Hitachi ZW550 6 Wheel Loader Workshop Manual WNHK40 EN 00
File details:
Hitachi ZW550 6 Wheel Loader Workshop Manual WNHK40 EN 00
Language : English
Pages : 722
Size : 32.4 MB
Downloadable : Yes
Format : PDF
Part No : TWNHK40-EN-00
Video Preview:
Image Preview:
Table of Contents:
Hitachi ZW550 6 Wheel Loader Workshop Manual WNHK40 EN 00
WNHK40-EN-00..................................................................... 1 SECTION 1 GENERAL................................................................ 3 Group 1 Precautions for Disassembling and Assembling......................... 5 Precautions for Disassembling and Assembling............................. 5 Group 2 Tightening........................................................... 11 Tightening Bolts and Nuts................................................ 11 Piping Joint............................................................. 14 Group 3 Painting............................................................. 19 Painting................................................................. 19 Group 4 Bleeding Air......................................................... 25 Bleeding Air from Hydraulic Oil Tank..................................... 25 Bleeding Air from Hydraulic System....................................... 26 Bleed Air from Fuel System............................................... 27 Bleeding Air from Radiator/CCV Line...................................... 29 Bleeding Air from Brake (Axle)........................................... 32 Bleeding Air from Parking Brake.......................................... 33 Group 5 Pressure Release Procedure........................................... 35 Front Attachment Hydraulic Circuit Pressure Release Procedure............ 35 Ride Control Accumulator (Option) Pressure Release Procedure............. 36 Parking Brake Accumulator Pressure Release Procedure..................... 37 Group 6 Preparation.......................................................... 39 Preparation before Inspection and Maintenance............................ 39 SECTION 2 MAINTENANCE STANDARD................................................... 43 Group 1 Body................................................................. 45 Center Hinge............................................................. 45 Pilot Valve (Two Lever Type )............................................ 47 Group 2 Front Attachment..................................................... 49 Pin and Bushing.......................................................... 49 Standard Dimensions for Lift Arm and Bucket.............................. 51 SECTION 3 BODY................................................................... 53 Group 1 Cab.................................................................. 55 Removal and Installation of Cab.......................................... 55 Group 2 Counterweight........................................................ 71 Removal and Installation of Counterweight................................ 71 Group 3 Center Hinge......................................................... 75 Removal and Installation of Center Hinge................................. 75 Removal and Installation of the Hydraulic Hoses of Front Chassis Side.... 83 Group 4 Engine............................................................... 87 Removal and Installation of Engine....................................... 87 Removal and Installation of Exterior Parts...............................119 Removal and Installation of Air Cleaner..................................131 Group 5 Radiator Assembly....................................................135 Replacement of Radiator and Cooling System...............................135 Group 6 Hydraulic Oil Tank...................................................163 Removal and Installation of Hydraulic Oil Tank...........................163 Group 7 Fuel Tank............................................................171 Removal and Installation of Fuel Tank....................................171 Group 8 Pump Device..........................................................181 Removal and Installation of Pump Device..................................181 Disassembly and Assembly of Pump Device..................................187 Disassembly of Main Pump.................................................191 Assembly of Main Pump....................................................194 Disassembly of Regulator.................................................199 Assembly of Regulator....................................................203 Removal and Installation of Pilot Pump...................................207 Disassembly of Pilot Pump................................................209 Assembly of Pilot Pump...................................................214 Group 9 Control Valve........................................................219 Removal and Installation of Control Valve................................219 Disassembly and Assembly of Control Valve................................227 Group 10 Pilot Valve.........................................................233 Removal and Installation of Pilot Valve (Single Lever Type)..............233 Removal and Installation of Pilot Valve (Two Lever Type )................239 Disassembly of Pilot Valve (Single Lever Type)...........................245 Assembly of Pilot Valve (Single Lever Type)..............................248 Disassembly of Pilot Valve (Two Lever Type)..............................253 Assembly of Pilot Valve (Two Lever Type).................................259 Group 11 Brake Charge Valve..................................................267 Removal and Installation of Brake Charge Valve...........................267 Structure