Hitachi ZW 120-6 Front End Loader Manuals

Manuals and User Guides for Hitachi ZW 120-6 Front End Loader. We have 1 Hitachi ZW 120-6 Front End Loader manual available for free PDF download: Operator's Manual

Hitachi ZW 120-6 Operator's Manual

Hitachi ZW 120-6 Operator's Manual (364 pages)

Brand: Hitachi | Category: Front End Loaders | Size: 5.29 MB

Table of Contents

Table of Contents

5
- Machine Numbers
  
  9
- Safety
  
  11
- Safety Signs
  
  50
- Components Name
  
  59
- Getting On/Off the Machine
  
  60
- Operator's Station
  
  61
  - About Aftertreatment Device
    61
  - Cab Features
    64
  - Front Console
    65
  - Right Console
    66
    
    Multi-Function Joystick Type
    66
  - Monitor Panel
    67
  - Service Indicator
    68
  - Parking Brake Indicator (Red)
    69
  - Brake Oil Level Indicator (Red)
    69
  - HST Warning Indicator (Red)
    70
  - Discharge Warning Indicator (Red)
    70
  - Engine Trouble Indicator (Red)
    70
  - Urea Warning Indicator (Red)
    70
  - Overheat Indicator (Red)
    71
  - Engine Oil Low Pressure Indicator (Red)
    71
  - Aftertreatment Device Warning Indicator
    71
    
    Aftertreatment Device Regeneration Request (Blinking Yellow)
    71
  - Preheat Indicator (Yellow)
    72
  - HST Oil Temperature Indicator (Red)
    72
  - Seat Belt Indicator (Red)
    72
  - Water Separator Indicator (Red)
    72
  - Coolant Temperature Gauge
    73
  - Fuel Gauge
    73
  - HST Oil Temperature Gauge
    73
  - Turn Signal Indicator (Green)
    74
  - High Beam Indicator (Blue)
    74
  - Work Light Indicator (Yellow)
    74
  - Clearance Light Indicator (Green)
    75
  - Control Lever Lock Indicator (Red)
    75
  - Power Mode Indicator (Green)
    75
  - Maintenance Indicator (Yellow)
    75
  - Monitor Display
    76
    
    Forward/Reverse and Shift Position Indicator
    77
    
    Speedometer
    79
    
    Ride Control Indicator (Optional)
    80
    
    ECO Indicator
    80
    
    Def/Adblue® Level Gauge
    80
  - DEF/SCR System Alarm
    81
    
    Def/Adblue® Level Alarm
    81
    
    Urea SCR System Malfunction
    82
  - Machine Information Display
    83
    
    Shifting Item to be Indicated on Machine Information Display
    84
  - Resetting of Oil Change and Filter Replacement Intervals
    89
    
    Hydraulic Oil Change Interval Hour Meter
    89
    
    Hydraulic Oil Filter 1 Replacement Interval Hour Meter
    90
    
    Hydraulic Oil Filter 3 Replacement Interval Hour Meter
    91
    
    Transmission Oil Change Interval Hour Meter
    92
    
    Transmission Oil Filter Replacement Interval Hour Meter
    93
    
    Engine Oil Change Interval Hour Meter
    94
    
    Engine Oil Filter Replacement Interval Hour Meter
    95
    
    Fuel Filter Replacement Interval Hour Meter
    96
    
    Axle Oil Change Interval Hour Meter
    97
  - Clock Setting Mode
    98
    
    Clock (24H) Setting Procedures
    98
  - Switches, Steering Wheel and Pedals
    99
  - Forward/Reverse Lever/ Shift Switch
    100
    
    Forward/Reverse Lever
    100
    
    Shift Switch/Quick Shift Switch (QSS)
    100
  - Neutral Lever Lock (for the Forward/Reverse Lever)
    101
  - Steering
    101
  - Horn Button
    101
  - Turn Signal Lever
    102
  - Light Switch
    103
  - High-Low Beam Switch
    104
  - Key Switch
    104
  - Wiper Switch
    105
    
