 77 Warm-up the engine before measuring boom rising time......................................................................................... 77 Standard measurement value (sec)............................................................................................................. 77 Measurement procedure........................................................................................................................ 77 Full Steering Time............................................................................................................................... 79 Measurement instrument....................................................................................................................... 79 Warm-up the engine before measuring full steering time....................................................................................... 79 Standard measurement value (sec)............................................................................................................. 79 Measurement procedure........................................................................................................................ 79 Loading/Steering Circuit Relief Valve............................................................................................................ 81 Loading circuit relief valve setting pressures............................................................................................... 81 Measurement instruments.................................................................................................................. 81 Gauge port............................................................................................................................... 81 Standard measurement value MPa (kgf/cm2) (psi)........................................................................................... 82 Measuring loading circuit main relief pressure........................................................................................... 82 Measuring loading circuit overload relief pressure....................................................................................... 84 Measuring pilot circuit relief pressure.................................................................................................. 85 Steering circuit relief valve setting pressures.............................................................................................. 86 Measurement instruments.................................................................................................................. 86 Gauge port............................................................................................................................... 86 Standard measurement value MPa (kgf/cm2) (psi)........................................................................................... 87 Measuring steering circuit main relief pressure.......................................................................................... 87 Measuring steering circuit overload relief pressure...................................................................................... 89 Measuring pilot circuit relief pressure (reducing pressure).............................................................................. 90 Stop Valve....................................................................................................................................... 92 Stop valve adjustment procedure.............................................................................................................. 92 Fan Revolution................................................................................................................................... 93 Measurement instrument....................................................................................................................... 93 Measuring number of fan maximum revolutions.................................................................................................. 93 Service Brake.................................................................................................................................... 94 Service brake performance check.............................................................................................................. 94 Condition................................................................................................................................ 94 Standard measurement value............................................................................................................... 94 Parking Brake.................................................................................................................................... 95 Parking brake performance check.............................................................................................................. 95 Condition................................................................................................................................ 95 Standard measurement value............................................................................................................... 95 Brake Circuit Oil Pressure....................................................................................................................... 96 Unloader valve setting pressure.............................................................................................................. 96 Measurement instrument................................................................................................................... 97 Gauge port............................................................................................................................... 97 Standard measurement value............................................................................................................... 97 Measurement procedure.................................................................................................................... 97 Brake valve oil pressure..................................................................................................................... 99 Brake valve performance..................................................................................................................100 Auto brake reducing pressure.................................................................................................................101 Measurement instrument...................................................................................................................101 MODM.....................................................................................................................................101 Gauge port...............................................................................................................................101 Standard measurement value...............................................................................................................101 Measurement procedure....................................................................................................................101 Accumulator Circuit Charging Time................................................................................................................103 Measurement instrument.......................................................................................................................103 Gauge installation position..................................................................................................................103 Standard measurement valve (sec).............................................................................................................104 Measurement procedure........................................................................................................................104 Number of Brake Pedal Applications...............................................................................................................105 Standard measurement value...................................................................................................................105 Measurement procedure........................................................................................................................105 Possible causes of extremely low measurement value and solution..............................................................................105 Declutch Engagement..............................................................................................................................106 Measurement instrument.......................................................................................................................106 Warm-up the engine before measuring declutch engagement......................................................................................106 Standard measurement value...................................................................................................................106 Cause of extremely high measurement value and solution.......................................................................................106 Measurement procedure........................................................................................................................106 ZW550 Drawing & Diagrams.............................................................................................................................109 Axle Assembly....................................................................................................................................110 Torque Converter and Transmission................................................................................................................111 Hydraulic & Brake Circuit........................................................................................................................112 Brake Circuit....................................................................................................................................113 Electrical Wiring Diagram (S/N 9001~9006)........................................................................................................114 (1/3) .......................................................................................................................................114 (2/3)........................................................................................................................................115 (3/3) .......................................................................................................................................116 Electrical Wiring Diagram (S/N 9007~9050)........................................................................................................117 (1/3) .......................................................................................................................................116 (2/3) .......................................................................................................................................118 (3/3) .......................................................................................................................................119 Electrical Wiring Diagram (S/N 9051~9100)........................................................................................................120 (1/3) .......................................................................................................................................119 (2/3) .......................................................................................................................................121 (3/3) .......................................................................................................................................122 Electrical Wiring Diagram (S/N 9101~)............................................................................................................123 (1/3) .......................................................................................................................................123 (2/3) .......................................................................................................................................124 (3/3) .......................................................................................................................................125 Electrical Wiring Diagram........................................................................................................................126 Way of looking at connectors.................................................................................................................126 Electrical wiring diagram abbreviation chart.....................................................................................................128 Electrical Wiring Diagram (CAB)..................................................................................................................129 Electrical Connection Diagram (S/N 9001~9050)....................................................................................................130 (1/2) .......................................................................................................................................130 (2/2) .......................................................................................................................................131 Electrical Connection Diagram (S/N 9051~9100)....................................................................................................132 (1/2) .......................................................................................................................................132 (2/2) .......................................................................................................................................133 Electrical Connection Diagram (S/N 9101~)........................................................................................................134 (1/2) .......................................................................................................................................134 (2/2)........................................................................................................................................135 Electrical Equipment Layout......................................................................................................................136 Front chassis................................................................................................................................136 Rear chassis.................................................................................................................................137 Floor board..................................................................................................................................139 Front chassis (wiring).......................................................................................................................141 Floor board (wiring).........................................................................................................................141 Rear chassis (wiring)........................................................................................................................142 Cab (wiring).................................................................................................................................144 Electrical Wiring Diagram (Cabin Air Conditioner)................................................................................................145 Electrical Circuit Diagram (Cabin Air Conditioner)...............................................................................................146 Equipment Operation Table (Cabin Air Conditioner)................................................................................................147 Outline of MODM (Machine Operation Diagnostic Module) Operation..................................................................................148 Main Menu....................................................................................................................................149 Information Monitor..........................................................................................................................150 Replacement Monitor..........................................................................................................................151 Fault Log Monitor............................................................................................................................152 Input/Output Monitor.........................................................................................................................153 Parameter Setting Monitor....................................................................................................................154 Specification Setting Monitor................................................................................................................155 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table............................................................................157 Traction Control Switch Mount....................................................................................................................158 Maintenance Log......................................................................................................................................159 Notes................................................................................................................................................163
Please Note:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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Kohen Riley –
Everything was non dramatic, perfect