of Brake Charge Valve..........................................271 Disassembly of Brake Charge Valve........................................273 Assembly of Brake Charge Valve Valve.....................................274 Removal and Installation of Brake Accumulators...........................277 Group 12 Combination Valve...................................................281 Removal and Installation of Combination Valve............................281 Structure and Tightening Torque of Combination Valve Components..........287 Group 13 DEF Tank............................................................289 Removal and Installation of DEF Tank.....................................289 Disassembly of DEF Tank..................................................297 Assembly of DEF Tank.....................................................299 Group 14 Flow Regulator Valve................................................301 Removal and Installation of Flow Regulator Valve.........................301 Structure of Flow Regulator Valve........................................305 Group 15 Cooling Fan System..................................................307 Removal and Installation of Fan Control Valve............................307 Disassembly and Assembly of Fan Control Valve............................311 Removal and Installation of Fan Motor....................................313 Structure of Fan Motor...................................................317 Removal and Installation of Pilot Pump...................................319 Group 16 Aftertreatment Device...............................................321 Removal and Installation of Aftertreatment Device........................321 Group 17 Ride Control Valve and Accumulator..................................327 Removal and Installation of Ride Control Valve and Accumulator...........327 Disassembly of Ride Control Valve........................................333 Assembly of Ride Control Valve...........................................336 Group 18 Battery Disconnect Switch...........................................339 Removal of Battery Disconnect Switch.....................................339 Installation of Battery Disconnect Switch................................340 Structure of Battery Box Mount...........................................341 SECTION 4 TRAVEL SYSTEM..........................................................343 Group 1 Tire.................................................................345 Removal and Installation of Front Tire...................................345 Removal and Installation of Rear Tire....................................347 Group 2 Drive Unit...........................................................353 Removal and Installation of Torque Converter.............................353 Disassembly and Assembly of Torque Converter.............................357 Disassembly and Assembly of Torque Converter Sub Assembly................366 Removal and Installation of Transmission.................................373 Disassembly and Assembly of Transmission Assy............................383 Disassembly and Assembly of Clutch Assembly..............................405 Disassembly and Assembly of Low and Third Speed Clutch Assembly..........420 Disassembly and Assembly of Second Speed Clutch Assembly.................423 Disassembly and Assembly of Reverse Clutch Assembly......................426 Disassembly and Assembly of First Clutch Assembly........................429 Disassembly and Assembly of High Clutch Spider Assembly..................435 Disassembly and Assembly of Gear Box Assembly............................441 Removal and Installation of Transmission Control Valve...................445 Disassembly and Assembly of Transmission Control Valve...................449 Special Tools (For Transmission Assembly and Disassembly)................451 Drawings for Special Tools...............................................452 Group 3 Axle.................................................................457 Removal and Installation of Front Axle...................................457 Removal and Installation of Rear Axle....................................463 Disassembly of Axle......................................................471 Assembly of Axle.........................................................479 Disassembly and Assembly of Spider Assembly..............................490 Disassembly and Assembly of Internal Gear Hub Assembly...................492 Removal and Installation of Floating Seal................................496 Removal and Installation of Differential.................................499 Disassembly and Assembly of Differential.................................505 Disassembly and Assembly of Parking Brake Piston Assembly................527 Special Tools For Axle Assembly..........................................529 Drawings for Special Tools...............................................530 Group 4 Propeller Shaft......................................................537 Removal and Installation of Propeller Shaft..............................537 Group 5 Brake Valve..........................................................549 Removal and Installation of Brake Valve..................................549 Disassembly and Assembly of Brake Valve Assembly.........................553 Disassembly and Assembly of Brake Valve..................................559 Maintenance Standard.....................................................563 Group 6 Steering Pilot Valve.................................................565 Removal and Installation of Steering Pilot Valve.........................565 Disassembly of Steering Pilot Valve......................................569 Assembly of Steering