PDF Troubleshooting Technical Manual Hitachi ZW550 Wheel Loader - 2 MB
This technical manual is focused on troubleshooting for the Hitachi ZW550 Wheel Loader.
It is an indispensable resource for service technicians needing to diagnose and resolve mechanical and electrical issues quickly.
The manual contains fault codes, diagnostic flowcharts, and detailed system checks.
Reduce downtime and perform effective repairs with this expert guide.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 3 ---
01-3
Troubleshooting
Cautions Regarding Troubleshooting
Cautions Regarding Troubleshooting
Important points The following questions will be helpful in determining of
the cause. Answer the questions to prevent an incorrect
The important points for troubleshooting is to carefully diagnosis.
read the operation manual and shop manual to get
enough information on the operation, circuits, structure, 1. Did the problem occur suddenly?
and function of each component. If you have enough 2. When did the operator notice the problem?
knowledge of each component and system, you can 3. Is there any past problem that may be the cause of
easily determine the cause of the problem. this problem?
4. When the problem occurred, what kind of work was
There may be various causes for each problem, there- the operator doing?
fore experience will be needed to determine which is the 5. Has the machine had the same kind of problem
actual cause of the problem. before?
6. Has the machine been repaired or inspected
It is necessary to know the normal operation of each recently?
component. In addition, it is also important to know the 7. Does the machine have any other problem?
abnormal condition when a problem occurs. This chap-
ter shows various examples of past problems, and Troubleshooting
describes possible causes and remedies for each prob-
lem.
- Check before determination of cause
A problem may be caused by poor daily mainte-
Before starting troubleshooting nance, such as lack of grease, low or improper oil or
a clogged filter. Be sure to check the machine for oil
To prevent incorrect diagnosis, talk with the persons level, appearance, unpleasant odor, etc. to prevent
concerned, particularly with the operator, to get enough time loss due to other unnecessary tests.
information on the problem. If possible, check the
machine by repeating the symptom. - Inspection procedure
As a rule, check the easy-to-be-repaired system first
If the problem cannot be repeated, do not provide any (excluding the cases where the cause can be easily
repair service. determined based on the past experiences).
For instance, assume that the operator complains that This machine is controlled by electrical, hydraulic,
the boom power is low, and the rim-pull is also low. In and mechanical systems. The most easy-to-be-
this case, there are two possible causes; low hydraulic repaired system is the electrical system. Check the
power and low rim-pull. The remedies against both electrical system first. If no problem is detected in
causes are much different from each other. the electrical system, check the hydraulic system,
and then the mechanical system.
If you hastily determine the wrong cause without check-
ing the actual condition of the problem, it will take too Note
much time and expense to solve the problem. As a Check the error code on the MODM at first !
result, you will not be trusted by the user.
--- Page 4 ---
01-13
Troubleshooting
Torque Converter and Transmission Group
8. Machine moves reverse when
starting to climb up on a slope
using inching brake.
Check before starting work.
1. Check the error code No. shown on the
MODM.
Symptoms / check point
After pedal release, too much time is required to move.
Possible cause Solution
Refer to description of
Large time lag in clutch engagement ∗
time lag (No.5) ∗
Inching set-up condition abnormal Set-up normally
Defective inching sensor Replacement
--- Page 5 ---
01-23
Troubleshooting
Hydraulic Group
8. ELS (Efficient Loading System)
does not work.
(Excavating and scooping trac-
tive power does not become up
during ELS working condition)
Check before starting work.
1. Check the error code No. shown on the
Symptoms / check point
MODM.
At upper position of lower kickout setting, ELS works.
Pressing ELS switch, it does not function.
Without pressing ELS switch, if functions.
Possible cause Solution
ELS switch defective Repair
Solenoid valve coil or wiring failure Disassembly & repair
Solenoid valve spool stuck Disassembly & repair
Relief valve set pressure is extremely low. Disassembly & repair
Main controller failure Replacement
Kickout sensor defective or link, rod bent Replacement or repair
Speed sensor failure Replacement
Pump defective Refer to (No.1)
--- Page 6 ---
01-33
Troubleshooting
Electrical Group
Electrical Group
1. Instrument panel does not indi-
Speed indicated on the instrument panel does not correspond with the speed set by the
T/M (transmission) solenoid valve does not operate based on the speed set by the shift
cate properly.
Check before starting work.
Two or more monitor lamps will not light after setting the starter key to ON.
