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Hitachi ZW550 Wheel Loader Workshop Manual (W11C5-E-01) – PDF Download
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- Hitachi ZW550 Wheel Loader Workshop Manual
- Part No:W11C5-E-01
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Description
Hitachi ZW550 Wheel Loader Workshop Manual (W11C5-E-01)
File Details:
Hitachi ZW550 Wheel Loader Workshop Manual (W11C5-E-01)
- Manual Language:English
- Pages: 353
- Size: 53.3 MB
- Downloadable:Yes
- Format:PDF
HITACHI ZW550 WHEEL LOADER WORKSHOP MANUAL (W11C5-E-01) – PDF DOWNLOAD:
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Description:
Hitachi ZW550 Wheel Loader Workshop Manual (W11C5-E-01)
- To ensure good machine performance, reduce failures or problems, and prolong the service life of each component, it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.
- To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.
- For the engine, refer to the engine Shop Manual provided by the engine manufacturer.
- The purpose of this manual is to provide information on the product and the correct maintenance and repair methods. Please read this manual to ensure correct troubleshooting and good repair service.
- This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or requests, please inform us.
Table Of Contents:
Hitachi ZW550 Wheel Loader Workshop Manual (W11C5-E-01)
W11C5-E-01....................................................................... 1 Foreword......................................................................... 3 Safety precautions............................................................... 4 Safety Symbols................................................................... 5 CONTENTS......................................................................... 7 00 General Information........................................................... 13 Symbols...................................................................... 14 Weight of Main Components.................................................... 15 Bolt Tightening Torque....................................................... 16 Hose Band Tightening Torque.................................................. 20 Liquid Gasket and Screw Lock Agent........................................... 21 Cautions regarding parts removal......................................... 21 Cautions regarding reassembly............................................ 21 Screw lock agent application procedure................................... 22 How to wind a seal tape.................................................. 22 Cautions Regarding Welding Repair Service.................................... 23 Cautions Regarding Handling of Bearing....................................... 25 Bearing installation cautions............................................ 25 Interference fits for a bearing.......................................... 25 Bearing operation test after installation............................ 26 Bearing removal cautions................................................. 26 Applying and Storing Articulation Stopper.................................... 27 Applying articulation stopper............................................ 27 Storing articulation stopper............................................. 27 14 Disassembly & Reassembly Chassis Group........................................ 29 Deck......................................................................... 30 Deck removing and installing............................................. 30 Deck removing........................................................ 30 Deck installing...................................................... 31 Fuel Tank.................................................................... 32 Fuel tank removing and installing........................................ 32 Fuel tank removing................................................... 32 Fuel tank installing................................................. 32 Fuel tank installation cautions...................................... 32 Hydraulic Tank............................................................... 33 Hydraulic tank removing and installing................................... 33 Hydraulic tank removing.............................................. 33 Hydraulic tank installing............................................ 35 Hydraulic tank installation cautions................................. 35 Engine Room.................................................................. 36 Engine room removing and installing...................................... 36 Engine room removing................................................. 36 Engine room installing............................................... 38 Engine room installation cautions.................................... 38 ROPS and Cab................................................................. 39 ROPS removing and installing............................................. 39 ROPS removing........................................................ 39 ROPS installing...................................................... 39 Cab removing and installing.............................................. 40 Cab removing......................................................... 40 Cab installing....................................................... 41 Floor Board.................................................................. 42 Floor board removing and installing...................................... 42 Floor board removing................................................. 42 Floor board installing............................................... 44 Floor board installation cautions.................................... 44 Boom......................................................................... 45 Boom removing and installing............................................. 45 Boom removing........................................................ 45 Boom installing...................................................... 47 Boom installation cautions........................................... 48 Center Pin................................................................... 49 Upper center pin......................................................... 49 Center pin shim adjustment........................................... 49 Lower center pin......................................................... 50 Center pin removing and installing....................................... 51 Center pin removing.................................................. 51 Center pin installing................................................ 54 Center pin installation cautions..................................... 54 15 Service Standard Chassis Group................................................ 55 Linkage...................................................................... 56 Linkage Pin Standard Clearance Values........................................ 57 Liner clearance adjustment............................................... 57 Center Pin................................................................... 58 Center pin shim adjustment............................................... 58 Grease nipple installing................................................. 58 Bearing assy installing.................................................. 58 Attachment Leveler........................................................... 59 Attachment leveler....................................................... 60 Attachment leveler adjustable angle...................................... 60 24 Disassembly & Reassembly Power Group.......................................... 61 Power Line................................................................... 62 Power line tightening torque............................................. 62 Radiator..................................................................... 63 Radiator tightening torque............................................... 63 Radiator removing and installing......................................... 64 Radiator removing.................................................... 64 Radiator installing.................................................. 