    Wiper Operation
    105
    
    Front/Rear Wiper Switch
    106
  - Hazard Switch
    107
  - Work Light Switch
    108
  - Parking Brake Switch
    109
  - Accelerator Pedal
    110
  - Brake/Inching Pedal
    110
  - Tilt, Telescopic Lever/Steering Column Tilt Pedal
    111
  - Slow Speed (L) Select Switch
    112
  - Right Console
    113
    
    Multi-Function Joystick Type
    113
  - Control Lever
    114
  - Control Lever Lock Switch
    115
  - Armrest Adjust Handle
    116
  - Traction Control Switch
    117
  - Power Mode Switch
    118
  - Aftertreatment Device Regeneration Switch
    119
    
    Manual Regeneration Procedure
    120
  - Ride Control Switch
    122
    
    Auto
    122
    
    Off
    122
  - Forward/Reverse Selector Switch
    123
    
    Operational Procedure
    123
  - Cigar Lighter
    124
    
    Using Cigar Lighter
    124
    
    Using Cigar Lighter Port as External Power Source
    124
  - Ash Tray
    125
  - Auto Air Conditioner
    126
    
    Feature
    126
    
    Components Name
    127
    
    Controller Part Name and Function
    128
    
    Mode/Temperature Control Switch
    130
    
    Defroster Operation
    132
    
    Cool Head/Warm Feet Operation
    132
  - Tips for Optimal Air Conditioner Usage
    133
    
    For Rapid Cooling
    133
    
    When Windows Become Clouded
    133
    
    Off-Season Air Conditioner Maintenance
    133
  - Adjusting Operator's Seat (Air Suspension Type Seat) (Sears)
    134
    
    Components Name
    134
  - Rear Tray
    135
  - Electric Power Output
    135
  - Fuse Box
    136
    
    Fuse Box a
    137
    
    Fuse Box B
    137
  - Hot/Cool Box
    138
  - Tray and Drink Holder
    138
  - ROPS Cab
    139
  - Front Room Light
    141
  - Rear Room Light
    141
  - Sun Visor
    142
  - Emergency Evacuation Hammer
    142
  - Coat Hook
    142
  - Upper Switch Panel (Optional)
    143
  - Rear View Mirror Heater Switch
    143
  - Outside Rear View Mirror
    144
  - Room Rear View Mirror
    144
  - Cab Door
    144
  - Door Lock Knob
    145
  - Door Open/Close Lever
    145
  - Window Open/Close Levers
    145
  - When Fully Opening the Left Door
    146
  - Cab Door Release Lever
    146
  - Battery Disconnect Switch
    147
    
    Switch Operation
    148
  - Articulation Lock Bar
    149
  - Towing Pin
    150
  - Inspection/Maintenance Side Access Cover
    151
  - Steps
    152
  - Rear Grille
    152
    
    Opening the Rear Grille
    152
    
    Closing the Rear Grille
    152
  - Grease Gun Box
    152
  - Vandal-Proof Devices
    153
  - Seat Belt
    154
- Break-In
  
  155
  - Break-In Operation for New Machine
    155
- Operating Engine
  
  157
  - Inspect Machine Daily before Starting
    157
  - Check before Starting
    159
  - Starting Engine
    161
Operating Engine

163
- Starting in Cold Weather
  163
- Check after Starting
  164
  - Mptc-01-019
    164
- Using Booster Batteries
  165
  - Machine
    166
- WARNING: after Starting the Engine, Start the
  
  167
  - Warming up Operation
    167
- Machine Operation Only after Confirming that the Engine Speed Changes by Operating Accelerator Pedal
  
  167
  - Mndb-01-001
    167
- Otherwise, the Machine or the Front Attachment May
  
  167
- Unexpectedly Start Moving, Possibly Causing Accidents
  
  167
  - Warming up Operation in Cold Weather
    168
    
    NOTE: Illumination such as Headlight, Work Light or Room
    168
  - Stopping Engine
    170
- Driving Machine
  
