Hitachi ZW 550-6 User manual

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.

©2018 Hitachi Construction Machinery Co., Ltd.
All rights reserved.
INTRODUCTIONINTRODUCTION
Read this manual carefully to learn how to operate and
service your machine correctly. Failure to do so could
result in personal injury or machine damage.
This standard specification machine can be operated
under the following conditions without being modified.
Atmospheric Temperature: -20 °C to 45 °C (-4 °F to 113 °F)
Altitude: 0 m to 2000 m (0 ft to 6600 ft)
In case the machine is used under conditions other than
described above, consult your authorized dealer.
This manual should be considered a permanent part of
your machine and should remain with the machine when
you sell it.
This machine is of metric design. Measurements in this
manual are metric. Use only metric hardware and tools as
specified.
Right-hand and left-hand sides are determined by
facing in the direction of forward travel.
Write product identification numbers in the Machine
Numbers section. Accurately record all the numbers
to help in tracing the machine should it be stolen.
Your dealer also needs these numbers when you order
parts. If this manual is kept on the machine, also file the
identification numbers in a secure place off the machine.
Use only diesel fuel with quality specified in JIS K-2204,
EN-590 or ASTM D-975 which contents 15 ppm or lower
sulfur.
Also use fuel that complies with solid contamination level
of class 18/16/13 of ISO4406-1999 (solid contamination
includes dust). If the fuel specified above is not used,
exhaust gas that exceeds the regulation values may be
discharged, causing serious problem on the engine.
Consult your authorized dealer.
Warranty is provided as a part of Hitachi’s support
program for customers who operate and maintain their
equipment as described in this manual. The warranty is
explained on the warranty certificate which you should
have received from your dealer.
This warranty provides you with the assurance that
Hitachi will back its products where defects appear within
the warranty period. In some circumstances, Hitachi also
provides field improvements, often without charge to the
customer, even if the product is out of warranty.
Should the equipment be abused, or modified to
change its performance beyond the original factory
specifications, the warranty will become void and field
improvements may be denied.
Setting fuel delivery above specifications or otherwise
overpowering machines will result in such action.
Only qualified, experienced operators officially licensed
(according to local law) should be allowed to operate
the machine. Moreover, only officially licensed personnel
should be allowed to inspect and service the machine.
PRIOR TO OPERATING THIS MACHINE, INCLUDING
COMMUNICATION SYSTEM, IN A COUNTRY OTHER
THAN A COUNTRY OF ITS INTENDED USE, IT MAY
BE NECESSARY TO MAKE MODIFICATIONS TO IT SO
THAT IT COMPLIES WITH THE LOCAL REGULATORY
STANDARDS (INCLUDING SAFETY STANDARDS)
AND LEGAL REQUIREMENTS OF THAT PARTICULAR
COUNTRY. PLEASE DO NOT EXPORT OR OPERATE
THIS MACHINE OUTSIDE OF THE COUNTRY OF ITS
INTENDED USE UNTIL SUCH COMPLIANCE HAS
BEEN CONFIRMED. PLEASE CONTACT HITACHI
CONSTRUCTION MACHINERY CO., LTD. OR ANY OF
OUR AUTHORIZED DISTRIBUTOR OR DEALER IF YOU
HAVE ANY QUESTIONS CONCERNING COMPLIANCE.
In this manual, urea water is indicated as DEF/AdBlue®.
“DEF” stands for the Diesel Exhaust Fluid. AdBlue®
is a registered trademark of the Verband der
Automobilindustrie e.V. (VDA).
All information, illustrations and specifications in this manual are based on the latest product information available at the
time of publication. The right is reserved to make changes at any time without notice.

T
MACHINE NUMBERS
SAFETY
SAFETY LABELS
COMPONENTS NAME
OPERATOR’S STATION
BREAK-IN
OPERATING THE ENGINE
MOVING THE MACHINE
OPERATING THE MACHINE
TRANSPORTING
MAINTENANCE
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
STORAGE
SPECIFICATIONS
INDEX
INDEX
ENMNHK-NA1-1
TROUBLESHOOTING

