Service manual Hitachi ZW370 Wheel Loader | W97C5-E-02

Hitachi ZW370 Wheel Loader W97C5-E-02 (Preview)

Foreword
Safety precautions
Safety Symbols
CONTENTS
Symbols 00-2
Weight of Main Components 00-3
Bolt Tightening Torque 00-4
Hose Band Tightening Torque 00-8
Liquid Gasket and Screw Lock Agent 00-9
Cautions regarding parts removal 00-9
Cautions regarding reassembly 00-9
Screw lock agent application procedure 00-10
How to wind a seal tape 00-10
Cautions Regarding Welding Repair Service 00-11
Cautions Regarding Handling of Bearing 00-13
Bearing installation cautions 00-13
Interference fits for a bearing 00-13
Bearing removal cautions 00-14
Applying and Storing Articulation Stopper 00-15
Applying articulation stopper 00-15
Storing articulation stopper 00-16
Deck 14-2
Deck removing and installing 14-2
Fuel Tank 14-4
Fuel tank removing and installing 14-4
Hydraulic Tank 14-5
Hydraulic tank removing and installing 14-5
Engine Room 14-8
Engine room removing and installing 14-8
Cab 14-11
Cab removing and installing 14-11
Floor Board 14-13
Floor board removing and installing 14-13
Boom 14-16
Boom removing and installing 14-16
Center Pin 14-19
Upper center pin 14-19
Lower center pin 14-20
Center pin removing and installing 14-21
Partition Plate 14-25
Partition plate removing and installing 14-25
Linkage 15-2
Linkage Pin Standard Clearance Values 15-3
Liner clearance adjustment 15-3
Center Pin 15-4
Center pin shim adjustment 15-4
Bearing cover installing 15-4
Lower center pin bearing outer ring installing 15-5
Attachment Leveler 15-6
Attachment leveler 15-7
Attachment leveler adjustable angle 15-7
Power Line 24-2
Power line tightening torque 24-2
Radiator 24-3
Radiator tightening torque 24-3
Radiator removing and installing 24-4
Torque Converter Oil Cooler 24-8
Torque converter oil cooler removing and installing 24-8
Engine 24-10
Engine removing and installing 24-10
Propeller Shaft 24-13
Propeller shaft removing and installing 24-13
Air Cleaner 24-15
Air cleaner removing and installing 24-15
Muffler 24-17
Muffler removing and installing 24-17
Fan 24-18
Fan removing and installing 24-18
Front Axle Assembly 24-20
Front axle assembly tightening torque 24-20
Front axle assembly removing and installing 24-22
Front axle disassembling and assembling 24-25
Floating Seal 24-34
Internal Gear Hub 24-36
Internal gear hub disassembling and assembling 24-36
Internal gear hub assembly cautions 24-39
Spider Assembly 24-41
Spider assembly disassembling and assembling 24-41
Special Tool 24-43
Special tool for axle 24-43
Rear Axle Assembly 24-48
Rear axle assembly tightening torque 24-48
Rear axle assembly removing and installing 24-50
Rear axle disassembling and assembling 24-52
Axle Support 24-53
Axle support tightening torque 24-53
Axle support disassembling and assembling 24-54
Differential Assembly 24-57
Differential assembly removing and installing 24-57
Differential assembly disassembling and assembling 24-59
Propeller Shaft Service Standard 25-2
Axle and Differential Service Standard 25-3
Axle group 25-3
Differential 25-4
Torque Converter and Transmission Assembly 34-2
Torque converter and transmission assembly tightening torque 34-2
Torque converter and transmission assembly removing and installing 34-3
Torque Converter Assembly 34-9
Torque converter assembly bolt tightening torque 34-9
Torque converter assembly disassembling and assembling 34-10
Lock-up torque converter disassembling and assembling 34-15
Transmission Assembly 34-17
Transmission assembly bolt tightening torque 34-17
Transmission assembly disassembling and assembling 34-18
Clutch Assembly 34-25
Clutch assembly disassembling and assembling 34-25
Clutch Spider Assembly 34-37
Low and 3rd clutch spider disassembling and assembling 34-37
2nd clutch spider disassembling and assembling 34-38
Reverse Clutch Spider 34-40
Reverse clutch spider disassembling and assembling 34-40
1st Clutch Assembly 34-42
1st clutch assembly disassembling and assembling 34-42
High Clutch Assembly 34-46
High clutch assembly disassembling and assembling 34-46
Control Valve Assembly 34-51
Control valve assembly removing and installing 34-51
Transmission Assembly 35-2
Torque Converter Gear Pump 35-4
Gear pump specifications 35-4
Gear pump specifications 35-5
Gear Train and Number of Teeth 35-6
Clutch specifications 35-6
Clutch Oil Pressure 35-7
Hydraulic Parts Removal and Installation Warning 44-2
Hydraulic Parts Disassembly and Assembly Cautions 44-3
Hydraulic parts disassembly cautions 44-3
Hydraulic parts assembly cautions 44-3
Hydraulic Pump Assembly 44-4
Hydraulic pump assembly removing and installing 44-4
Hydraulic pump assembly disassembling and assembling 44-6
Hydraulic Cylinder 44-13
