Hitachi ZW550-5B Wheel Loader WNHF-EN-00 (Preview)
WNHF-EN-00
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
Symbol and Abbreviation
SAFETY
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Prepare for Emergencies
Wear Protective Clothing
Protect Against Noise
Inspect Machine
General Precautions for Cab
Use Handrails and Steps
Never Ride Attachment
Adjust Operator’s Seat
Ensure Safety Before Rising from or LeavingOperator’s Seat
Fasten Your Seat Belt
Move and Operate Machine Safely
Handle Starting Aids Safely
Operate Only from Operator’s Seat
Jump Starting
Investigate Job Site Beforehand
Equipment of Head Guard, ROPS, FOPS
Provide Signals for Jobs Involving MultipleMachines
Keep Riders Off Machine
Drive Safely
Drive Machine Safely (Work Site)
Drive Safely with Bucket Loaded
Drive on Snow Safely
Travel on Public Roads Safely
Avoid Injury from Rollaway Accidents
Avoid Accidents from Backing Up and Turning
Avoid Positioning Bucket or Attachment OverAnyone
Avoid Tipping
Never Undercut a High Bank
Dig with Caution
Perform Truck Loading Safely
Avoid Power Lines
Precautions for Operation
Precautions for Lightning
Object Handling
Protect Against Flying Debris
Park Machine Safely
Store Attachments Safely
Transport Safely
Handle Fluids Safely−Avoid Fires
Practice Safe Maintenance
Warn Others of Service Work
Support Machine Properly
Stay Clear of Moving Parts
Support Maintenance Properly
Prevent Parts from Flying
Prevent Burns
Replace Rubber Hoses Periodically
Avoid High-Pressure Fluids
Prevent Fires
Evacuating in Case of Fire
Beware of Exhaust Fumes
Precautions for Welding and Grinding
Avoid Heating Near Pressurized Fluid Lines
Avoid Applying Heat to Lines ContainingFlammable Fluids
Precautions for Handling Accumulator and GasDamper
Remove Paint Before Welding or Heating
Beware of Asbestos and Silicon Dust and OtherContamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Notes for Muffler Filter
Precautions for Communication Terminal
Precaution for Communication TerminalEquipment
Before Returning the Machine to the Customer
SECTION AND GROUP CONTENTS
SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling
Precautions for Disassembling andAssembling
Group 2 Tightening
Tightening Bolts and Nuts
Group 3 Painting
Painting
Group 4 Bleeding Air
Bleeding Air from Hydraulic Oil Tank
Bleeding Air from Hydraulic System
Bleed Air from Fuel System
Bleeding Air from Radiator
Bleeding Air from Brake (Axle)
Bleeding Air from Parking Brake
Group 5 Pressure Release Procedure
Front Attachment Hydraulic Circuit PressureRelease Procedure
Ride Control Accumulator (Option) PressureRelease Procedure
Parking Brake Accumulator Pressure ReleaseProcedure
Group 6 Preparation
Preparation before Inspection andMaintenance
SECTION 2 MAINTENANCE STANDARD
Group 1 Body
Center Hinge
Pilot Valve (Two Lever Type )
Group 2 Front Attachment
Pin and Bushing
Standard Dimensions for Lift Arm and Bucket
SECTION 3 BODY
Group 1 Cab
Removal and Installation of Cab
Group 2 Counterweight
Removal and Installation of Counterweight
Group 3 Center Hinge
Removal and Installation of Center Hinge
Removal and Installation of the HydraulicHoses of Front Chassis Side
Group 4 Engine
Removal and Installation of Engine
Removal and Installation of Exterior Parts
Removal and Installation of ROPS (Roll OverProtective Structure)
Removal and Installation of Deck and Step/Covers
Removal and Installation of Air Cleaner
Group 5 Radiator Assembly
Replacement of Radiator and Cooling System
Group 6 Hydraulic Oil Tank
Removal and Installation of Hydraulic Oil Tank
Group 7 Fuel Tank
Removal and Installation of Fuel Tank
Group 8 Pump Device
Removal and Installation of Pump Device
Disassembly and Assembly of Pump Device
Disassembly of Main Pump
Assembly of Main Pump
Disassembly of Regulator
Assembly of Regulator
Removal and Installation of Accessory Pump
Disassembly of Accessory Pump
Assembly of Accessory Pump
Group 9 Control Valve
Removal and Installation of Control Valve
Disassembly of Control Valve
Assembly of Control Valve
Group 10 Pilot Valve
Removal and Installation of Pilot Valve
Removal and Installation of Pilot Valve (TwoLever Type )
Disassembly of Pilot Valve
Assembly of Pilot Valve
Disassembly of Pilot Valve (Two Lever Type)
Assembly of Pilot Valve (Two Lever Type)
Group 11 Unloader Valve
Removal and Installation of Unloader Valve(Brake Charge Valve)
Structure of Unloader Valve
Disassembly of Unloader Valve
Removal and Installation of BrakeAccumulators
Group 12 Combination Valve
Removal and Installation of CombinationValve
