Name: Hitachi ZW 550-6
Brand: Hitachi
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550

-6

ENMNHK-NA1-1ZW550-6 WHEEL LOADER OPERATOR'S MANUAL

PRINTED IN JAPAN (T) 2018, 03

URL:http://www.hitachi-c-m.com

ENMNHK-NA1-1

PART NO.

Wheel Loader

Operator's Manual

Serial No. 005201 and up

This book is printed on recycled paper.

Table of Contents5
Machine Numbers11
Safety13
Recognize Safety Information13
Understand Signal Words13
Follow Safety Instructions14
Prepare for Emergencies15
Wear Protective Clothing15
Protect against Noise16
Inspect Machine16
General Precautions for Cab17
Use Handrails and Steps18
Never Ride Attachment18
Adjust Operator's Seat18
Ensure Safety before Rising from or Leaving Operator's Seat19
Fasten Your Seat Belt19
Move and Operate Machine Safely20
Handle Starting Aids Safely20
Operate Only from Operator's Seat21
Jump Starting21
Investigate Job Site Beforehand22
Equipment of Head Guard, ROPS, FOPS23
Provide Signals for Jobs Involving Multiple Machines23
Keep Riders off Machine24
Drive Safely24
Drive Machine Safely (Work Site25
Drive Safely with Bucket Loaded26
Drive on Snow Safely26
Travel on Public Roads Safely27
Avoid Injury from Rollaway Accidents27
Avoid Accidents from Backing up and Turning28
Avoid Positioning Bucket or Attachment over Anyone29
Avoid Tipping29
Never Undercut a High Bank30
Dig with Caution30
Perform Truck Loading Safely30
Avoid Power Lines31
Precautions for Operation31
Precautions for Lightning31
Object Handling32
Protect against Flying Debris32
Park Machine Safely33
Store Attachments Safely33
Transport Safely34
Handle Fluids Safely−Avoid Fires35
Practice Safe Maintenance36
Warn Others of Service Work37
Support Machine Properly37
Stay Clear of Moving Parts38
Support Maintenance Properly38
Prevent Parts from Flying39
Prevent Burns39
Replace Rubber Hoses Periodically40
Avoid High-Pressure Fluids40
Prevent Fires41
Evacuating in Case of Fire42
Beware of Exhaust Fumes43
Precautions for Welding and Grinding43
Avoid Heating Near Pressurized Fluid Lines43
Avoid Applying Heat to Lines Containing Flammable Fluids44
Precautions for Handling Accumulator and Gas Damper44
Precautions for Diesel Exhaust Fluid (DEF44
Remove Paint before Welding or Heating45
Beware of Asbestos and Silicon Dust and Other Contamination45
Prevent Battery Explosions46
Service Air Conditioning System Safely46
Handle Chemical Products Safely47
Dispose of Waste Properly47
Notes on Aftertreatment Device48
Precautions for Communication Terminal48
Precaution for Communication Terminal Equipment49
Articulation Stopper (Lock Bar50
Joystick Steering System ON/OFF51
ROPS (Roll over Protective Structure52
Safety Labels53
Components Name65
Operator's Station67
Aftertreatment Device67
Automatic Regeneration69
Cab Features71
Front Console72
Joystick Steering73
Right Console74
Fingertip Control Type74
Multi-Function Joystick Type75
Monitor Panel76
Parking Brake Indicator (Red)77
Brake Oil Low Pressure Indicator (Red)77
Hydraulic Oil Level Indicator (Red)77
Low Steering Oil Pressure Indicator (Option) (Red)78
Transmission Warning Indicator (Red)78
Communication Error Indicator (Yellow)78
Discharge Warning Indicator (Red)78
Engine Warning Indicator (Red)79
Overheat Indicator (Red)79
Engine Oil Low Pressure Indicator (Red)79
Air Filter Restriction Indicator (Red)80
Preheat Indicator (Yellow)80
Coolant Temperature Gauge81
Fuel Gauge81
Turn Signal Indicator (Green)82
High Beam Indicator (Blue)82
Work Light Indicator (Yellow)82
Clearance Light Indicator (Green)82
Control Lever Lock Indicator (Red)82
Multi Function Monitor83
Feature83
Screen Configuration83
Default Setting84
Basic Screen85
How to Use Screens86
Displaying Basic Screen86
Monitor Operation90
Alarm Occurrence Screen91
Remedy93
DEF/SCR System Alarm96
Def/Adblue® Level Alarm96
Urea SCR System Malfunction97
Aftertreatment Device Regeneration98