CONTENTS
MACHINE NUMBERS .........................................................1
SAFETY .......................................................................... S-1
Recognize Safety Information ....................................................S-1
Understand Signal Words.............................................................S-1
Follow Safety Instructions............................................................S-2
Prepare for Emergencies...............................................................S-3
Wear Protective Clothing..............................................................S-3
Protect Against Noise ....................................................................S-4
Inspect Machine ..............................................................................S-4
General Precautions for Cab........................................................S-5
Use Handrails and Steps ...............................................................S-6
Never Ride Attachment.................................................................S-6
Adjust Operator’s Seat...................................................................S-6
Ensure Safety Before Rising from or Leaving Operator’s
Seat .................................................................................................S-7
Fasten Your Seat Belt......................................................................S-7
Move and Operate Machine Safely...........................................S-8
Handle Starting Aids Safely .........................................................S-8
Operate Only from Operator’s Seat ..........................................S-9
Jump Starting ...................................................................................S-9
Investigate Job Site Beforehand ............................................. S-10
Equipment of Head Guard, ROPS, FOPS............................... S-11
Provide Signals for Jobs Involving Multiple Machines.... S-11
Keep Riders Off Machine ........................................................... S-12
Drive Safely..................................................................................... S-12
Drive Machine Safely (Work Site)............................................ S-13
Drive Safely with Bucket Loaded ............................................ S-14
Drive on Snow Safely .................................................................. S-14
Travel on Public Roads Safely................................................... S-15
Avoid Injury from Rollaway Accidents.................................. S-15
Avoid Accidents from Backing Up and Turning ................ S-16
Avoid Positioning Bucket or Attachment Over
Anyone........................................................................................ S-17
Avoid Tipping................................................................................. S-17
Never Undercut a High Bank.................................................... S-18
Dig with Caution........................................................................... S-18
Perform Truck Loading Safely .................................................. S-18
Avoid Power Lines........................................................................ S-19
Precautions for Operation......................................................... S-19
Precautions for Lightning.......................................................... S-19
Object Handling ........................................................................... S-20
Protect Against Flying Debris .................................................. S-20
Park Machine Safely..................................................................... S-21
Store Attachments Safely.......................................................... S-21
Transport Safely ............................................................................ S-22
Handle Fluids Safely−Avoid Fires............................................S-23
Practice Safe Maintenance ....................................................... S-24
Warn Others of Service Work ................................................... S-25
Support Machine Properly........................................................ S-25
Stay Clear of Moving Parts ........................................................ S-26
Support Maintenance Properly............................................... S-26
Prevent Parts from Flying .......................................................... S-27
Prevent Burns................................................................................. S-27
Replace Rubber Hoses Periodically........................................ S-28
Avoid High-Pressure Fluids....................................................... S-28
Prevent Fires................................................................................... S-29
Evacuating in Case of Fire.......................................................... S-30
Beware of Exhaust Fumes..........................................................S-31
Precautions for Welding and Grinding ................................. S-31
Avoid Heating Near Pressurized Fluid Lines....................... S-31
Avoid Applying Heat to Lines Containing Flammable
Fluids ........................................................................................... S-32
Precautions for Handling Accumulator and Gas
Damper....................................................................................... S-32
Precautions for Diesel Exhaust Fluid (DEF).......................... S-32
Remove Paint Before Welding or Heating........................... S-33
Beware of Asbestos and Silicon Dust and Other
Contamination......................................................................... S-33
Prevent Battery Explosions ....................................................... S-34
Service Air Conditioning System Safely ............................... S-34
Handle Chemical Products Safely........................................... S-35
Dispose of Waste Properly......................................................... S-35
Notes on Aftertreatment Device ............................................ S-36
Precautions for Communication Terminal........................... S-36
Precaution for Communication Terminal Equipment ..... S-37
Articulation Stopper (Lock Bar)............................................... S-38
Joystick Steering System ON/OFF .......................................... S-39
ROPS (Roll Over Protective Structure)................................... S-40
SAFETY LABELS........................................................... S-41
COMPONENTS NAME.................................................... 1-1
Components Name ........................................................................1-1
OPERATOR’S STATION .................................................. 1-3
Aftertreatment Device...................................................................1-3
Automatic Regeneration .............................................................1-5
Repeated Inhibiting of Exhaust Filter Cleaning ..............1-6
Cab Features......................................................................................1-7
Front Console....................................................................................1-8
Joystick Steering..............................................................................1-9
Right Console.................................................................................1-10
Fingertip Control Type ..........................................................1-10
Multi-Function Joystick Type .............................................. 1-11
Monitor Panel ................................................................................1-12
Parking Brake Indicator (Red)...................................................1-13
Brake Oil Low Pressure Indicator (Red)................................. 1-13
Hydraulic Oil Level Indicator (Red)......................................... 1-13
Low Steering Oil Pressure Indicator (Option) (Red) .........1-14
Transmission Warning Indicator (Red)..................................1-14
Communication Error Indicator (Yellow) ............................. 1-14
Discharge Warning Indicator (Red)........................................1-14
Engine Warning Indicator (Red)..............................................1-15
Overheat Indicator (Red) ...........................................................1-15
Engine Oil Low Pressure Indicator (Red) ..............................1-15
Air Filter Restriction Indicator (Red)....................................... 1-16
Preheat Indicator (Yellow)......................................................... 1-16
Coolant Temperature Gauge....................................................1-17
Fuel Gauge......................................................................................1-17
Turn Signal Indicator (Green) ...................................................1-18
High Beam Indicator (Blue)....................................................... 1-18
Work Light Indicator (Yellow)................................................... 1-18
Clearance Light Indicator (Green) .......................................... 1-18
Control Lever Lock Indicator (Red)......................................... 1-18