Boom cylinder removing and installing 44-13
Bucket cylinder removing and installing 44-15
Steering cylinder removing and installing 44-18
Hydraulic cylinder disassembling and assembling 44-20
Pilot Valve 44-26
Pilot valve removing and installing 44-26
Pilot valve disassembling and assembling 44-28
Multiple Control Valve 44-47
Multiple control valve removing and installing 44-47
Multiple control valve disassembling and assembling 44-50
Orbitrol® 44-54
Orbitrol® removing and installing 44-54
Orbitrol® disassembling and assembling 44-56
Steering Valve 44-64
Steering valve removing and installing 44-64
Steering valve disassembling and assembling 44-66
Stop Valve 44-69
Stop valve removing and installing 44-69
Stop valve disassembling and assembling 44-71
Fan Motor 44-73
Fan motor removing and installing 44-73
Hydraulic Cylinder 45-2
Pilot Valve 45-4
Steering Valve 45-6
Unloader Valve 54-2
Unloader valve removing and installing 54-2
Unloader valve disassembling and assembling 54-4
Manifold Valve Assembly 54-8
Valve assembly removing and installing 54-8
Valve assembly disassembling and assembling 54-10
Accumulator 54-11
Accumulator removing and installing 54-11
Accumulator disassembling and assembling 54-12
Nitrogen gas charging 54-14
Brake Valve 54-16
Brake valve removing and installing 54-16
Brake valve disassembling and assembling 54-18
Service Brake 54-24
Service brake disassembling and assembling 54-24
Parking Brake 54-26
Parking brake disassembling and assembling 54-26
Parking Brake Piston 54-32
Parking brake piston assembly disassembling and assembling 54-32
Brake Valve 55-2
Service Brake 55-4
Air Conditioner 74-2
Air conditioner removing and installing 74-2
Air conditioner disassembling and assembling 74-4
Compressor V-belt 74-12
Air Conditioner 75-2
Periodical Inspection/Servicing 75-2
Tightening Torque 75-2
ZW370 General Information
Symbols
Weight of Main Components
Bolt Tightening Torque
Hose Band Tightening Torque
Liquid Gasket and Screw Lock Agent
Cautions regarding parts removal
Cautions regarding reassembly
Screw lock agent application procedure
How to wind a seal tape
Cautions Regarding Welding Repair Service
Cautions Regarding Handling of Bearing
Bearing installation cautions
Interference fits for a bearing
Bearing operation test after installation
Bearing removal cautions
Applying and Storing Articulation Stopper
Applying articulation stopper
Storing articulation stopper
ZW370 Disassembly & Reassembly Chassis Group
Deck
Deck removing and installing
Deck removing
Deck installing
Fuel Tank
Fuel tank removing and installing
Fuel tank removing
Fuel tank installing
Fuel tank installation cautions
Hydraulic Tank
Hydraulic tank removing and installing
Hydraulic tank removing
Hydraulic tank installing
Hydraulic tank installation cautions
Engine Room
Engine room removing and installing
Engine room removing
Engine room installing
Engine room installation cautions
Cab
Cab removing and installing
Cab removing
Cab installing
Floor Board
Floor board removing and installing
Floor board removing
Floor board installation cautions
Boom
Boom removing and installing
Boom removing
Boom installing
Boom installation cautions
Center Pin
Upper center pin
Center pin shim adjustment
Lower center pin
Center pin removing and installing
Center pin removing
Center pin installing
Center pin assembly cautions
Partition Plate
Partition plate removing and installing
Partition plate removing
Partition plate installing
ZW370 Service Standard Chassis Group
Linkage
Linkage Pin Standard Clearance Values
Liner clearance adjustment
Center Pin
Center pin shim adjustment
Bearing cover installing
Lower center pin bearing outer ring installing
Attachment Leveler
Attachment leveler
Attachment leveler adjustable angle
ZW370 Disassembly & Reassembly Power Group
Power Line
Power line tightening torque
Radiator
Radiator tightening torque
Radiator removing and installing
Radiator removing (S/N 9001~9150)
Radiator removing (S/N 9151~)
Radiator installing
Torque Converter Oil Cooler
Torque converter oil cooler removing and installing
Torque converter oil cooler removing
Torque converter oil cooler installing
Engine
Engine removing and installing
Engine removing
Engine installing
Engine installation cautions
Propeller Shaft
Propeller shaft removing and installing
Second propeller shaft removing
Third propeller shaft removing
Propeller shaft installing
Propeller shaft installation cautions
Air Cleaner
Air cleaner removing and installing
Air cleaner removing
Air cleaner installing
Air cleaner installation cautions
Muffler
Muffler removing and installing
Muffler removing
Muffler installing
Muffler installation cautions
Fan
Fan removing and installing
Fan removing
Fan installing
Front Axle Assembly