One of the monitor lamps will not light after setting the starter key to ON.
1. Check the fuses.
2. Lamp test
Turn the starter switch key to "ON" position
During operation, two or more monitor lamps light improperly. ∗
During operation, one of the monitor lamps lights improperly. ∗
and leave it there for 3 seconds. Check the
indicator lamps.
Symptoms / check point
3. Check the error code No. shown on the
Pointers of all the gauges are deflected to their limits.
MODM.
One of the gauges does not indicate properly. ∗
Pointer of the speedometer does not move.
One of the gauge pointers does not move.
All the gauge pointers do not move.
Hour meter does not operate.
shift lever.
lever.
Possible cause Solution
Bulb of monitor lamp burnt out Bulb replacement
Defective sensor or improper wiring Sensor replacement
Disconnected or defective electrical circuit Repairing cable
Connector check &
Loose connector
re-connection
T/M controller failure alarm turned on Inspection & repair
Controller replace-
Defective controller
ment
Defective inside mechanism of gauge or meter Replacement
Defective board of instrument panel Replacement
T/M solenoid valve improperly connected. Properly connect
Gauge circuit grounded improperly. Inspection & repair
∗ If the gauge and warning lamps do not agree there probably is a defect in the wiring. Stop immediately and diagnose the defect.
Remarks
--- Page 7 ---
01-43
Troubleshooting
Electrical Group
FAULT
CODE/ DESCRIPTION
LAMP
ZW550
EG1358 Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted
Yellow high.
EG1359 Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted
Yellow low.
EG1361 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or
Yellow shorted low.
EG1376 Engine Camshaft Speed / Position Sensor - data erratic, intermittent, or
Orange incorrect.
EG1595 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or
Yellow shorted high.
EG1597 Engine Control Module Critical Internal Failure - bad intelligent device or
Orange component.
EG1845 Water in Fuel Indicator Sensor Circuit - voltage above normal or shorted to high
Orange source.
EG1846 Water in Fuel Indicator Sensor Circuit - voltage below normal or shorted to low
Orange source.
EG1852 Water in Fuel Indicator - data valid but above normal operational range -
Yellow moderately severe level.
EG1911
Injector Metering Rail 1 Pressure - above normal operating range.
Yellow
EG2185
Sensor Supply Voltage #4 Circuit - shorted high.
Yellow
EG2186
Sensor Supply Voltage #4 Circuit - shorted low.
Yellow
EG2215 Fuel Pump Delivery Pressure - data valid but below normal operational range -
Yellow moderately severe level.
EG2249
Fuel Pump Delivery Pressure Sensor Circuit - shorted low.
Yellow
EG2261 Fuel Pump Delivery Pressure - data valid but above normal operational range -
Orange least severe level.
EG2262 Fuel Pump Delivery Pressure - data valid but below normal operational range -
Orange least severe level.
EG2265
Fuel Priming Pump Control Signal Circuit - shorted high.
Yellow
EG2266
Fuel Priming Pump Control Signal Circuit - shorted low.
Yellow
EG2311
Fueling Actuator #1 Circuit Error - condition exists.
Yellow
EG2321
Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.
None
EG2322
Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.
None
EG2697 Accelerator Pedal Position Sensor Circuit and Idling Position Detection Switch
Orange Circuit - data erratic, intermittent, or incorrect.
EG2963
Engine Coolant Temperature High - warning.
None
EG2964
Intake Manifold Temperature High - warning.
None
EG2973
Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.
Yellow
(09D20E)
--- Page 8 ---
03-1
Measurement for Performance Check
03
Cautions on Safety ............................................................................................................................................ 03-2
Standard Measurement Values for Performance Check ................................................................................... 03-3
Preparation for Performance Check ................................................................................................................. 03-6
Engine ............................................................................................................................................................... 03-8
Measuring engine speed ............................................................................................................................. 03-8
Clutch Oil Pressure and Time Lag .................................................................................................................. 03-12
Measuring clutch oil pressure ................................................................................................................... 03-12
Hydraulic Cylinder ........................................................................................................................................... 03-16
Cylinder natural drift .................................................................................................................................. 03-16
Boom Rising Time ........................................................................................................................................... 03-17
Full Steering Time ........................................................................................................................................... 03-19
Loading/Steering Circuit Relief Valve .............................................................................................................. 03-21
Loading circuit relief valve setting pressures ............................................................................................ 03-21