66 Radiator installation cautions....................................... 66 Fan.......................................................................... 67 Fan removing and installing.............................................. 67 Fan removing......................................................... 67 Fan installing....................................................... 68 Fan installation cautions............................................ 68 Engine....................................................................... 69 Engine removing and installing........................................... 69 Engine removing...................................................... 69 Engine installing.................................................... 70 Engine installation cautions......................................... 70 Propeller Shaft.............................................................. 71 Propeller shaft removing and installing.................................. 71 Second propeller shaft removing...................................... 72 First propeller shaft removing....................................... 72 Third propeller shaft removing....................................... 72 Propeller shaft installing........................................... 73 Propeller shaft installation cautions................................ 73 Air Cleaner.................................................................. 74 Air cleaner removing and installing...................................... 74 Air cleaner removing................................................. 74 Air cleaner installing............................................... 75 Air cleaner installation cautions.................................... 75 Muffler...................................................................... 76 Muffler removing and installing.......................................... 76 Muffler removing..................................................... 76 Muffler installing................................................... 77 Muffler installation cautions........................................ 77 Front Axle Assembly.......................................................... 78 Front axle assembly tightening torque.................................... 78 Axle nut tightening procedure........................................ 79 Floating seal installation........................................... 79 Front axle assembly removing and installing.............................. 80 Front axle assembly removing......................................... 80 Front axle assembly installing....................................... 81 Front axle assembly installation cautions............................ 81 Brake air bleeding procedure......................................... 82 Front axle disassembling and assembling.................................. 83 Front axle disassembling............................................. 83 Front axle assembling................................................ 86 Front axle assembly cautions............................................. 87 Floating seal installation........................................... 87 Wheel hub installation............................................... 89 Internal gear hub installation....................................... 89 Axle nut tightening.................................................. 90 Brake adjustment..................................................... 90 Brake disc installation.............................................. 91 Internal Gear Hub............................................................ 93 Internal gear hub disassembling and assembling........................... 93 Internal gear hub disassembling...................................... 93 Internal gear hub assembling......................................... 95 Internal gear hub assembly cautions.................................. 95 Spider Assembly.............................................................. 97 Spider assembly disassembling and assembling............................. 97 Spider assembly disassembling........................................ 97 Spider assembly assembling........................................... 97 Spider assy assembly cautions........................................ 98 Special Tool................................................................. 99 Special tool for axle.................................................... 99 Rear Axle Assembly...........................................................104 Rear axle assembly tightening torque.....................................104 Axle nut tightening procedure........................................105 Floating seal installation...........................................105 Rear axle assembly removing and installing...............................106 Rear axle assembly removing..........................................106 Rear axle assembly installing........................................108 Rear axle disassembling and assembling...................................108 Axle Support.................................................................109 Axle support tightening torque...........................................109 Axle support disassembling and assembling................................110 Axle support disassembling...........................................110 Axle support assembling..............................................111 Axle support assembly cautions.......................................111 Differential Assembly........................................................113 Differential assembly removing and installing............................113 Differential assembly removing.......................................113 Differential assembly installing.....................................114 Differential assembly installation cautions..........................114 Differential assembly disassembling and assembling.......................115 Front differential tightening torque.................................115 Rear differential tightening torque..................................117 Differential assembly disassembling..................................118 Differential assy assembling.........................................121 Differential assy assembly cautions..................................121 25 Service Standard Power Group..................................................129 Propeller Shaft Service Standard.............................................130 Axle and Differential Service Standard.......................................132 Axle group...............................................................132 Differential.............................................................133 34 Disassembly & Reassembly Torque Converter and Transmission Group..............135 Torque Converter and Transmission Assembly...................................136 Torque converter and transmission assembly tightening torque.............136 Torque Converter Assembly....................................................137 Torque converter removing and installing.................................137 Torque converter removing............................................137 Torque converter installing..........................................139 Torque converter installation cautions...............................139 Torque converter disassembling and assembling............................140 Torque converter bolt tightening torque..............................140 Torque converter disassembling.......................................141 Torque converter assembling..........................................143 Torque converter assembly cautions...................................143 Lock-up torque converter (OPT) disassembling and assembling..............144 Lock-up torque converter disassembling...............................144 Transmission Assembly........................................................146 Transmission assembly removing and installing............................146 Transmission assembly removing.......................................146 Transmission assembly installing.....................................149 Transmission assembly