Front axle assembly tightening torque
Axle nut tightening procedure
Floating seal installing
Front axle assembly removing and installing
Front axle assembly removing
Front axle assembly installing
Front axle assembly installation cautions
Service brake air bleeding procedure
Front axle disassembling and assembling
Front axle disassembling
Front axle assembling
Front axle assembly cautions
Floating Seal
Floating seal location
Internal Gear Hub
Internal gear hub disassembling and assembling
Internal gear hub disassembling
Internal gear hub assembling
Internal gear hub assembly cautions
Spider Assembly
Spider assembly disassembling and assembling
Spider assembly disassembling
Spider assembly assembling
Spider assy assembly cautions
Special Tool
Special tool for axle
Rear Axle Assembly
Rear axle assembly tightening torque
Axle nut tightening procedure
Floating seal installing
Rear axle assembly removing and installing
Rear axle assembly removing
Rear axle assembly installing
Rear axle disassembling and assembling
Axle Support
Axle support tightening torque
Axle support disassembling and assembling
Axle support disassembling
Axle support assembling
Axle support assembly cautions
Differential Assembly
Differential assembly removing and installing
Differential assembly removing
Differential assembly installing
Differential assembly installation cautions
Differential assembly disassembling and assembling
Front differential tightening torque
Rear differential tightening torque
Differential assembly disassembling
Differential assembly assembling
Differential assy assembly cautions
ZW370 Service Standard Power Group
Propeller Shaft Service Standard
Axle and Differential Service Standard
Axle group
Differential
ZW370 Disassembly & Reassembly Torque Converter and Transmission Group
Torque Converter and Transmission Assembly
Torque converter and transmission assembly tightening torque
Torque converter and transmission assembly removing and installing
Torque converter and transmission assembly removing
Torque converter and transmission assembly installing
Transmission assembly installation cautions
Torque Converter Assembly
Torque converter assembly bolt tightening torque
Torque converter assembly disassembling and assembling
Torque converter assembly disassembling
Torque converter assembly assembling
Torque converter assy assembly cautions
Lock-up torque converter disassembling and assembling
Lock-up torque converter disassembling
Lock-up torque converter assy assembling
Lock-up torque converter assy assembly cautions
Transmission Assembly
Transmission assembly bolt tightening torque
Transmission assembly disassembling and assembling
Transmission assembly disassembling
Transmission assembly assembling
Transmission assy assembly cautions
Clutch Assembly
Clutch assembly disassembling and assembling
Clutch assembly disassembling
Clutch assembly assembling
Clutch Spider Assembly
Low and 3rd clutch spider disassembling and assembling
Low and 3rd clutch spider disassembling
Low and 3rd clutch spider assembling
Low and 3rd clutch spider assembly cautions
2nd clutch spider disassembling and assembling
2nd clutch spider disassembling
2nd clutch spider assembling
2nd clutch spider assembly cautions
Reverse Clutch Spider
Reverse clutch spider disassembling and assembling
Reverse clutch spider disassembling
Reverse clutch spider assembling
Reverse clutch spider assembly cautions
1st Clutch Assembly
1st clutch assembly disassembling and assembling
1st clutch assembly disassembling
1st clutch assembly assembling
High Clutch Assembly
High clutch assembly disassembling and assembling
High clutch assembly disassembling
High clutch assembly assembling
Control Valve Assembly
Control valve assembly removing and installing
Control valve assembly removing
Control valve assembly installing
Control valve assembly installation cautions
ZW370 Service Standard Torque Converter and Transmission Group
Transmission Assembly
Torque Converter Gear Pump
Gear pump specifications
Gear pump specifications
Gear Train and Number of Teeth
Clutch specifications
Clutch Oil Pressure
ZW370 Disassembly & Reassembly Hydraulic Group
Hydraulic Parts Removal and Installation Warning
Hydraulic Parts Disassembly and Assembly Cautions
Hydraulic parts disassembly cautions
Hydraulic parts assembly cautions
Hydraulic Pump Assembly
Hydraulic pump assembly removing and installing
Hydraulic pump assembly removing
Hydraulic pump assembly installing
Hydraulic pump installation cautions
Hydraulic pump assembly disassembling and assembling
Hydraulic pump assembly cross section and tightening torque
Oil seal replacement procedure
Hydraulic pump disassembling
Hydraulic pump assembling