Structure and Tightening Torque of Combination Valve Components
Combination Valve 1 (Manifold Valve Block)
Combination Valve 2 (Solenoid Valve Block)
Group 14 Flow Regulator Valve
Removal and Installation of Flow RegulatorValve
Structure of Flow Regulator Valve
Group 15 Cooling Fan System
Removal and Installation of Fan ControlValve
Disassembly and Assembly of Fan Control Valve
Removal and Installation of Fan Motor
Structure of Fan Motor
Removal and Installation of Fan Pump
Disassembly and Assembly of Fan Pump
Group 16 Exhaust Filter
Removal and Installation of Exhaust Filter
Removal and Installation of Exhaust FilterRegeneration Control Solenoid Valve
Disassembly and Assembly of Exhaust FilterRegeneration Control Solenoid Valve
Group 17 Ride Control Valve and Accumulator
Removal and Installation of Ride ControlValve and Accumulator
Disassembly of Ride Control Valve
Assembly of Ride Control Valve
Group 18 Battery Disconnect Switch
Removal of Battery Disconnect Switch
Installation of Battery Disconnect Switch
SECTION 4 TRAVEL SYSTEM
Group 1 Tire
Removal and Installation of Front Tire
Removal and Installation of Rear Tire
Group 2 Drive Unit
Removal and Installation of Torque Converter
Disassembly and Assembly of TorqueConverter
Disassembly and Assembly of Torque ConverterSub Assembly
Removal and Installation of Transmission
Disassembly and Assembly of Transmission Assy
Disassembly and Assembly of Clutch Assembly
Disassembly and Assembly of Low and ThirdSpeed Clutch Assembly
Disassembly and Assembly of Second SpeedClutch Assembly
Disassembly and Assembly of Reverse ClutchAssembly
Disassembly and Assembly of First ClutchAssembly
Disassembly and Assembly of High ClutchSpider Assembly
Disassembly and Assembly of Gear Box Assembly
Disassembly and Assembly of Accumulator Assembly
Removal and Installation of TransmissionControl Valve
Disassembly and Assembly of Transmission Control Valve
Special Tools (For Transmission Assembly and Disassembly)
Drawings for Special Tools
Group 3 Axle
Removal and Installation of Front Axle
Removal and Installation of Rear Axle
Disassembly of Axle
Assembly of Axle
Disassembly and Assembly of Spider Assembly
Disassembly and Assembly of Internal GearHub Assembly
Removal and Installation of Floating Seal
Removal and Installation of Differential
Disassembly and Assembly of Differential
Disassembly and Assembly of Parking BrakePiston Assembly
Special Tools For Axle Assembly
Drawings for Special Tools
Group 4 Propeller Shaft
Removal and Installation of Propeller Shaft
Group 5 Brake Valve
Removal and Installation of Brake Valve
Disassembly and Assembly of Brake ValveAssembly
Disassembly and Assembly of Brake Valve
Maintenance Standard
Group 6 Steering Pilot Valve
Removal and Installation of Steering PilotValve
Disassembly of Steering Pilot Valve
Assembly of Steering Pilot Valve
Group 7 Steering Valve
Removal and Installation of Steering Valve
Disassembly of Steering Valve
Assembly of Steering Valve
Group 8 Steering Cylinder
Removal and Installation of Steering Cylinder
Disassembly of Steering Cylinder
Assembly of Steering Cylinder
Removal and Installation of SteeringAccumulator
Tools for Steering Cylinder Disassembly andAssembly
Group 9 Secondary Steering Device
Removal and Installation of SecondarySteering Pump (Option)
Group 10 Reducing Valve
Removal and Installation of Reducing Valve
Disassembly of Reducing Valve
Assembly of Reducing Valve
Group 11 Stop Valve
Removal and Installation of Stop Valve
Disassembly of Stop Valve
Assembly of Stop Valve
Group 12 Main Pressure Block
Removal and Installation of Main Pressure Block
Structure of Main Pressure Block
Group 13 Priority Hammer Valve and Shuttle Valve
Removal and Installation of Priority HammerValve and Shuttle Valve
Structure of Priority Hammer Valve andShuttle Valve
Group 14 Check Valve
Removal and Installation of Check Valve
Structure of Check Valve
SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment
Removal and Installation of Front Attachment
Removal and Installation of Lever (Bell Crank))
Removal and Installation of Bucket
Group 2 Cylinder
Removal and Installation of Lift Arm Cylinder
Removal and Installation of Bucket Cylinder
Disassembly of Lift Arm Cylinder
Assembly of Lift Arm Cylinder
Disassembly of Bucket Cylinder
Assembly of Bucket Cylinder
Tools for Cylinder Disassembly and Assembly
Wrench
Tools for Packing (2) Seal Ring
Pin Bushing Press Fitting Tool
Dust Seal Press Fitting Tool
Rod Cover Press Fitting Tool
SERVICE MANUAL REVISION REQUEST FORM
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