Hitachi ZW120-6 Wheel Loader Workshop Manual (WNSA60-EN-00) – PDF Download

Description

Hitachi ZW120-6 Wheel Loader Workshop Manual (WNSA60-EN-00)

File Details:

Hitachi ZW120-6 Wheel Loader Workshop Manual (WNSA60-EN-00)

• Manual Language:English
• Pages: 821
• Size: 46.7 MB
• Format:PDF
• Downloadable:Yes

HITACHI ZW120-6 WHEEL LOADER WORKSHOP MANUAL (WNSA60-EN-00) – PDF DOWNLOAD:

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Description:

Hitachi ZW120-6 Wheel Loader Workshop Manual (WNSA60-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 ZW120-6 Wheel Loader Workshop Manual (WNSA60-EN-00)

WNSA60-EN-00................................................................  1
	INTRODUCTION............................................................  3
		Safety Alert Symbol and Headline Notations..........................  4
		Units Used..........................................................  4
	SYMBOL AND ABBREVIATION.................................................  5
	SAFETY..................................................................  7
		Recognize Safety Information........................................  7
		Understand Signal Words.............................................  7
		Follow Safety Instructions..........................................  8
		Prepare for Emergencies.............................................  9
		Wear Protective Clothing............................................  9
		Protect Against Noise............................................... 10
		Inspect Machine..................................................... 10
		General Precautions for the Cab..................................... 11
		Use Handrails and Steps............................................. 12
		Never Ride Attachment............................................... 12
		Adjust Operator’s Seat.............................................. 12
		Ensure Safety Before Rising from or Leaving Operator’s Seat......... 13
		Fasten Your Seat Belt............................................... 13
		Move and Operate Machine Safely..................................... 14
		Handle Starting Aids Safely......................................... 14
		Operate Only from Operator’s Seat................................... 15
		Jump Starting....................................................... 15
		Investigate Job Site Beforehand..................................... 16
		Equipment of Head Guard, ROPS, FOPS................................. 17
		Provide Signals for Jobs Involving Multiple Machines................ 17
		Keep Riders Off Machine............................................. 18
		Drive Safely........................................................ 18
		Drive Machine Safely (Work Site).................................... 19
		Drive Safely with Bucket Loaded..................................... 20
		Drive on Snow Safely................................................ 20
		Travel on Public Roads Safely....................................... 21
		Avoid Injury from Rollaway Accidents................................ 21
		Avoid Accidents from Backing Up and Turning......................... 22
		Avoid Positioning Bucket or Attachment Over Anyone.................. 23
		Avoid Tipping....................................................... 23
		Never Undercut a High Bank.......................................... 24
		Dig with Caution.................................................... 24
		Perform Truck Loading Safely........................................ 24
		Avoid Power Lines................................................... 25
		Precautions for Operation........................................... 25
		Precautions for Lightning........................................... 25
		Object Handling..................................................... 26
		Protect Against Flying Debris....................................... 26
		Park Machine Safely................................................. 27
		Store Attachments Safely............................................ 27
		Transport Safely.................................................... 28
		Handle Fluids Safely−Avoid Fires.................................... 29
		Practice Safe Maintenance........................................... 30
		Warn Others of Service Work......................................... 31
		Support Machine Properly............................................ 31
		Stay Clear of Moving Parts.......................................... 32
		Support Maintenance Properly........................................ 32
		Prevent Parts from Flying........................................... 33
		Prevent Burns....................................................... 33
		Replace Rubber Hoses Periodically................................... 34
		Avoid High-Pressure Fluids.......................................... 34
		Prevent Fires....................................................... 35
		Evacuating in Case of Fire.......................................... 37
		Beware of Exhaust Fumes............................................. 37
		Precautions for Welding and Grinding................................ 37
		Avoid Heating Near Pressurized Fluid Lines.......................... 38
		Avoid Applying Heat to Lines Containing Flammable Fluids............ 38
		Precautions for Handling Accumulator and Gas Damper................. 38
		Remove Paint Before Welding or Heating.............................. 39
		Beware of Asbestos and Silica Dust and Other Contamination.......... 39
		Prevent Battery Explosions.......................................... 40
		Service Air Conditioning System Safely.............................. 40
		Handle Chemical Products Safely..................................... 41
		Dispose of Waste Properly........................................... 41
		Notes on Aftertreatment Device...................................... 42
		Precautions for Communication Terminal.............................. 42
		Precaution for Communication Terminal Equipment..................... 43
		Before Returning the Machine to the Customer........................ 44
	SECTION AND GROUP CONTENTS.............................................. 45
	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 Paint....................................................... 67
		Group 4 Bleeding Air................................................ 77
			Bleeding Air from Hydraulic System.............................. 77
			Bleeding Air from Fuel System................................... 78
			Bleeding Air from Brake Circuit................................. 79
			Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping.... 81
		Group 5 Preparation................................................. 83
			Preparation before Inspection and Maintenance................... 83
			Hydraulic Circuit Pressure Release Procedure.................... 88
			Pressure Release from Ride Control Accumulator.................. 89
			Pressure Release from Hydraulic Oil Tank........................ 90
			Pressure Release from Expansion Tank............................ 91
	SECTION 2 MAINTENANCE STANDARD.......................................... 95
		Group 1 Body........................................................ 97
			Center Hinge.................................................... 97
		Group 2 Travel System............................................... 99
			Axle............................................................ 99