CONTENTS
Multi Function Monitor ..............................................................1-19
Feature........................................................................................1-19
Screen Configuration.............................................................1-19
Default Setting ..............................................................................1-20
Basic Screen....................................................................................1-21
How to Use Screens.....................................................................1-22
Displaying Basic Screen........................................................ 1-22
Monitor Operation ................................................................. 1-26
Alarm Occurrence Screen.......................................................... 1-27
Remedy....................................................................................... 1-29
DEF/SCR System Alarm...............................................................1-32
DEF/AdBlue® Level Alarm .................................................... 1-32
Urea SCR System Malfunction............................................ 1-33
Aftertreatment Device Regeneration ................................... 1-34
Aftertreatment Device Regeneration Status
Display...................................................................................1-34
Automatic regeneration (Auto-regeneration).............. 1-35
Manual Regeneration............................................................ 1-36
Main Menu......................................................................................1-37
Ride Control Drive Speed Setting (Option).........................1-38
Dual Lift Arm Auto-Leveler ....................................................... 1-39
Height Kickout ON/OFF, Stop Height Setting............... 1-40
Lower Kickout ON/OFF, Stop Height Setting ................ 1-41
Brightness Adjustment...............................................................1-42
Mail (Option) ..................................................................................1-44
Setting Menu .................................................................................1-46
Date and Time................................................................................1-47
Time Adjustment ....................................................................1-47
Date Adjustment.....................................................................1-49
Display Mode Setting............................................................ 1-51
Auto Idling Stop............................................................................1-53
Auto Idling Stop: ON/OFF .................................................... 1-53
Acting Time Setting................................................................ 1-54
Rear View Camera Monitor .......................................................1-55
Aftertreatment Device Regeneration Inhibited................ 1-57
Setting Procedure................................................................... 1-57
Transmission Setting................................................................... 1-59
Shift Change Delay Mode Setting ....................................1-59
Lockup Setting......................................................................... 1-61
Traction Control Setting ....................................................... 1-63
Parallel/Tandem Switching Height Setting.........................1-65
Warm Up Operation ....................................................................1-67
Display Item Selection................................................................ 1-69
Main Menu Display Order Change......................................... 1-71
Information Menu........................................................................ 1-73
Operation Condition...................................................................1-74
Fuel Consumption .................................................................. 1-74
Maintenance ..................................................................................1-76
Maintenance Notice............................................................... 1-76
Time Remains and Maintenance Interval....................... 1-78
Troubleshooting ...........................................................................1-80
Monitoring......................................................................................1-82
Front Console Switches, Pedals, and Joystick Steering... 1-85
Hazard Switch................................................................................ 1-86
Work Light Switch ........................................................................ 1-87
Parking Brake Switch...................................................................1-88
Key Switch.......................................................................................1-89
Accelerator Pedal..........................................................................1-90
Brake Pedal .....................................................................................1-90
Service Brake ............................................................................ 1-90
Declutch Brake......................................................................... 1-90
Joystick Steering........................................................................... 1-91
Joystick Steering Lever .........................................................1-91
Forward/Reverse Switch....................................................... 1-91
Joystick Steering System Switch .......................................1-91
Shift Switch ...............................................................................1-92
Light Switch.................................................................................... 1-93
Wiper Switch ..................................................................................1-94
Wiper Operation...................................................................... 1-94
Front/Rear Wiper Switch....................................................... 1-95
Right Console/Switches .............................................................1-96
Fingertip Control Type ..........................................................1-96
Loading Control Levers ..............................................................1-97
Lift Arm Control Lever........................................................... 1-97
Bucket Control Lever .............................................................1-97
Right Console/Switches .............................................................1-99
Multi-Function Joystick Type .............................................. 1-99
Loading Multi-Function Joystick Lever (Option).............1-100
Auxiliary Control Lever (Option) ...........................................1-101
Turn Signal Switch......................................................................1-101
Loading Control Lever Lock Switch .....................................1-102
Armrest Adjust Handle.............................................................1-102
Declutch Position Switch.........................................................1-103
Travel Mode Selector Switch..................................................1-104
Power Mode Selector Switch .................................................1-105
2nd/3rd Speed Limit Switch (Option).................................1-105
Fan Reverse Rotation Switch..................................................1-106
OFF.............................................................................................1-106
AUTO ........................................................................................1-106
Manual Operation ................................................................1-107
Hydraulic Coupler Switch (Option)......................................1-107
Secondary Steering Operation Check Switch
(Option) ....................................................................................1-108
Aftertreatment Device Regeneration Switch...................1-108
Ride Control Switch (Option) .................................................1-109
AUTO..........................................................................................1-109
OFF.............................................................................................1-109
Hold Switch ..................................................................................1-110
Quick Power Switch...................................................................1-111
Right Console Slide Lever........................................................1-111
DSS (Down Shift Switch)..........................................................1-112
Horn Switch .................................................................................1-113
Cigar Lighter (24 V DC Electrical Outlet) ............................1-114
Using Cigar Lighter...............................................................1-114
Ash Tray..........................................................................................1-114
Auto Air Conditioner.................................................................1-115
Feature......................................................................................1-115
Components Name..............................................................1-116
Controller Part Name and Function ...............................1-117
Mode/Temperature Control Switch ...............................1-117
Fan/AUTO Switch ..................................................................1-118
Air Conditioner ON/OFF Switch.......................................1-118

