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
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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]