			Transmission....................................................103
		Group 3 Front Attachment............................................111
			Pin and Bushing.................................................111
			Standard Dimensions for Lift Arm and Bucket.....................113
			Cylinder........................................................115
	SECTION 3 VEHICLE.......................................................119
		Group 1 Cab.........................................................121
			Removal and Installation of Cab.................................121
		Group 2 Counter Weight..............................................151
			Removal and Installation of Counter Weight......................151
		Group 3 Center Hinge................................................155
			Removal and Installation of Center Hinge........................155
		Group 4 Engine......................................................183
			Removal and Installation of Engine..............................183
		Group 5 Radiator Assembly...........................................233
			Removal and Installation of Radiator Assembly...................233
		Group 6 Hydraulic Oil Tank..........................................263
			Removal and Installation of Hydraulic Oil Tank..................263
		Group 7 Fuel Tank...................................................281
			Removal and Installation of Fuel Tank...........................281
		Group 8 Pump Device.................................................303
			Pump Device.....................................................303
			Disassembly of HST Pump.........................................327
			Assembly of HST Pump............................................330
			Disassembly of 2-Gear Pump Unit.................................333
			Assembly of 2-Gear Pump Unit....................................337
		Group 9 Control Valve...............................................341
			Removal and Installation of Control Valve.......................341
			Disassembly of Control Valve....................................349
			Assembly of Control Valve.......................................354
		Group 10 Pilot Valve................................................359
			Removal and Installation of Pilot Valve.........................359
			Disassembly of Pilot Valve......................................367
			Assembly of Pilot Valve.........................................370
		Group 13 Solenoid Valve.............................................375
			Removal and Installation of Pilot Shut-Off Solenoid Valve.......375
			Disassembly of Pilot Shut-Off Solenoid Valve....................385
			Assembly of Pilot Shut-Off Solenoid Valve.......................387
		Group 14 Priority Valve.............................................389
			Removal and Installation of Priority Valve......................389
			Structure of Priority Valve.....................................401
		Group 16 Ride Control Device........................................403
			Removal and Installation of Ride Control Valve..................403
			Disassembly of Ride Control Valve...............................409
			Assembly of Ride Control Valve..................................412
			Removal and Installation of Ride Control Accumulator............417
		Group 17 Battery Disconnect Switch..................................425
			Removal and Installation of Battery Disconnect Switch...........425
		Group 18 Aftertreatment Device......................................429
			Removal and Installation of Aftertreatment Device...............429
		Group 19 DEF Tank...................................................459
			Removal and Installation of DEF Tank............................459
		Group 20 Coolant Control Valve......................................475
			Removal and Installation of Coolant Control Valve...............475
		Group 21 DEF Supply Module..........................................479
			Removal and Installation of DEF Supply Module...................479
		Group 22 Exterior Parts.............................................483
			Removal and Installation of Exterior Parts......................483
	SECTION 4 TRAVEL SYSTEM.................................................545
		Group 1 Tire........................................................547
			Removal and Installation of Front Tire..........................547
			Removal and Installation of Rear Tire...........................553
		Group 2 Drive Unit..................................................559
			Removal and Installation of HST Motor...........................559
			Disassembly of HST Motor........................................575
			Assembly of HST Motor...........................................577
			Removal and Installation of Transmission........................581
			Disassembly of Transmission.....................................589
			Assembly of Transmission........................................596
			Disassembly of Clutch Assembly..................................605
			Assembly of Clutch Assembly.....................................608
		Group 3 Axle........................................................611
			Removal and Installation of Front Axle..........................611
			Removal and Installation of Rear Axle...........................617
			Disassembly of Axle.............................................633
			Assembly of Axle................................................648
		Group 4 Propeller Shaft.............................................669
			Removal and Installation of Propeller Shaft.....................669
		Group 5 Brake Valve.................................................679
			Removal and Installation of Brake Valve.........................679
			Disassembly of Brake Valve......................................691
			Assembly of Brake Valve.........................................695
			Removal and Installation of Inching Valve.......................699
			Structure of Inching Valve......................................707
		Group 6 Steering Device.............................................709
			Removal and Installation of Steering Valve......................709
			Disassembly of Steering Valve...................................717
			Assembly of Steering Valve......................................720
			Removal and Installation of Steering Cylinder...................725
			Disassembly of Steering Cylinder................................749
			Assembly of Steering Cylinder...................................753
	SECTION 5 FRONT ATTACHMENT..............................................759
		Group 1 Front Attachment............................................761
			Removal and Installation of Front Attachment....................761
			Removal and Installation of Bell Crank..........................769
			Removal and Installation of Bucket..............................779
			Removal and Installation of Bushing.............................783
		Group 2 Cylinder....................................................787
			Removal and Installation of Lift Arm Cylinder...................787
			Removal and Installation of Bucket Cylinder.....................795
			Disassembly of Lift Arm Cylinder and Bucket Cylinder............809
			Assembly of Lift Arm Cylinder and Bucket Cylinder...............814
	SERVICE MANUAL REVISION REQUEST FORM....................................821

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]