CONTENTS
Circulation/Fresh Air Switch..............................................1-118
Defroster Switch....................................................................1-118
Cab Heater Operation .........................................................1-119
Cooling Operation................................................................1-120
Defroster Operation.............................................................1-121
Cool Head/Warm Feet Operation....................................1-121
Tips for Optimal Air Conditioner Usage .............................1-122
For Rapid Cooling .................................................................1-122
When Windows Become Fogged ....................................1-122
Off-Season Air Conditioner Maintenance....................1-122
Adjusting Operator's Seat (Air Suspension Type
Seat)...........................................................................................1-123
Components Name..............................................................1-123
Rear Tray ........................................................................................1-124
Electric Power Output (Option).............................................1-124
Fuse Box.........................................................................................1-125
Fuse Box A ...............................................................................1-126
Fuse Box B................................................................................1-126
Hot/Cool Box................................................................................1-127
Tray and Drink Holder...............................................................1-127
Cab...................................................................................................1-128
Front Interior Light.....................................................................1-130
Rear Interior Light ......................................................................1-130
Sun Visor........................................................................................1-131
Emergency Exit Hammer.........................................................1-131
Coat/Hat Hook.............................................................................1-131
Upper Switch Panel (Option)..................................................1-132
Rotary Light Switch (Option)..................................................1-132
Outside Rear View Mirror.........................................................1-133
Inside Rear View Mirror ............................................................1-133
Cab Door........................................................................................1-133
Door Open/Close Lever............................................................1-134
Window Open/Close Levers ...................................................1-134
Battery Disconnect Switch .....................................................1-135
Switch Operation ..................................................................1-136
Articulation Stopper (Lock Bar).............................................1-137
Towing Pin ....................................................................................1-138
Inspection/Maintenance Access Covers ............................1-139
Rear Grille......................................................................................1-140
Steps................................................................................................1-141
Tool Box .........................................................................................1-141
Vandal-Resistant Devices.........................................................1-142
BREAK-IN ....................................................................... 2-1
Break-in Period for New Machine..............................................2-1
Work Mode for Break-in ................................................................2-1
OPERATING THE ENGINE .............................................. 3-1
Inspect Machine Daily Before Starting ....................................3-1
Check Before Starting....................................................................3-3
Starting Engine ................................................................................3-6
Starting in Cold Weather...............................................................3-8
Preheating ....................................................................................3-8
Check After Starting .......................................................................3-9
Check Monitor Operation.......................................................3-9
Check Engine Noise and Exhaust Gas Color.....................3-9
Using Booster Batteries..............................................................3-10
Warm Up.......................................................................................... 3-12
Cold Weather Warm Up.............................................................. 3-13
Stopping Engine...........................................................................3-15
MOVING THE MACHINE ................................................ 4-1
Driving the Machine.......................................................................4-1
Precautions for Starting to Move .........................................4-1
Starting to Move..............................................................................4-2
Shift Range of Auto Transmission ........................................4-5
Power Mode Selector ...............................................................4-6
Shift Change Delay Mode .......................................................4-6
Parking Brake Switch......................................................................4-7
Drive Speed Change (Manual Shift) .........................................4-8
Changing Forward/Reverse Drive Direction..........................4-8
Steering...............................................................................................4-9
Secondary Steering (Option) ...................................................4-10
Emergency Stop and Restart of Operation......................... 4-11
Precautions for Traveling ...........................................................4-12
Operating in Water or on Soft Ground............................ 4-13
Precautions for Driving on Slopes.......................................... 4-14
Precautions to be Taken if Machine Failure Occurs..........4-15
Stop ................................................................................................... 4-16
Parking .............................................................................................4-18
Emergency Stopping ..................................................................4-19
When the Engine has Stalled During Operation ......... 4-19
Auto Brake.......................................................................................4-20
OPERATING THE MACHINE........................................... 5-1
Loading Control Levers .................................................................5-1
Fingertip Control Type .............................................................5-1
Loading Multi-Function Joystick Lever (Option) ............5-3
Control Lever Lock ..........................................................................5-4
Control Lever Lock Operation ...............................................5-4
Declutch Position Switch..............................................................5-5
Adjustment of Bucket Auto Leveler..........................................5-6
Adjustment of Bucket Angle Switch.........................................5-8
Adjustment of Dual Lift Arm Auto Leveler.......................... 5-10
Auto Idling Stop............................................................................5-11
Auto Idling Stop Operating Condition............................ 5-12
Aftertreatment Device Manual Regeneration ...................5-13
Manual Regeneration Procedure ...................................... 5-13
Before Operation .......................................................................... 5-16
Precautions for Operation.........................................................5-16
Ensure Safety When Operating on Road Shoulders ........ 5-16
Avoid Overloading.......................................................................5-17
Avoid Rapid Steering Changes and/or Sudden
Braking........................................................................................ 5-17
Avoid Operation with Loads on Only One Side................. 5-17
Excavation.......................................................................................5-18
Loading Accumulated Soil...................................................5-18
Digging and Loading Level Ground................................. 5-19
Grading ............................................................................................5-20
Loading ............................................................................................5-21
Load and Carrying Method ................................................. 5-21
Loader and Dump Truck Combination Method...........5-22
V-Shape Loading..................................................................... 5-22
I-Shape Loading ...................................................................... 5-22

