Hitachi ZW120-5B Wheel Loader Workshop Manual (WNCC-EN-00) – PDF Download

Description

Hitachi ZW120-5B Wheel Loader Workshop Manual (WNCC-EN-00)

File Details:

Hitachi ZW120-5B Wheel Loader Workshop Manual (WNCC-EN-00)

• Manual Language:English
• Pages: 586
• Size: 8.52 MB
• Format:PDF
• Downloadable:Yes

HITACHI ZW120-5B WHEEL LOADER WORKSHOP MANUAL (WNCC-EN-00) – PDF DOWNLOAD:

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Description:

Hitachi ZW120-5B Wheel Loader Workshop Manual (WNCC-EN-00)

To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
The machine specification and description according to destination may be explained on this manual.
 Be sure to thoroughly read this manual for correct product information and service procedures.
 If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
Additional References
Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.
 Information included in the Technical Manual:Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
 Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.
 Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.

Table Of Contents:

Hitachi ZW120-5B Wheel Loader Workshop Manual (WNCC-EN-00)

WNCC-EN-00.............................................................................  1
INTRODUCTION...........................................................................  3
SYMBOL AND ABBREVIATION................................................................  5
SAFETY.................................................................................  7
SECTION AND GROUP CONTENTS............................................................. 47
SECTION 1 GENERAL...................................................................... 49
	Group 1 Precautions for Disassembling and Assembling............................... 51
		Precautions for Disassembling and Assembling................................... 51
	Group 2 Tightening................................................................. 57
		Tightening Bolts and Nuts...................................................... 57
		Piping Joint................................................................... 60
	Group 3 Painting................................................................... 67
		Painting....................................................................... 67
	Group 4 Bleeding Air............................................................... 75
		Bleeding Air from Hydraulic Oil Tank........................................... 75
		Bleeding Air from Hydraulic System............................................. 76
		Bleeding Air from Fuel System.................................................. 77
		Bleeding Air from Radiator..................................................... 78
		Bleeding Air from Brake Circuit................................................ 79
	Group 5 Releasing Pressure......................................................... 81
		Front Attachment Hydraulic Circuit Pressure Release Procedure.................. 81
		Ride Control Accumulator Pressure Release Procedure............................ 83
	Group 6 Preparation................................................................ 85
		Preparation before Inspection and Maintenance.................................. 85
SECTION 2 MAINTENANCE STANDARD......................................................... 93
	Group 1 Body....................................................................... 95
		Center Hinge................................................................... 95
	Group 2 Travel System.............................................................. 97
		Axle........................................................................... 97
		Transmission...................................................................101
	Group 3 Front Attachment...........................................................109
		Pin and Bushing................................................................109
		Standard Dimensions for Lift Arm and Bucket....................................111
		Cylinder.......................................................................113
SECTION 3 BODY.........................................................................117
	Group 1 Cab........................................................................119
		Removal and Installation of Cab................................................119
	Group 2 Counterweight..............................................................147
		Removal and Installation of Counterweight......................................147
		Removal and Installation of Battery Box(Without Battery Disconnect Switch).....151
		Removal and Installation of Battery Box(Attached Battery Disconnect Switch)....159
		Removal and Installation of Battery Disconnect Switch..........................163
	Group 3 Center Hinge...............................................................167
		Removal and Installation of Center Hinge.......................................167
	Group 4 Engine.....................................................................187
		Removal and Installation of Engine.............................................187
		Removal And Installation of Exterior Parts.....................................225
	Group 5 Radiator Assembly..........................................................235
		Replacement of Radiator, Oil Cooler, and Intercooler...........................235
	Group 6 Hydraulic Oil Tank.........................................................263
		Removal and Installation of Hydraulic Oil Tank.................................263
	Group 7 Pump Device................................................................277
		Removal and Installation of Pump Device........................................277
		Disassembly of HST Pump........................................................289
		Assembly of HST Pump...........................................................292
		Disassembly of 2-Gear Pump Unit................................................295
		Assembly of 2-Gear Pump Unit...................................................299
	Group 8 Control Valve..............................................................303
		Removal and Installation of Control Valve(Manual Type).........................303
		Disassembly of Control Valve (Manual Type).....................................307
		Assembly of Control Valve (Manual Type)........................................309
		Disassembly of Bucket Spool Assembly (Manual Type).............................311
		Assembly of Bucket Spool Assembly (Manual Type)................................313
		Disassembly of Lift Arm Spool Assembly(Manual Type)............................315
		Assembly of Lift Arm Spool Assembly (Manual Type)..............................317
	Group 9 Priority Valve.............................................................321
		Removal and Installation of Priority Valve.....................................321
		Structure of Priority Valve....................................................325
	Group 10 Ride Control Device.......................................................327
		Removal and Installation of Ride Control Valve.................................327
		Disassembly of Ride Control Valve..............................................331
		Assembly of Ride Control Valve.................................................334
		Removal and Installation of Ride Control Accumulator...........................339
SECTION 4 TRAVEL SYSTEM................................................................345
	Group 1 Tire.......................................................................347
		Removal and Installation of Front Tire.........................................347
		Removal and Installation of Rear Tire..........................................351
	Group 2 HST Motor..................................................................355
		Removal and Installation of HST Motor..........................................355
		Disassembly of HST Motor.......................................................363
		Assembly of HST Motor..........................................................365
	Group 3 Transmission...............................................................369
		Removal and Installation of Transmission.......................................369
		Disassembly of Transmission....................................................377
		Assembly of Transmission.......................................................384
		Disassembly of Clutch Assembly.................................................393
		Assembly of Clutch Assembly....................................................396
		Structure of Control Valve.....................................................399
	Group 4 Axle.......................................................................401
		Removal and Installation of Front Axle.........................................401
		Removal and Installation of Rear Axle..........................................405
		Disassembly of Axle............................................................413
		Assembly of Axle...............................................................428
	Group 5 Propeller Shaft............................................................449
		Removal and Installation of Propeller Shaft....................................449
	Group 6 Brake Valve................................................................457
		Removal and Installation of Brake Valve........................................457
		Disassembly of Brake Valve.....................................................465
		Assembly of Brake Valve........................................................469
		Removal and Installation of Inching Valve......................................473
		Structure of Inching Valve.....................................................481
	Group 7 Steering Device............................................................483
		Removal and Installation of Steering Valve.....................................483
		Disassembly of Steering Valve..................................................493
		Assembly of Steering Valve.....................................................496
		Removal and Installation of Steering Cylinder..................................501
		Disassembly of Steering Cylinder...............................................509
		Assembly of Steering Cylinder..................................................513
SECTION 5 FRONT ATTACHMENT.............................................................519
	Group 1 Front Attachment...........................................................521
		Removal and Installation of Front Attachment...................................521
		Removal and Installation of Bell Crank.........................................533
		Removal and Installation of Bucket.............................................543
	Group 2 Cylinder...................................................................549
		Removal and Installation of Lift Arm Cylinder..................................549
		Removal and Installation of Bucket Cylinder....................................557
		Disassembly of Lift Arm Cylinder and Bucket Cylinder...........................573
		Assembly of Lift Arm Cylinder and Bucket Cylinder..............................578
SERVICE MANUAL REVISION REQUEST FORM...................................................585

Please Note:

⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]