Pilot Valve.........................................572 Group 7 Steering Valve.......................................................577 Removal and Installation of Steering Valve...............................577 Disassembly of Steering Valve............................................581 Assembly of Steering Valve...............................................584 Group 8 Steering Cylinder....................................................587 Removal and Installation of Steering Cylinder............................587 Disassembly of Steering Cylinder.........................................593 Assembly of Steering Cylinder............................................596 Removal and Installation of Steering Accumulator.........................601 Tools for Steering Cylinder Disassembly and Assembly.....................603 Group 9 Emergency Steering Device............................................607 Removal and Installation of Emergency Steering Pump......................607 Group 10 Reducing Valve......................................................615 Removal and Installation of Reducing Valve...............................615 Disassembly of Reducing Valve............................................617 Assembly of Reducing Valve...............................................619 Group 11 Stop Valve..........................................................621 Removal and Installation of Stop Valve...................................621 Disassembly of Stop Valve................................................625 Assembly of Stop Valve...................................................626 Group 12 Main Pressure Block.................................................627 Removal and Installation of Main Pressure Block..........................627 Structure of Main Pressure Block.........................................629 Group 13 Priority Hammer Valve and Shuttle Valve.............................631 Removal and Installation of Priority Hammer Valve and Shuttle Valve......631 Structure of Priority Hammer Valve and Shuttle Valve.....................635 Group 14 Check Valve.........................................................637 Removal and Installation of Check Valve..................................637 Structure of Check Valve.................................................639 SECTION 5 FRONT ATTACHMENT.......................................................641 Group 1 Front Attachment.....................................................643 Removal and Installation of Front Attachment.............................643 Removal and Installation of Lever (Bell Crank)...........................657 Removal and Installation of Bucket.......................................671 Group 2 Cylinder.............................................................679 Removal and Installation of Lift Arm Cylinder............................679 Removal and Installation of Bucket Cylinder..............................687 Disassembly of Lift Arm Cylinder.........................................699 Assembly of Lift Arm Cylinder............................................703 Disassembly of Bucket Cylinder...........................................709 Assembly of Bucket Cylinder..............................................713 Tools for Cylinder Disassembly and Assembly..............................719
Content From The Manual:
Hitachi ZW550 6 Wheel Loader Workshop Manual WNHK40 EN 00
- Precautions for Disassembling and Assembling Precautions for Disassembling Clean the Machine Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling / assembling, resulting in damage to machine components, as well as decreased efficiency in service work.
- Inspect the Machine Be sure to thoroughly understand all disassembling / assembling procedures beforehand to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. The machine model, machine serial number, and hour meter reading
- Reason for disassembly (symptoms, failed parts, and causes). Clogging of filters and oil, water or air leaks, if any. Capacities and condition of lubricants. Loose or damaged parts. Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work. Precautions for Disassembling and Assembling
- Precautions for Disassembling Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Before disassembling, clean the exterior of the components and place on a workbench. Drain hydraulic oil and gear oil from the hydraulic components and reduction gear.
- Be sure to provide appropriate containers for draining fluids. Use matching marks for easier reassembling if necessary. Be sure to use the specified special tools when instructed. If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause (s), then take the appropriate measures to remove it.
- Orderly arrange disassembled parts. Mark and tag them if necessary. Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. Measure and record the degree of wear and clearances. Precautions for Assembling Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. Apply appropriate lubricant oil onto parts in order to prevent them from seizing
- Be sure to replace O-rings, backup rings, oil seals, and floating seals with new ones once they have been disassembled. Apply grease before installing Be sure that liquid-gasket-applied surfaces are clean and dry. If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. Fit the matching marks made when disassembling and assemble them. Be sure to use the designated tools to assemble bearings, bushings, and oil seals. Keep a record of the number of tools used for disassembly / assembly. After assembling is completed, count the number of tools so as to make sure that no forgotten tools remain in the assembled machine.
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]