Aftertreatment Device Regeneration Status98
Display98
Automatic Regeneration (Auto-Regeneration)99
Manual Regeneration100
Main Menu101
Ride Control Drive Speed Setting (Option)102
Dual Lift Arm Auto-Leveler103
Height Kickout ON/OFF, Stop Height Setting104
Lower Kickout ON/OFF, Stop Height Setting105
Brightness Adjustment106
Mail (Option)108
Setting Menu110
Date and Time111
Time Adjustment111
Date Adjustment113
Display Mode Setting115
Auto Idling Stop117
Auto Idling Stop: ON/OFF117
Acting Time Setting118
Rear View Camera Monitor119
Aftertreatment Device Regeneration Inhibited121
Setting Procedure121
Transmission Setting123
Shift Change Delay Mode Setting123
Lockup Setting125
Traction Control Setting127
Parallel/Tandem Switching Height Setting129
Warm up Operation131
Display Item Selection133
Main Menu Display Order Change135
Information Menu137
Operation Condition138
Fuel Consumption138
Maintenance140
Maintenance Notice140
Time Remains and Maintenance Interval142
Troubleshooting144
Monitoring146
Front Console Switches, Pedals, and Joystick Steering149
Hazard Switch150
Work Light Switch151
Parking Brake Switch152
Key Switch153
Accelerator Pedal154
Brake Pedal154
Service Brake154
Declutch Brake154
Joystick Steering155
Joystick Steering Lever155
Forward/Reverse Switch155
Joystick Steering System Switch155
Shift Switch156
Light Switch157
Wiper Switch158
Wiper Operation158
Front/Rear Wiper Switch159
Right Console/Switches160
Fingertip Control Type160
Loading Control Levers161
Lift Arm Control Lever161
Bucket Control Lever161
Right Console/Switches163
Multi-Function Joystick Type163
Loading Multi-Function Joystick Lever (Option)164
Auxiliary Control Lever (Option)165
Turn Signal Switch165
Loading Control Lever Lock Switch166
Armrest Adjust Handle166
Declutch Position Switch167
Travel Mode Selector Switch168
Power Mode Selector Switch169
2Nd/3Rd Speed Limit Switch (Option)169
Fan Reverse Rotation Switch170
Off170
Auto170
Manual Operation171
Hydraulic Coupler Switch (Option)171
Secondary Steering Operation Check Switch (Option)172
Aftertreatment Device Regeneration Switch172
Ride Control Switch (Option)173
Auto173
Off173
Hold Switch174
Quick Power Switch175
Right Console Slide Lever175
DSS (down Shift Switch)176
Horn Switch177
Cigar Lighter (24 V DC Electrical Outlet)178
Using Cigar Lighter178
Ash Tray178
Auto Air Conditioner179
Feature179
Components Name180
Controller Part Name and Function181
Mode/Temperature Control Switch181
Fan/Auto Switch182
Air Conditioner ON/OFF Switch182
Circulation/Fresh Air Switch182
Defroster Switch182
Cab Heater Operation183
Cooling Operation184
Defroster Operation185
Cool Head/Warm Feet Operation185
Tips for Optimal Air Conditioner Usage186
For Rapid Cooling186
When Windows Become Fogged186
Off-Season Air Conditioner Maintenance186
Adjusting Operator's Seat (Air Suspension Type Seat)187
Components Name187
Rear Tray188
Electric Power Output (Option)188
Fuse Box189
Fuse Box a190
Fuse Box B190
Hot/Cool Box191
Tray and Drink Holder191
Cab192
Front Interior Light194
Rear Interior Light194
Sun Visor195
Emergency Exit Hammer195
Coat/Hat Hook195
Upper Switch Panel (Option)196
Rotary Light Switch (Option)196
Outside Rear View Mirror197
Inside Rear View Mirror197
Cab Door197
Door Open/Close Lever198
Window Open/Close Levers198
Battery Disconnect Switch199
Switch Operation200
Articulation Stopper (Lock Bar)201
Towing Pin202
Inspection/Maintenance Access Covers203
Rear Grille204
Steps205
Tool Box205
Vandal-Resistant Devices206
Break-In209
Break-In Period for New Machine209
Work Mode for Break-In209
Operating the Engine211
Inspect Machine Daily before Starting211
Check before Starting213
Starting Engine216
Starting in Cold Weather218
Preheating218
Check after Starting219
Check Monitor Operation219
Check Engine Noise and Exhaust Gas Color219
Using Booster Batteries220
Warm up222
Cold Weather Warm up223
