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Front End Loaders
ZW 550-6
Hitachi ZW 550-6 User Manual
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MAINTENANCE
7-5
Symbols
The follo
wing symbols are used in the lubrication chart.
Grease point
G
Multipurpose grease
HO
Hydraulic oil
Check and add if necessary
GO
Gear oil
TO
Engine oil
Oil replacement
EO
Engine oil
115Z7-44794-24380
Lubrication Guide
The lubrication chart is affixed on the left side of the front
chassis. L
ubricate and/or ser
vice the parts at the inter
vals as
instructed in the char
t so that all necessary maintenance can
be per
formed regularly
.
Lubrication Chart
288
290
Table of Contents
Table of Contents
5
Machine Numbers
11
Safety
13
Recognize Safety Information
13
Understand Signal Words
13
Follow Safety Instructions
14
Prepare for Emergencies
15
Wear Protective Clothing
15
Protect against Noise
16
Inspect Machine
16
General Precautions for Cab
17
Use Handrails and Steps
18
Never Ride Attachment
18
Adjust Operator's Seat
18
Ensure Safety before Rising from or Leaving Operator's Seat
19
Fasten Your Seat Belt
19
Move and Operate Machine Safely
20
Handle Starting Aids Safely
20
Operate Only from Operator's Seat
21
Jump Starting
21
Investigate Job Site Beforehand
22
Equipment of Head Guard, ROPS, FOPS
23
Provide Signals for Jobs Involving Multiple Machines
23
Keep Riders off Machine
24
Drive Safely
24
Drive Machine Safely (Work Site
25
Drive Safely with Bucket Loaded
26
Drive on Snow Safely
26
Travel on Public Roads Safely
27
Avoid Injury from Rollaway Accidents
27
Avoid Accidents from Backing up and Turning
28
Avoid Positioning Bucket or Attachment over Anyone
29
Avoid Tipping
29
Never Undercut a High Bank
30
Dig with Caution
30
Perform Truck Loading Safely
30
Avoid Power Lines
31
Precautions for Operation
31
Precautions for Lightning
31
Object Handling
32
Protect against Flying Debris
32
Park Machine Safely
33
Store Attachments Safely
33
Transport Safely
34
Handle Fluids Safely−Avoid Fires
35
Practice Safe Maintenance
36
Warn Others of Service Work
37
Support Machine Properly
37
Stay Clear of Moving Parts
38
Support Maintenance Properly
38
Prevent Parts from Flying
39
Prevent Burns
39
Replace Rubber Hoses Periodically
40
Avoid High-Pressure Fluids
40
Prevent Fires
41
Evacuating in Case of Fire
42
Beware of Exhaust Fumes
43
Precautions for Welding and Grinding
43
Avoid Heating Near Pressurized Fluid Lines
43
Avoid Applying Heat to Lines Containing Flammable Fluids
44
Precautions for Handling Accumulator and Gas Damper
44
Precautions for Diesel Exhaust Fluid (DEF
44
Remove Paint before Welding or Heating
45
Beware of Asbestos and Silicon Dust and Other Contamination
45
Prevent Battery Explosions
46
Service Air Conditioning System Safely
46
Handle Chemical Products Safely
47
Dispose of Waste Properly
47
Notes on Aftertreatment Device
48
Precautions for Communication Terminal
48
Precaution for Communication Terminal Equipment
49
Articulation Stopper (Lock Bar
50
Joystick Steering System ON/OFF
51
ROPS (Roll over Protective Structure
52
Safety Labels
53
Components Name
65
Operator's Station
67
Aftertreatment Device
67
Automatic Regeneration
69
Cab Features
71
Front Console
72
Joystick Steering
73
Right Console
74
Fingertip Control Type
74
Multi-Function Joystick Type
75
Monitor Panel
76
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 Gauge
81
Fuel Gauge
81
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 Monitor
83
Feature
83
Screen Configuration
83
Default Setting
84
Basic Screen
85
How to Use Screens
86
Displaying Basic Screen
86
Monitor Operation
90
Alarm Occurrence Screen
91
Remedy
93
DEF/SCR System Alarm
96
Def/Adblue® Level Alarm
96
Urea SCR System Malfunction
97
Aftertreatment Device Regeneration
98
Aftertreatment Device Regeneration Status
98
Display
98
Automatic Regeneration (Auto-Regeneration)
99
Manual Regeneration
100
Main Menu
101
Ride Control Drive Speed Setting (Option)