CONTENTS
Dumping into Truck or Hopper..........................................5-23
Dozing.............................................................................................. 5-24
Stock Piling .....................................................................................5-24
Removing Snow............................................................................5-25
Lifting Wheel Loader................................................................... 5-25
Precautions for After Operation..............................................5-26
TRANSPORTING ............................................................ 6-1
Transporting by Road ....................................................................6-1
Selecting a Trailer ............................................................................6-1
Loading/Unloading on Trailer.....................................................6-2
Ramp/Loading Dock.................................................................6-2
Loading/Unloading on Trailer ...............................................6-3
Loading..........................................................................................6-3
Fastening Machine for Transporting ........................................6-4
Transporting Wheel Loader (Urgent Situation) ....................6-5
Precautions for Driving On Roads........................................6-5
Precautions for Towing ............................................................6-6
Releasing Parking Brake ..........................................................6-7
Towing Method................................................................................6-9
Lifting Machine .............................................................................6-10
MAINTENANCE.............................................................. 7-1
Correct Maintenance and Inspection Procedures...............7-1
Check the Hour Meter Regularly................................................7-3
Layout..................................................................................................7-4
Lubrication Guide............................................................................7-5
Preparations for Inspection and Maintenance .....................7-6
Articulation Lock..............................................................................7-8
Inspection/Maintenance Access Covers .................................7-9
Rear Grille........................................................................................ 7-10
Inspection and Maintenance Table........................................7-11
Kind of Oils...................................................................................... 7-15
Grease .........................................................................................7-15
Engine Oil .................................................................................. 7-15
Transmission Oil ...................................................................... 7-15
Axle Oil........................................................................................7-16
Hydraulic Oil ............................................................................. 7-16
Recommended Coolant ....................................................... 7-16
List of Consumable Parts ...........................................................7-17
A. Greasing......................................................................................7-19
B. Engine.......................................................................................... 7-25
Check Engine Oil Level ......................................................... 7-25
Change Engine Oil .................................................................7-26
Replace Engine Oil Filter.......................................................7-28
C. Power Train ................................................................................ 7-30
Check Transmission Oil Level..............................................7-30
Change Transmission Oil...................................................... 7-31
Clean Suction Strainer...........................................................7-31
Change Transmission Oil Filter........................................... 7-31
Clean Transmission and Torque Converter
Air Breathers........................................................................ 7-34
Check Axle Oil Level...............................................................7-35
Check Differential Gear Oil Level .................................7-35
Check Planetary Gear Oil Level.....................................7-36
Change Axle Oil....................................................................... 7-37
Change Differential Gear Oil .........................................7-37
Change Planetary Gear Oil.............................................7-38
Replace Axle Oil Cooler Line Filter (Option).................. 7-39
Clean Axle Oil Cooler Fins (Option) .................................. 7-40
D. Hydraulic System.....................................................................7-41
Inspection and Maintenance of Hydraulic
Equipment ...........................................................................7-41
Check Hydraulic Oil Level ....................................................7-43
Change Hydraulic Oil............................................................. 7-44
Bleed Air from the Hydraulic System..........................7-45
Clean Suction Filter ................................................................7-46
Clean Pilot Oil Filter................................................................7-47
Line Filter in Steering Circuit ......................................... 7-47
Line Filter in Brake Circuit............................................... 7-48
Replace Hydraulic Oil Return Filter................................... 7-49
Replace Air Breather Element............................................. 7-50
Check Pilot Circuit Accumulator Function, Gas
Leakage, Looseness, and Damage ..............................7-51
Check Ride Control Accumulator Function, Gas
Leakage, Looseness, and Damage (Option) ............ 7-52
Check Gas Pressure in Ride Control Accumulator
(Option).................................................................................7-52
Check Gas Pressure in Steering Accumulator...............7-52
Check Hoses and Lines .........................................................7-53
Service Recommendations for Hydraulic
Fittings................................................................................... 7-56
Flat Face O-ring Seal Fitting (ORS Fitting)................. 7-56
Metal Face Seal Fittings................................................... 7-56
E. Fuel System................................................................................ 7-57
Check Fuel Level......................................................................7-57
Recommended Fuel ......................................................... 7-57
About Biodiesel Fuel ........................................................7-57
Refueling ..............................................................................7-58
Drain Water and Sediment from Fuel Tank .................... 7-58
Drain Fuel Filter........................................................................ 7-59
Draining Procedures (Pre-Filter)................................... 7-59
Bleed Air from the Fuel System .................................... 7-60
Air Bleeding Procedure ................................................... 7-60
If Air Mixed After Common Rail.................................... 7-61
Replace Fuel Main Filter Element......................................7-62
Replace Fuel Pre-Filter Element.........................................7-64
Clean Fuel Pump Strainer.....................................................7-66
Clean Fuel Priming Solenoid Pump Strainer.................7-67
Check Fuel Hoses .................................................................... 7-69
F. Air Cleaner...................................................................................7-71
Replace Air Cleaner Element...............................................7-71
G. Cooling System ........................................................................ 7-72
Coolant..................................................................................7-72
Check Coolant Level .............................................................. 7-73
Check Drive Belt ...................................................................... 7-74
Measurement of Deflection Amount and Vibration
Frequency ............................................................................ 7-74
Adjusting Drive Belt.......................................................... 7-74
Replacing Drive Belt ......................................................... 7-75
Change Coolant.......................................................................7-76
Clean Radiator/Oil Cooler Cores and Other Cooling
System ...................................................................................7-79