Stopping Engine225
Moving the Machine227
Driving the Machine227
Precautions for Starting to Move227
Starting to Move228
Shift Range of Auto Transmission231
Power Mode Selector232
Shift Change Delay Mode232
Parking Brake Switch233
Drive Speed Change (Manual Shift)234
Changing Forward/Reverse Drive Direction234
Steering235
Secondary Steering (Option)236
Emergency Stop and Restart of Operation237
Precautions for Traveling238
Operating in Water or on Soft Ground239
Precautions for Driving on Slopes240
Precautions to be Taken if Machine Failure Occurs241
Stop242
Parking244
Emergency Stopping245
When the Engine Has Stalled During Operation245
Auto Brake246
Operating the Machine247
Loading Control Levers247
Fingertip Control Type247
Loading Multi-Function Joystick Lever (Option)249
Control Lever Lock250
Control Lever Lock Operation250
Declutch Position Switch251
Adjustment of Bucket Auto Leveler252
Adjustment of Bucket Angle Switch254
Adjustment of Dual Lift Arm Auto Leveler256
Auto Idling Stop257
Auto Idling Stop Operating Condition258
Aftertreatment Device Manual Regeneration259
Manual Regeneration Procedure259
Before Operation262
Precautions for Operation262
Ensure Safety When Operating on Road Shoulders262
Avoid Overloading263
Avoid Rapid Steering Changes And/Or Sudden Braking263
Avoid Operation with Loads on Only One Side263
Excavation264
Loading Accumulated Soil264
Digging and Loading Level Ground265
Grading266
Loading267
Load and Carrying Method267
Loader and Dump Truck Combination Method268
V-Shape Loading268
I-Shape Loading268
Dumping into Truck or Hopper269
Dozing270
Stock Piling270
Removing Snow271
Lifting Wheel Loader271
Precautions for after Operation272
Transporting275
Transporting by Road275
Selecting a Trailer275
Loading/Unloading on Trailer276
Ramp/Loading Dock276
Loading/Unloading on Trailer277
Loading277
Fastening Machine for Transporting278
Transporting Wheel Loader (Urgent Situation)279
Precautions for Driving on Roads279
Precautions for Towing280
Releasing Parking Brake281
Towing Method283
Lifting Machine284
Maintenance285
Correct Maintenance and Inspection Procedures285
Check the Hour Meter Regularly287
Layout288
Lubrication Guide289
Preparations for Inspection and Maintenance290
Articulation Lock292
Inspection/Maintenance Access Covers293
Rear Grille294
Inspection and Maintenance Table295
Kind of Oils299
Grease299
Engine Oil299
Transmission Oil299
Axle Oil300
Hydraulic Oil300
Recommended Coolant300
List of Consumable Parts301
Greasing303
Engine309
Check Engine Oil Level309
Change Engine Oil310
Replace Engine Oil Filter312
Power Train314
Check Transmission Oil Level314
Change Transmission Oil315
Clean Suction Strainer315
Change Transmission Oil Filter315
Clean Transmission and Torque Converter Air Breathers318
Check Axle Oil Level319
Check Differential Gear Oil Level319
Check Planetary Gear Oil Level320
Change Axle Oil321
Change Differential Gear Oil321
Change Planetary Gear Oil322
Replace Axle Oil Cooler Line Filter (Option)323
Clean Axle Oil Cooler Fins (Option)324
Hydraulic System325
Inspection and Maintenance of Hydraulic Equipment325
Check Hydraulic Oil Level327
Change Hydraulic Oil328
Bleed Air from the Hydraulic System329
Clean Suction Filter330
Clean Pilot Oil Filter331
Line Filter in Brake Circuit332
Replace Hydraulic Oil Return Filter333
Replace Air Breather Element334
Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, and Damage335
Check Ride Control Accumulator Function, Gas Leakage, Looseness, and Damage (Option)336
Check Gas Pressure in Ride Control Accumulator (Option)336
Check Gas Pressure in Steering Accumulator336
Check Hoses and Lines337
Service Recommendations for Hydraulic Fittings340
Flat Face O-Ring Seal Fitting (ORS Fitting)340
Metal Face Seal Fittings340
Fuel System341
Check Fuel Level341
Recommended Fuel341
About Biodiesel Fuel341
Refueling342