installation cautions..........................149 Transmission assembly disassembling and assembling.......................151 Transmission assembly bolt tightening torque.........................151 Transmission assy disassembling......................................152 Transmission assy assembling.........................................155 Transmission assy assembly cautions..................................155 Gear Box Assembly............................................................159 Gear box disassembling and assembling....................................159 Gear box disassembling...............................................159 Gear box assembling..................................................159 Gear box assembly cautions...........................................160 Transmission Clutch Assembly.................................................161 Transmission clutch assy disassembling and assembling....................161 Transmission clutch assy disassembling...............................161 Transmission clutch assy assembling..................................166 Clutch Spider Assembly.......................................................174 Transmission low/3rd speed clutch spider disassembling and assembling....174 Transmission low/3rd speed clutch spider disassembling...............174 Transmission low/3rd speed clutch spider assembling..................175 Transmission low/3rd speed clutch spider assembly cautions...........175 Transmission 2nd speed clutch spider disassembling and assembling........176 Transmission 2nd speed clutch spider disassembling...................176 Transmission 2nd speed clutch spider assembling......................177 Transmission 2nd speed clutch spider assembly cautions...............177 Reverse Clutch Spider........................................................178 Transmission reverse clutch spider disassembling and assembling..........178 Transmission reverse clutch spider disassembling.....................178 Transmission reverse clutch spider assembling........................179 Transmission reverse clutch spider assembly cautions.................179 Transmission 1st Clutch Assembly.............................................180 Transmission 1st speed clutch assy disassembling and assembling..........180 Transmission 1st speed clutch assy disassembling.....................180 Transmission 1st speed clutch assy assembling........................182 Transmission High Clutch Assembly............................................184 Transmission high clutch assy disassembling and assembling...............184 Transmission high clutch assy disassembling..........................184 Transmission high clutch assy assembling.............................186 Control Valve Assembly.......................................................189 Control valve removing and installing....................................189 Control valve removing...............................................189 Control valve installing.............................................191 Control valve installation cautions..................................191 35 Service Standard Torque Converter and Transmission Group......................193 Transmission Assembly........................................................194 Torque Converter Gear Pump...................................................198 Gear pump specifications.................................................198 Gear Train and Number of Teeth...............................................199 Clutch specifications....................................................200 Clutch Oil Pressure..........................................................201 Transmission oil pressure test port location.............................201 44 Disassembly & Reassembly Hydraulic Group......................................203 Hydraulic Parts Removal and Installation Warning.............................204 Hydraulic Parts Disassembly and Assembly Cautions............................205 Hydraulic parts disassembly cautions.....................................205 Hydraulic parts assembly cautions........................................205 Hydraulic Pump Assembly......................................................206 Hydraulic pump assy removing and installing..............................206 Hydraulic pump assy removing.........................................206 Hydraulic pump assy installing.......................................207 Hydraulic pump assy installation cautions............................207 Hydraulic pump assy disassembling and assembling.........................208 Hydraulic pump assy cross section and tightening torque..............209 Oil seal replacement procedure.......................................210 Hydraulic pump disassembling.........................................211 Hydraulic pump assembling............................................214 Hydraulic pump assembly cautions.....................................214 Hydraulic Cylinder...........................................................216 Boom cylinder removing and installing....................................216 Boom cylinder removing...............................................216 Boom cylinder installing.............................................217 Boom cylinder installation cautions..................................218 Bucket cylinder removing and installing..................................219 Bucket cylinder removing.............................................219 Bucket cylinder installing...........................................220 Bucket cylinder installation cautions................................220 Steering cylinder removing and installing................................221 Steering cylinder removing...........................................221 Steering cylinder installing.........................................221 Steering cylinder installation cautions..............................222 Hydraulic cylinder disassembling and assembling..........................223 Hydraulic cylinder cross section and tightening torque...............223 Hydraulic cylinder disassembling.....................................225 Hydraulic cylinder assembling........................................227 Hydraulic cylinder assembly cautions.................................227 Pilot Valve..................................................................229 Pilot valve removing and installing......................................229 Pilot valve removing.................................................229 Pilot valve installing...............................................230 Pilot valve installation cautions....................................230 Pilot valve disassembling and assembling.................................231 Pilot valve cross section and tightening torque......................231 Pilot valve disassembling (S/N 9001~9105)............................234 Pilot valve assembling...............................................241 Pilot valve assembly cautions........................................241 Pilot valve disassembling (S/N 9106~)................................243 Pilot valve assembling...............................................248 Pilot valve assembly cautions........................................248 Multiple Control Valve.......................................................250 Multiple control valve removing and installing...........................250 Multiple control valve removing......................................250 Multiple control valve installing....................................251 Multiple control valve installation cautions.........................252 Multiple control valve disassembling and assembling......................253 Multiple control valve cross section and tightening torque...........253 Multiple control valve disassembling.................................254 Multiple control valve assembling....................................256 Multiple control valve assembly cautions.............................256 Orbitrol®....................................................................257 Orbitrol® removing and installing........................................257 