CONTENTS
H. Electrical System......................................................................7-80
Batteries .....................................................................................7-80
Electrolyte Level Check ................................................... 7-82
Check Electrolyte Specific Gravity...............................7-83
Replace Batteries ...............................................................7-84
Check Monitor Functions and All Other Instrument
Operation .............................................................................7-84
Check Work Lights ..................................................................7-85
Check Horn and Backup Alarm..........................................7-85
Check Electrical Harnesses and Fuses .............................7-86
Fuse Box A............................................................................7-87
Fuse Box B ............................................................................ 7-87
I. Brake System...............................................................................7-88
Check Right and Left Brake Interlocking
Performance........................................................................ 7-88
Check Brake Performance .............................................. 7-88
Check Play in Brake Pedal Stroke................................. 7-88
Check Parking Brake Force .................................................. 7-89
Check Parking Brake Gear Oil Level..................................7-90
Change Parking Brake Gear Oil..........................................7-91
Check Accumulator Function, Gas Leakage,
Looseness, and Damage................................................. 7-92
Check Brake Disks (Service and Parking)........................ 7-93
Check Gas Pressure in Accumulator................................. 7-93
J. Tire..................................................................................................7-94
Check and Replace Tire (Tire Pressure)............................7-94
Check Air Pressure.............................................................7-94
Check Tire for Damage..........................................................7-95
Check Wheel Bolt Torque .....................................................7-95
Replace Tire..........................................................................7-95
Tire Sizes to be Used.........................................................7-96
Driving on Public Roads: Standard Pressure............ 7-96
Tire Rotation........................................................................7-97
Rotation Procedure........................................................... 7-97
How to Check Wear Amount (Tread Design Groove
Depth)....................................................................................7-97
Removal and Installation of Tire...................................7-98
Tire Wheel.............................................................................7-98
K. Air Conditioner .........................................................................7-99
Clean/Replace Air Conditioner Circulation/
Fresh Air Filters................................................................... 7-99
Clean Fresh Air Filter......................................................... 7-99
Clean Circulation Air Filter............................................7-100
Check Air Conditioner.........................................................7-101
Check Air Conditioner Piping ...........................................7-101
Check Air Conditioner Condenser..................................7-102
Check Air Conditioner Compressor Belt.......................7-102
Compressor Belt Tension Adjustment
Procedure...........................................................................7-102
Check Refrigerant .................................................................7-103
Replace Air Conditioner Receiver Dryer .......................7-103
Check Compressor and Pulley..........................................7-103
Check Compressor..........................................................7-103
L. Aftertreatment Device .........................................................7-104
Check and Clean Aftertreatment Device......................7-104
M. Urea SCR System...................................................................7-105
Specified DEF/AdBlue® .......................................................7-105
Check DEF Level ....................................................................7-106
Refill DEF.............................................................................7-106
Clean DEF Strainer...........................................................7-107
DEF Exchange Procedure..............................................7-108
Replace DEF Supply Module Main Filter.......................7-109
Check Dosing Module.........................................................7-110
Replace DEF Tank Inlet Filter.............................................7-110
N. Miscellaneous.........................................................................7-111
Check Bucket Teeth..............................................................7-111
Check and Replace Seat Belt and Lower Tether.........7-112
Check ROPS, ROPS Mounting Bolts, and Cab .............7-112
Check Windshield Washer Fluid Level ...........................7-113
Check Play Amount in Joystick Steering
Movement..........................................................................7-113
Check Accelerator Pedal Operation, and Exhaust
Gas Color and Noise .......................................................7-114
Exhaust Gas Color and Noise ......................................7-114
Check Rearview Mirror and Inside Rearview
Mirror ...................................................................................7-115
Check Steps and Handrails for Damage and
Looseness...........................................................................7-115
Clean Engine Compartment and Hood ........................7-116
Check Sound Absorbing Mat Around Engine ............7-116
Check and Adjust Valve Clearance..................................7-116
Check Engine Compression Pressure ............................7-116
Check and Clean Starter and Alternator.......................7-116
Check Fuel Injector...............................................................7-117
Check Turbocharger.............................................................7-117
Check and Adjust Engine Controller (ECM).................7-117
Check and Clean EGR Valve...............................................7-117
Check and Clean EGR Cooler ............................................7-117
Check Urea SCR System......................................................7-117
Cleaning of Rear View Camera Lens...............................7-118
Retighten Front Axle and Rear Axle Support
Mounting Bolts.................................................................7-118
Check Tightening Torque of Nuts and Bolts................7-119
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS ................................................................. 9-1
Maintenance Under Special Environmental Conditions...9-1
Precautions for Maintenance During Cold Weather
Season............................................................................................9-2
STORAGE ..................................................................... 10-1
Storing the Machine.................................................................... 10-1
Removing the Machine from Storage............................. 10-2
TROUBLESHOOTING................................................... 11-1
Troubleshooting ...........................................................................11-1
1. Engine.....................................................................................11-1
2. Engine Auxiliaries............................................................... 11-1
3. Engine does not Start. ...................................................... 11-2
4. Control Lever........................................................................ 11-3
5. Hydraulic System................................................................ 11-3
6. Drive Function ..................................................................... 11-4
7. Others..................................................................................... 11-5