102
Dual Lift Arm Auto-Leveler
103
Height Kickout ON/OFF, Stop Height Setting
104
Lower Kickout ON/OFF, Stop Height Setting
105
Brightness Adjustment
106
Mail (Option)
108
Setting Menu
110
Date and Time
111
Time Adjustment
111
Date Adjustment
113
Display Mode Setting
115
Auto Idling Stop
117
Auto Idling Stop: ON/OFF
117
Acting Time Setting
118
Rear View Camera Monitor
119
Aftertreatment Device Regeneration Inhibited
121
Setting Procedure
121
Transmission Setting
123
Shift Change Delay Mode Setting
123
Lockup Setting
125
Traction Control Setting
127
Parallel/Tandem Switching Height Setting
129
Warm up Operation
131
Display Item Selection
133
Main Menu Display Order Change
135
Information Menu
137
Operation Condition
138
Fuel Consumption
138
Maintenance
140
Maintenance Notice
140
Time Remains and Maintenance Interval
142
Troubleshooting
144
Monitoring
146
Front Console Switches, Pedals, and Joystick Steering
149
Hazard Switch
150
Work Light Switch
151
Parking Brake Switch
152
Key Switch
153
Accelerator Pedal
154
Brake Pedal
154
Service Brake
154
Declutch Brake
154
Joystick Steering
155
Joystick Steering Lever
155
Forward/Reverse Switch
155
Joystick Steering System Switch
155
Shift Switch
156
Light Switch
157
Wiper Switch
158
Wiper Operation
158
Front/Rear Wiper Switch
159
Right Console/Switches
160
Fingertip Control Type
160
Loading Control Levers
161
Lift Arm Control Lever
161
Bucket Control Lever
161
Right Console/Switches
163
Multi-Function Joystick Type
163
Loading Multi-Function Joystick Lever (Option)
164
Auxiliary Control Lever (Option)
165
Turn Signal Switch
165
Loading Control Lever Lock Switch
166
Armrest Adjust Handle
166
Declutch Position Switch
167
Travel Mode Selector Switch
168
Power Mode Selector Switch
169
2Nd/3Rd Speed Limit Switch (Option)
169
Fan Reverse Rotation Switch
170
Off
170
Auto
170
Manual Operation
171
Hydraulic Coupler Switch (Option)
171
Secondary Steering Operation Check Switch (Option)
172
Aftertreatment Device Regeneration Switch
172
Ride Control Switch (Option)
173
Auto
173
Off
173
Hold Switch
174
Quick Power Switch
175
Right Console Slide Lever
175
DSS (down Shift Switch)
176
Horn Switch
177
Cigar Lighter (24 V DC Electrical Outlet)
178
Using Cigar Lighter
178
Ash Tray
178
Auto Air Conditioner
179
Feature
179
Components Name
180
Controller Part Name and Function
181
Mode/Temperature Control Switch
181
Fan/Auto Switch
182
Air Conditioner ON/OFF Switch
182
Circulation/Fresh Air Switch
182
Defroster Switch
182
Cab Heater Operation
183
Cooling Operation
184
Defroster Operation
185
Cool Head/Warm Feet Operation
185
Tips for Optimal Air Conditioner Usage
186
For Rapid Cooling
186
When Windows Become Fogged
186
Off-Season Air Conditioner Maintenance
186
Adjusting Operator's Seat (Air Suspension Type Seat)
187
Components Name
187
Rear Tray
188
Electric Power Output (Option)
188
Fuse Box
189
Fuse Box a
190
Fuse Box B
190
Hot/Cool Box
191
Tray and Drink Holder
191
Cab
192
Front Interior Light
194
Rear Interior Light
194
Sun Visor
195
Emergency Exit Hammer
195
Coat/Hat Hook
195
Upper Switch Panel (Option)
196
Rotary Light Switch (Option)
196
Outside Rear View Mirror
197
Inside Rear View Mirror
197
Cab Door
197
Door Open/Close Lever
198
Window Open/Close Levers
198
Battery Disconnect Switch
199
Switch Operation
200
Articulation Stopper (Lock Bar)
201
Towing Pin
202
Inspection/Maintenance Access Covers
203
Rear Grille
204
Steps
205
Tool Box
205
Vandal-Resistant Devices
206
Break-In
209
Break-In Period for New Machine
209
Work Mode for Break-In
209
Operating the Engine
211
Inspect Machine Daily before Starting
211
Check before Starting
213
Starting Engine
216
Starting in Cold Weather
218
Preheating
218
Check after Starting
219
Check Monitor Operation
219
Check Engine Noise and Exhaust Gas Color
219
Using Booster Batteries
220
Warm up
222
Cold Weather Warm up
223
Stopping Engine
225
Moving the Machine
227
Driving the Machine
227