Orbitrol® removing...................................................257 Orbitrol® installing.................................................258 Orbitrol® installation cautions......................................258 Orbitrol® disassembling and assembling...................................259 Orbitrol® cross section and tightening torque........................259 Orbitrol® disassembling..............................................260 Orbitrol® assembling.................................................263 Steering Valve...............................................................267 Steering valve removing and installing...................................267 Steering valve removing..............................................267 Steering valve installing............................................268 Steering valve installation cautions.................................268 Steering valve disassembling and assembling..............................269 Steering valve cross section and tightening torque...................269 Steering valve disassembling.........................................270 Steering valve assembling............................................271 Stop Valve...................................................................272 Stop valve removing and installing.......................................272 Stop valve removing..................................................272 Stop valve installing................................................272 Stop valve installation cautions.....................................273 Stop valve disassembling and assembling..................................274 Stop valve cross section and tightening torque.......................274 Stop valve disassembling.............................................275 Stop valve assembling................................................275 Fan Motor....................................................................276 Fan motor removing and installing........................................276 Fan motor removing...................................................276 Fan motor installing.................................................278 45 Service Standard Hydraulic Group..............................................281 Hydraulic Cylinder...........................................................282 Pilot Valve..................................................................284 Steering Valve...............................................................286 54 Disassembly & Reassembly Brake Group..........................................287 Unloader Valve...............................................................288 Unloader valve removing and installing...................................288 Unloader valve removing..............................................288 Unloader valve installing............................................289 Unloader valve installation cautions.................................289 Unloader valve disassembling and assembling..............................290 Unloader valve cross section and tightening torque...................290 Unloader valve disassembling.........................................293 Unloader valve assembling............................................293 Manifold Valve Assembly......................................................294 Valve assembly removing and installing...................................294 Valve assembly removing..............................................294 Valve assembly installing............................................295 Valve assembly installation cautions.................................295 Valve assembly disassembling and assembling..............................295 Valve assembly cross section and tightening torque...................296 Accumulator..................................................................297 Accumulator removing and installing......................................297 Accumulator removing.................................................297 Accumulator installing...............................................298 Accumulator installation cautions....................................298 Accumulator disassembling and assembling.................................299 Accumulator disassembling............................................299 Accumulator assembling...............................................300 Nitrogen gas charging....................................................301 Nitrogen gas charging procedure......................................301 Brake Valve..................................................................303 Brake valve removing and installing......................................303 Brake valve removing.................................................303 Brake valve installing...............................................304 Brake valve installation cautions....................................304 Brake valve disassembling and assembling.................................305 Brake valve cross section and tightening torque (main valve).........305 Brake valve disassembling............................................306 Brake valve assembling...............................................309 Brake valve assembly cautions........................................310 Service Brake................................................................311 Service brake disassembling and assembling...............................311 Service brake installation cautions..................................311 Parking Brake................................................................313 Parking brake disassembling and assembling...............................313 Parking brake tightening torque......................................313 Parking brake disassembling..........................................314 Parking brake assembling.............................................316 Parking brake assembly cautions......................................316 Parking Brake Piston.........................................................319 Parking brake piston assembly disassembling and assembling...............319 Parking brake piston assembly disassembling..........................319 Parking brake piston assy assembling.................................320 Parking brake piston assy assembly cautions..........................320 55 Service Standard Brake Group..................................................321 Brake Valve..................................................................322 Service Brake................................................................324 74 Disassembly & Reassembly Operator Station Group...............................325 Air Conditioner..............................................................326 Air conditioner removing and installing..................................326 Air conditioner removing.............................................326 Air conditioner installing...........................................327 Air conditioner disassembling and assembling.............................328 Air conditioner tightening torque....................................328 Air conditioner disassembling........................................331 Air conditioner assembling...........................................335 Compressor V-belt........................................................336 Compressor V-belt adjustment procedure...............................337 75 Service Standard Operator Station Group.......................................339 Air Conditioner..............................................................340 Periodical Inspection/Servicing..........................................340 Tightening Torque........................................................340 Tightening torque for hose and pipes.................................340 Tightening torque for screws and bolts in special control regions....340 INDEX............................................................................341 Maintenance Log..................................................................346 Notes............................................................................350
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