Hydraulic pump assembly cautions
Hydraulic Cylinder
Boom cylinder removing and installing
Boom cylinder removing
Boom cylinder installing
Boom cylinder installation cautions
Bucket cylinder removing and installing
Bucket cylinder removing
Bucket cylinder installing
Bucket cylinder installation cautions
Steering cylinder removing and installing
Steering cylinder removing
Steering cylinder installing
Steering cylinder installation cautions
Hydraulic cylinder disassembling and assembling
Hydraulic cylinder cross section and tightening torque
Hydraulic cylinder disassembling
Hydraulic cylinder assembling
Hydraulic cylinder assembly cautions
Pilot Valve
Pilot valve removing and installing
Pilot valve removing
Pilot valve installing
Pilot valve installation cautions
Pilot valve disassembling and assembling
Pilot valve cross section and tightening torque
Pilot valve disassembling (S/N 9001~9255)
Pilot valve assembling
Pilot valve assembly cautions
Pilot valve disassembling (S/N 9256~)
Pilot valve assembling
Pilot valve assembly cautions
Multiple Control Valve
Multiple control valve removing and installing
Multiple control valve removing
Multiple control valve installing
Multiple control valve installation cautions
Multiple control valve disassembling and assembling
Multiple control valve cross section and tightening torque
Multiple control valve disassembling
Multiple control valve assembling
Multiple control valve assembly cautions
Orbitrol®
Orbitrol® removing and installing
Orbitrol® removing
Orbitrol® installing
Orbitrol® installation cautions
Orbitrol® disassembling and assembling
Orbitrol® cross section and tightening torque
Orbitrol® disassembling
Orbitrol® assembling
Steering Valve
Steering valve removing and installing
Steering valve removing
Steering valve installing
Steering valve installation cautions
Steering valve disassembling and assembling
Steering valve cross section and tightening torque
Steering valve disassembling
Steering valve assembling
Stop Valve
Stop valve removing and installing
Stop valve removing
Stop valve installing
Stop valve installation cautions
Stop valve disassembling and assembling
Stop valve cross section and tightening torque
Stop valve disassembling
Stop valve assembling
Fan Motor
Fan motor removing and installing
Fan motor removing
Fan motor installing
Fan motor installation cautions
ZW370 Service Standard Hydraulic Group
Hydraulic Cylinder
Pilot Valve
Steering Valve
ZW370 Disassembly & Reassembly Brake Group
Unloader Valve
Unloader valve removing and installing
Unloader valve removing
Unloader valve installing
Unloader valve installation cautions
Unloader valve disassembling and assembling
Unloader valve cross section and tightening torque
Unloader valve disassembling
Unloader valve assembling
Manifold Valve Assembly
Valve assembly removing and installing
Valve assembly removing
Valve assembly installing
Valve assembly installation cautions
Valve assembly disassembling and assembling
Valve assembly cross section and tightening torque
Accumulator
Accumulator removing and installing
Accumulator removing
Accumulator installing
Accumulator installation cautions
Accumulator disassembling and assembling
Accumulator disassembling
Accumulator assembling
Nitrogen gas charging
Nitrogen gas charging procedure
Brake Valve
Brake valve removing and installing
Brake valve removing
Brake valve installing
Brake valve installation cautions
Brake valve disassembling and assembling
Brake valve cross section and tightening torque (main valve)
Brake valve disassembling
Brake valve assembling
Brake valve assembly cautions
Service Brake
Service brake disassembling and assembling
Service brake installation cautions
Parking Brake
Parking brake disassembling and assembling
Parking brake tightening torque
Parking brake disassembling
Parking brake assembling
Parking brake assembly cautions
Parking Brake Piston
Parking brake piston assembly disassembling and assembling
Parking brake piston assembly disassembling
Parking brake piston assy assembling
Parking brake piston assy assembly cautions
ZW370 Service Standard Brake Group
Brake Valve
Service Brake
ZW370 Disassembly & Reassembly Operator Station Group
Air Conditioner
Air conditioner removing and installing
Air conditioner removing
Air conditioner installing
Air conditioner disassembling and assembling
Air conditioner tightening torque
Air conditioner disassembling
Air conditioner assembling
Compressor V-belt
ZW370 Service Standard Operator Station Group
Air Conditioner
Periodical Inspection/Servicing
Tightening Torque
Tightening torque for hose and pipes
Tightening torque for screws and bolts in special control regions
INDEX
A
B
C
D
E
F
G
H
I
L
M
N
O
P
R
S
T
U
V
W
Maintenance Log
Notes