Precautions for Starting to Move
227
Starting to Move
228
Shift Range of Auto Transmission
231
Power Mode Selector
232
Shift Change Delay Mode
232
Parking Brake Switch
233
Drive Speed Change (Manual Shift)
234
Changing Forward/Reverse Drive Direction
234
Steering
235
Secondary Steering (Option)
236
Emergency Stop and Restart of Operation
237
Precautions for Traveling
238
Operating in Water or on Soft Ground
239
Precautions for Driving on Slopes
240
Precautions to be Taken if Machine Failure Occurs
241
Stop
242
Parking
244
Emergency Stopping
245
When the Engine Has Stalled During Operation
245
Auto Brake
246
Operating the Machine
247
Loading Control Levers
247
Fingertip Control Type
247
Loading Multi-Function Joystick Lever (Option)
249
Control Lever Lock
250
Control Lever Lock Operation
250
Declutch Position Switch
251
Adjustment of Bucket Auto Leveler
252
Adjustment of Bucket Angle Switch
254
Adjustment of Dual Lift Arm Auto Leveler
256
Auto Idling Stop
257
Auto Idling Stop Operating Condition
258
Aftertreatment Device Manual Regeneration
259
Manual Regeneration Procedure
259
Before Operation
262
Precautions for Operation
262
Ensure Safety When Operating on Road Shoulders
262
Avoid Overloading
263
Avoid Rapid Steering Changes And/Or Sudden Braking
263
Avoid Operation with Loads on Only One Side
263
Excavation
264
Loading Accumulated Soil
264
Digging and Loading Level Ground
265
Grading
266
Loading
267
Load and Carrying Method
267
Loader and Dump Truck Combination Method
268
V-Shape Loading
268
I-Shape Loading
268
Dumping into Truck or Hopper
269
Dozing
270
Stock Piling
270
Removing Snow
271
Lifting Wheel Loader
271
Precautions for after Operation
272
Transporting
275
Transporting by Road
275
Selecting a Trailer
275
Loading/Unloading on Trailer
276
Ramp/Loading Dock
276
Loading/Unloading on Trailer
277
Loading
277
Fastening Machine for Transporting
278
Transporting Wheel Loader (Urgent Situation)
279
Precautions for Driving on Roads
279
Precautions for Towing
280
Releasing Parking Brake
281
Towing Method
283
Lifting Machine
284
Maintenance
285
Correct Maintenance and Inspection Procedures
285
Check the Hour Meter Regularly
287
Layout
288
Lubrication Guide
289
Preparations for Inspection and Maintenance
290
Articulation Lock
292
Inspection/Maintenance Access Covers
293
Rear Grille
294
Inspection and Maintenance Table
295
Kind of Oils
299
Grease
299
Engine Oil
299
Transmission Oil
299
Axle Oil
300
Hydraulic Oil
300
Recommended Coolant
300
List of Consumable Parts
301
Greasing
303
Engine
309
Check Engine Oil Level
309
Change Engine Oil
310
Replace Engine Oil Filter
312
Power Train
314
Check Transmission Oil Level
314
Change Transmission Oil
315
Clean Suction Strainer
315
Change Transmission Oil Filter
315
Clean Transmission and Torque Converter Air Breathers
318
Check Axle Oil Level
319
Check Differential Gear Oil Level
319
Check Planetary Gear Oil Level
320
Change Axle Oil
321
Change Differential Gear Oil
321
Change Planetary Gear Oil
322
Replace Axle Oil Cooler Line Filter (Option)
323
Clean Axle Oil Cooler Fins (Option)
324
Hydraulic System
325
Inspection and Maintenance of Hydraulic Equipment
325
Check Hydraulic Oil Level
327
Change Hydraulic Oil
328
Bleed Air from the Hydraulic System
329
Clean Suction Filter
330
Clean Pilot Oil Filter
331
Line Filter in Brake Circuit
332
Replace Hydraulic Oil Return Filter
333
Replace Air Breather Element
334
Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, and Damage
335
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 Accumulator
336
Check Hoses and Lines
337
Service Recommendations for Hydraulic Fittings
340
Flat Face O-Ring Seal Fitting (ORS Fitting)
340
Metal Face Seal Fittings
340
Fuel System
341
Check Fuel Level
341
Recommended Fuel
341
About Biodiesel Fuel
341
Refueling
342
Drain Water and Sediment from Fuel Tank
342
Drain Fuel Filter
343
Draining Procedures (Pre-Filter)
343
Bleed Air from the Fuel System