  171
  - Driving the Machine
    171
  - Starting to Move
    172
  - Parking Brake Switch
    174
  - Drive Speed Change
    175
  - Changing Forward/Reverse Drive Direction
    175
  - Steering Wheel
    176
  - Stop and Restart of Driving
    177
  - Precautions for Driving on Slopes
    180
  - Precautions for Driving Speeds
    181
  - Precautions to be Taken if Machine Failure Occurs
    182
  - Stop the Machine
    183
  - Parking
    185
  - Emergency Evacuation
    186
- Operating Machine
  
  187
  - Control Lever
    187
  - Control Lever Lock Switch
    188
  - Ride Control Switch (Optional)
    189
  - Lift Arm Kick out
    191
  - Bucket Auto Leveler
    192
  - Before Operation
    194
  - Precautions for Operation
    194
  - Ensure Safety When Operating on Road Shoulders
    194
  - Avoid Overloading
    195
  - Avoid Rapid Steering Changes And/Or Sudden Braking
    195
  - Avoid Operation with Biased Loads
    195
  - Excavation
    196
  - Grading
    198
  - Loading
    199
  - Dozing
    202
  - Scooping
    202
  - Removing Snow
    203
  - Lifting Wheel Loader
    203
  - Precautions for after Operations
    204
- Transporting
  
  207
  - Transporting by Road
    207
  - Transporting by Trailer
    207
  - Loading / Unloading on Trailer
    208
  - Fastening Machine for Transporting
    210
  - Transporting Wheel Loader (Urgent Situation)
    211
  - Towing Method
    215
  - Lifting Machine
    216
- Maintenance
  
  219
  - Correct Maintenance and Inspection Procedures
    219
  - Check the Hour Meter Regularly
    221
  - Layout
    222
  - Preparations for Inspection and Maintenance
    225
  - Lock Frames
    227
  - Inspection/Maintenance Access Side Cover
    228
  - Rear Grille
    229
  - Inspection and Maintenance Table
    230
  - Kind of Oils
    234
  - List of Consumable Parts
    237
  - Greasing
    239
  - Engine
    245
    
    Check Engine Oil Level
    245
    
    Change Engine Oil
    246
    
    Replace Engine Oil Filter
    248
  - Power Train
    249
    
    Check Transmission Oil Level
    249
    
    Change Transmission Oil
    250
    
    Clean Transmission Strainer
    250
    
    Replace Transmission Oil Filter
    252
    
    Change Axle Oil
    254
    
    Check Surroundings Around Axle and Covers for Oil Leaks
    256
    
    Clean Transmission Air Breather
    256
  - Hydraulic System
    257
  - Inspection and Maintenance of Hydraulic Equipment
    257
    
    Check Hydraulic Oil Level
    259
    
    Change Hydraulic Oil/Clean Hydraulic Oil Tank
    260
    
    Clean Suction Filter
    260
    
    Replace Hydraulic Tank Oil Filter
    262
    
    Replace HST Charge Filter
    264
    
    Replace Air Breather Element
    266
    
    Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, and Damage
    267
    
    Replace Pilot Circuit Accumulator
    268
    
    Check Ride Control Accumulator Function, Gas Leakage, Looseness, and Damage
    268
    
    Check Gas Pressure in Ride Control Accumulator (Optional)
    268
    
    Check Hoses and Lines
    269
  - Fuel System
    274
    
    Check Fuel Level
    274
    
    Drain Water and Sediment from Fuel Tank
    276
    
    Drain Fuel Pre-Filter
    277
    
    Replace Fuel Main Filter Element
    279
    
    Replace Fuel Pre-Filter Element
    280
    
    Check Fuel Hoses
    281
  - Air Cleaner
    282
    
    Inspect the Air Cleaner Element for Clogging
    282
    
    Clean and Replace Air Cleaner Element
    283
  - Cooling System
    284
    
    Check Coolant Level
    285
    
    Check Drive Belt
    286
    
    Replace Drive Belt
    286
    
    Replace Automatic Tensioner
    286
    
    Change Coolant
    287
    
    Clean Radiator/Oil Cooler and Other Cooling System
    288
  - Electrical System
    289
    