Drain Water and Sediment from Fuel Tank342
Drain Fuel Filter343
Draining Procedures (Pre-Filter)343
Bleed Air from the Fuel System344
Air Bleeding Procedure344
If Air Mixed after Common Rail345
Replace Fuel Main Filter Element346
Replace Fuel Pre-Filter Element348
Clean Fuel Pump Strainer350
Clean Fuel Priming Solenoid Pump Strainer351
Check Fuel Hoses353
Air Cleaner355
Replace Air Cleaner Element355
Cooling System356
Coolant356
Check Coolant Level357
Check Drive Belt358
Measurement of Deflection Amount and Vibration Frequency358
Adjusting Drive Belt358
Replacing Drive Belt359
Change Coolant360
Clean Radiator/Oil Cooler Cores and Other Cooling System363
Electrical System364
Batteries364
Electrolyte Level Check366
Check Electrolyte Specific Gravity367
Replace Batteries368
Check Monitor Functions and All Other Instrument Operation368
Check Work Lights369
Check Horn and Backup Alarm369
Check Electrical Harnesses and Fuses370
Fuse Box a371
Fuse Box B371
Brake System372
Check Right and Left Brake Interlocking Performance372
Check Brake Performance372
Check Play in Brake Pedal Stroke372
Check Parking Brake Force373
Check Parking Brake Gear Oil Level374
Change Parking Brake Gear Oil375
Check Accumulator Function, Gas Leakage376
Looseness, and Damage376
Check Brake Disks (Service and Parking)377
Check Gas Pressure in Accumulator377
Tire378
Check and Replace Tire (Tire Pressure)378
Check Air Pressure378
Check Tire for Damage379
Check Wheel Bolt Torque379
Replace Tire379
Tire Sizes to be Used380
Driving on Public Roads: Standard Pressure380
Tire Rotation381
Rotation Procedure381
How to Check Wear Amount (Tread Design Groove Depth)381
Removal and Installation of Tire382
Tire Wheel382
Air Conditioner383
Clean/Replace Air Conditioner Circulation/Fresh Air Filters383
Clean Fresh Air Filter383
Clean Circulation Air Filter384
Check Air Conditioner385
Check Air Conditioner Piping385
Check Air Conditioner Condenser386
Check Air Conditioner Compressor Belt386
Compressor Belt Tension Adjustment Procedure386
Check Refrigerant387
Replace Air Conditioner Receiver Dryer387
Check Compressor and Pulley387
Check Compressor387
Aftertreatment Device388
Check and Clean Aftertreatment Device388
Urea SCR System389
Specified Def/Adblue389
Check DEF Level390
Refill DEF390
Clean DEF Strainer391
DEF Exchange Procedure392
Replace DEF Supply Module Main Filter393
Check Dosing Module394
Replace DEF Tank Inlet Filter394
Miscellaneous395
Check Bucket Teeth395
Check and Replace Seat Belt and Lower Tether396
Check ROPS, ROPS Mounting Bolts, and Cab396
Check Windshield Washer Fluid Level397
Check Play Amount in Joystick Steering Movement397
Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise398
Exhaust Gas Color and Noise398
Check Rearview Mirror and Inside Rearview Mirror399
Check Steps and Handrails for Damage and Looseness399
Clean Engine Compartment and Hood400
Check Sound Absorbing Mat Around Engine400
Check and Adjust Valve Clearance400
Check Engine Compression Pressure400
Check and Clean Starter and Alternator400
Check Fuel Injector401
Check Turbocharger401
Check and Adjust Engine Controller (ECM)401
Check and Clean EGR Valve401
Check and Clean EGR Cooler401
Check Urea SCR System401
Cleaning of Rear View Camera Lens402
Retighten Front Axle and Rear Axle Support Mounting Bolts402
Check Tightening Torque of Nuts and Bolts403
Maintenance under Special Environmental Conditions415
Maintenance under Special Environmental Conditions416
Precautions for Maintenance During Cold Weather Season416
Storage419
Storing the Machine419
Removing the Machine from Storage420
Troubleshooting423
Engine423
Engine Auxiliaries423
Engine Does Not Start424
Control Lever425
Hydraulic System425
Drive Function426
Others427

Brand	Hitachi
Model	ZW 550-6
Category	Front End Loaders
Language	English

Hitachi ZW 550-6 User Manual

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