344
Air Bleeding Procedure
344
If Air Mixed after Common Rail
345
Replace Fuel Main Filter Element
346
Replace Fuel Pre-Filter Element
348
Clean Fuel Pump Strainer
350
Clean Fuel Priming Solenoid Pump Strainer
351
Check Fuel Hoses
353
Air Cleaner
355
Replace Air Cleaner Element
355
Cooling System
356
Coolant
356
Check Coolant Level
357
Check Drive Belt
358
Measurement of Deflection Amount and Vibration Frequency
358
Adjusting Drive Belt
358
Replacing Drive Belt
359
Change Coolant
360
Clean Radiator/Oil Cooler Cores and Other Cooling System
363
Electrical System
364
Batteries
364
Electrolyte Level Check
366
Check Electrolyte Specific Gravity
367
Replace Batteries
368
Check Monitor Functions and All Other Instrument Operation
368
Check Work Lights
369
Check Horn and Backup Alarm
369
Check Electrical Harnesses and Fuses
370
Fuse Box a
371
Fuse Box B
371
Brake System
372
Check Right and Left Brake Interlocking Performance
372
Check Brake Performance
372
Check Play in Brake Pedal Stroke
372
Check Parking Brake Force
373
Check Parking Brake Gear Oil Level
374
Change Parking Brake Gear Oil
375
Check Accumulator Function, Gas Leakage
376
Looseness, and Damage
376
Check Brake Disks (Service and Parking)
377
Check Gas Pressure in Accumulator
377
Tire
378
Check and Replace Tire (Tire Pressure)
378
Check Air Pressure
378
Check Tire for Damage
379
Check Wheel Bolt Torque
379
Replace Tire
379
Tire Sizes to be Used
380
Driving on Public Roads: Standard Pressure
380
Tire Rotation
381
Rotation Procedure
381
How to Check Wear Amount (Tread Design Groove Depth)
381
Removal and Installation of Tire
382
Tire Wheel
382
Air Conditioner
383
Clean/Replace Air Conditioner Circulation/Fresh Air Filters
383
Clean Fresh Air Filter
383
Clean Circulation Air Filter
384
Check Air Conditioner
385
Check Air Conditioner Piping
385
Check Air Conditioner Condenser
386
Check Air Conditioner Compressor Belt
386
Compressor Belt Tension Adjustment Procedure
386
Check Refrigerant
387
Replace Air Conditioner Receiver Dryer
387
Check Compressor and Pulley
387
Check Compressor
387
Aftertreatment Device
388
Check and Clean Aftertreatment Device
388
Urea SCR System
389
Specified Def/Adblue
389
Check DEF Level
390
Refill DEF
390
Clean DEF Strainer
391
DEF Exchange Procedure
392
Replace DEF Supply Module Main Filter
393
Check Dosing Module
394
Replace DEF Tank Inlet Filter
394
Miscellaneous
395
Check Bucket Teeth
395
Check and Replace Seat Belt and Lower Tether
396
Check ROPS, ROPS Mounting Bolts, and Cab
396
Check Windshield Washer Fluid Level
397
Check Play Amount in Joystick Steering Movement
397
Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise
398
Exhaust Gas Color and Noise
398
Check Rearview Mirror and Inside Rearview Mirror
399
Check Steps and Handrails for Damage and Looseness
399
Clean Engine Compartment and Hood
400
Check Sound Absorbing Mat Around Engine
400
Check and Adjust Valve Clearance
400
Check Engine Compression Pressure
400
Check and Clean Starter and Alternator
400
Check Fuel Injector
401
Check Turbocharger
401
Check and Adjust Engine Controller (ECM)
401
Check and Clean EGR Valve
401
Check and Clean EGR Cooler
401
Check Urea SCR System
401
Cleaning of Rear View Camera Lens
402
Retighten Front Axle and Rear Axle Support Mounting Bolts
402
Check Tightening Torque of Nuts and Bolts
403
Maintenance under Special Environmental Conditions
415
Maintenance under Special Environmental Conditions
416
Precautions for Maintenance During Cold Weather Season
416
Storage
419
Storing the Machine
419
Removing the Machine from Storage
420
Troubleshooting
423
Engine
423
Engine Auxiliaries
423
Engine Does Not Start
424
Control Lever
425
Hydraulic System
425
Drive Function
426
Others
427
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Hitachi ZW 550-6 Specifications
General
Brand
Hitachi
Model
ZW 550-6
Category
Front End Loaders
Language
English
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