CONTENTS
SPECIFICATIONS ......................................................... 12-1
Specifications.................................................................................12-1
Intended Use ............................................................................ 12-1
INDEX........................................................................... 14-1

MACHINE NUMBERS
1
The manufacturing Nos. explained in this group is the
individual number (serial No.) given to each machine and
hydraulic components. These numbers are requested
when inquiring any information on the machine and/or
components. Fill these serial Nos. in the blank spaces in this
group to immediately make them available upon request.
Machine
Model/type :
Product
Identification Number :
Engine
TYPE :
MFG. NO. :
550SN_plate_US
6WG1_SN

MACHINE NUMBERS
2
Aftertreatment Device
SCR
TYPE :
MFG. NO. :
DOC
TYPE :
MFG. NO. :
95Z7B-SCR4
95Z7B-SCR4

SAFETY
S-1
Recognize Safety Information
These are the SAFETY ALERT SYMBOLS.
When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating
practices.
Understand Signal Words
On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs.
Some safety signs do not use any of the designated signal
words above after the safety alert symbol has been used
on this machine.
To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.
fNOTE indicates an additional explanation for an
element of information.
SA-2644
SA-1223

SAFETY
S-2
Follow Safety Instructions
Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
Safety signs should be installed, maintained and replaced
when necessary.
If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
Learn how to operate the machine and its controls correctly
and safely.
Allow only trained, qualified, authorized personnel to
operate the machine.
Keep your machine in proper working condition.
Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
Never attempt to modify or disassemble the inlet/exhaust
parts and the exhaust filter. Avoid giving shocks on the
exhaust filter by striking elements with other objects or
dropping the elements. Failure to do so may affect the
exhaust gas purifying device, possibly damaging it or
lowering its performance.
Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Carefully read and
follow all instructions for use and safety in the operator's
manual for the attachment. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.
The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.
SA-003

SAFETY
S-3
Prepare for Emergencies
Be prepared if a fire starts or if an accident occurs.
Keep a first aid kit and fire extinguisher on hand.
Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher
at the recommended intervals as specified in the fire
extinguisher manual.
Establish emergency procedure guidelines to cope with
fires and accidents.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone.
Wear Protective Clothing
Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
SA-438
SA-437

SAFETY
S-4
Protect Against Noise
Prolonged exposure to loud noise can cause impairment or
loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
Inspect Machine
Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
In the walk-around inspection, be sure to cover all points
described in the “Inspect Machine Daily Before Starting”
section in the operator’s manual.
SA-435
SA-434

SAFETY
S-5
General Precautions for Cab
Before entering the cab, thoroughly remove all dirt and /
or oil from the soles of your work boots.
If any controls such as a pedal is operated while with dirt
and / or oil on the soles of the operator’s work boots the
operator’s foot may slip off the pedal, possibly resulting in
a personal accident.
Do not leave parts and / or tools lying around the
operator’s seat. Store them in their specified locations.
Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
Refrain from using music headphones or mobile
telephones in the cab while operating the machine.
Keep all flammable objects and / or explosives away from
the machine.
After using the ashtray, always cover it to extinguish the
match and / or tobacco.
Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
Use proper floor mat dedicated to the machine.
If another floor mat is used, it may be displaced and
contact with the accelerator or brake pedals during
operation, resulting in serious injury or death.
Never weld, drill or in any way modify the ROPS without
approval from the manufacturer.

SAFETY
S-6
Use Handrails and Steps
Falling is one of the major causes of personal injury.
When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
Do not use any controls as handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
Never get on and off the machine with tools in your
hands.
Never Ride Attachment
Never allow anyone to ride attachment or the load. This is
an extremely dangerous practice.
Adjust Operator’s Seat
A poorly adjusted seat for either the operator or the
work at hand may quickly fatigue the operator leading to
misoperations.
The seat should be adjusted whenever changing the
operator for the machine.
The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
If not, move the seat forward or backward, and check
again.
Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
SA-439
SA-462

SAFETY
S-7
Ensure Safety Before Rising from or Leaving
Operator’s Seat
Before rising from the operator’s seat to open / close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the control lever lock switch to the lock ( ) position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with a
control lever, possibly resulting in serious personal injury or
death.
Before leaving the machine, be sure to first lower the front
attachment to the ground and then move the control
lever lock switch to the lock ( ) position. Turn the parking
brake switch ON, and the key switch OFF to stop the
engine.
Before leaving the machine, close all windows, doors, and
access covers and lock them up.
Fasten Your Seat Belt
If the machine should overturn, the operator may become
injured and / or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident.
We recommend that the seat belt be replaced every three
years regardless of its apparent condition.
SA-237

SAFETY
S-8
Move and Operate Machine Safely
Bystanders can be run over.
Take extra care not to run over bystanders. Be advised
that there may be blind spots with rear view camera.
Confirm the location of bystanders before moving,
swinging, or operating the machine by sight and mirrors
as well as the rear view monitor.
Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
Use a signal person when moving, or operating the
machine in congested areas. Coordinate hand signals
before starting the machine.
Use appropriate illumination. Check that all lights are
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
Ensure the cab door, windows, doors and covers are
securely locked.
Check the mirrors and the monitor in the CAB for
problems.
If there is, replace the problem part(s) or clean the mirror,
camera and the monitor.
Refer to Rear View Monitor section on the cleaning of the
camera and the monitor.
Handle Starting Aids Safely
Starting fluid:
Starting fluid is highly flammable.
Keep all sparks and flame away when using it.
Keep starting fluid well away from batteries and cables.
Remove container from machine if engine does not need
starting fluid.
To prevent accidental discharge when storing a
pressurized container, keep the cap on the container, and
store it in a cool, well-protected location.
Do not incinerate or puncture a starting fluid container. SA-293
SA-398