    Batteries
    289
    
    Check Monitor Functions and All Other Instrument Operation
    293
    
    Check Lights
    294
    
    Check Horn and Reverse Buzzer
    294
    
    Check Electrical Harnesses and Fuses
    295
  - Brake System
    297
    
    Check Brake Oil Level
    297
    
    Check Right and Left Brake Interlocking Performance
    298
    
    Check Parking Brake Force
    299
    
    Check Brake Disks (Service and Parking)
    300
    
    Change Brake Oil
    300
  - Tire
    301
    
    Check and Replace Tire (Tire Pressure)
    301
    
    Check Tire for Damage
    301
    
    Check Wheel Bolt Torque
    302
  - Removal and Installation of Tire
    305
  - Air Conditioner
    306
    
    Clean/Replace Air Conditioner Circulation/Fresh Air
    306
    
    Filters
    306
    
    Check Air Conditioner
    310
    
    Check Air Conditioner Piping
    310
    
    Check Air Conditioner Condenser
    311
    
    Check Air Conditioner Fan Belt
    311
    
    Check Refrigerant
    312
    
    Check Compressor and Pulley
    312
  - Miscellaneous
    313
    
    Check Cutting Edge
    313
    
    Check and Replace Seat and Seat Belt
    314
    
    Check ROPS Cab Mounting Bolts
    314
    
    Check Windshield Washer Fluid Level
    314
    
    Check Play Amount in Steering Wheel Stroke
    315
    
    Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise
    316
    
    Check Rearview Mirror and Inside Rearview Mirror
    317
    
    Check Steps and Handrails for Damage and Looseness
    317
    
    Clean Engine Compartment and Hood
    318
    
    Check Sound Absorbing Mat Around Engine
    318
    
    Check Engine Cylinder Head Bolts
    319
    
    Check Engine Compression Pressure
    319
    
    Check and Clean Starter and Alternator
    319
    
    Retighten Front Axle and Rear Axle Support Mounting Bolts
    319
    
    Check and Replace EGR Device
    320
    
    Clean EGR Cooler
    320
    
    Check Turbocharger
    320
    
    Check and Clean Injector Nozzle
    320
Maintenance

321
- Tightening and Retightening Torque of Nuts and Bolts
  321
- Front Axle Mounting Bolt
  323
- Rear Axle Support Mounting Bolt
  323
- Wheel Rim Mounting Bolt
  323
- Propeller Shaft Mounting Bolt
  324
- Propeller Shaft Support Bearing Mounting Bolt
  324
- Transmission Mounting Bolt: Frame Side
  324
- HST Motor Mounting Bolt
  325
- HST Pump Mounting Bolt
  325
- Transmission Mounting Bolt: Transmission Side 16
  325
- 10. Engine Mounting Bolt: Bracket
  326
  - Front Rear
    326
- 11. Engine Mounting Bolt: Cushion Rubber
  326
- 12. Aftertreatment Device Mounting Bolt: Bracket
  326
- 13. Counterweight Mounting Bolt
  327
- 14. Top Center Pin Lock
  327
- 15. Bottom Center Pin Flange Lock Bolt
  327
- 16. Loader Front Pin Lock
  328
- 17. Steering Cylinder Pin Lock
  328
- 18. Radiator Frame Mounting Bolt
  328
- 19. Radiator Mounting Bolt
  329
- 20. Intercooler Mounting Bolt
  329
- 21. Oil Cooler Mounting Bolt
  329
- 22. Air Conditioner Condenser Mounting Bolt
  330
- 24. Cab Cushion Rubber Mounting Bolt
  330
- Air Conditioner Compressor Mounting Bolt 8
  330
- 25. Cutting Edge Mounting Bolt
  331
- Aftertreatment Device
  332
  - Check and Clean Aftertreatment Device
    332
- Urea SCR System
  333
- Maintenance under Special Environmental Conditions
  
  341
  - Maintenance under Special Environmental Conditions
    342
  - Precautions for Maintenance During Cold Weather Season
    342
- Storage
  
  345
  - Storing the Machine
    345
- Troubleshooting
  
  349
- Specifications
  
  355
- Optional Attachments
  
  357
  - Hydraulic Type Quick Coupler Operation
    357
- Index
  
  361

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