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Hitachi ZW 120-G User Manual

Hitachi ZW 120-G
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SAFETY
SA-3
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
Avoid wearing loose clothing, jewelry, or other
items that can catch on control levers or other
parts of the machine.
Operating equipment safely requires the full atten-
tion of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
SA-438
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause im-
pairment or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objec-
tionable or uncomfortably loud noises.
006-E01A-0434
SA-434
NSPECT MACHINE
Inspect your machine carefully each day or shift by
walking around it before you start it to avoid per-
sonal injury.
In the walk-around inspection be sure to cover all
points described in the “PRE-START INSPEC-
TION” chapter in the operator’s manual.
007-E01A-0435
SA-435

Table of Contents

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Hitachi ZW 120-G Specifications

General IconGeneral
BrandHitachi
ModelZW 120-G
CategoryFront End Loaders
LanguageEnglish

Summary

Introduction

To the Reader

Provides technical information for experienced technicians on machine maintenance and repair.

Additional References

Refers to other related materials like operator's manual and parts catalog.

Manual Composition

Details the structure of the Technical and Workshop Manuals.

Page Number

Explains the format and meaning of page numbers within the manual.

Safety Alert Symbol and Headline Notations

Explains safety alert symbols and signal words used in the manual and their meanings.

Units Used

Lists SI units and conversion factors for various quantities.

Safety

Recognize Safety Information

Explains safety alert symbols and their meanings.

Understand Signal Words

Explains signal words like DANGER, WARNING, CAUTION, IMPORTANT, NOTE.

Follow Safety Instructions

Guidelines for safe operation, maintenance, and modifications.

Prepare for Emergencies

Advice on first aid kits, fire extinguishers, and emergency contacts.

Wear Protective Clothing

Recommendations for appropriate personal protective equipment (PPE).

Protect Against Noise

Importance of hearing protection from loud noises.

Inspect Machine

Guidance on performing daily walk-around inspections.

General Precautions for Cab

Safety tips for working inside the operator's cab.

Use Handholds and Steps

Instructions for safe mounting and dismounting the machine.

Adjust the Operator's Seat

Proper adjustment of the operator's seat for comfort and control.

Ensure Safety Before Rising From or Leaving Operator's Seat

Procedures for safely exiting the operator's seat.

Fasten Your Seat Belt

Importance of seat belt use to prevent injury during overturns.

Move and Operate Machine Safely

Precautions for moving and operating the machine safely around others.

Handle Starting Aids Safely

Safe handling of starting fluids.

Operate Only From Operator's Seat

Rules for starting the engine safely from the operator's seat.

Jump Starting

Procedures and hazards associated with jump starting.

Investigate Job Site Beforehand

Importance of assessing job site conditions to prevent accidents.

Equipment of Head Guard, ROPS, FOPS

Requirements for protective structures like ROPS and FOPS.

Provide Signals for Jobs Involving Multiple Numbers of Machines

Using signals for coordinated work with multiple machines.

Keep Riders Off Machine

Prohibition of carrying unauthorized riders.

Drive Safely

General advice for safe driving on level ground and rough terrain.

Drive Machine Safely (Work Site)

Specific safety instructions for operating on slopes and work sites.

Drive Safely With Bucket Loaded

Precautions for driving with the bucket loaded to maintain balance.

Drive On Snow Safely

Safety tips for operating on snow or ice surfaces.

Travel On Public Roads Safely

Regulations and precautions for road travel.

Avoid Injury From Rollaway Accidents

Procedures to prevent machine rollaways and related injuries.

Avoid Accidents From Backing Up and Turning

Safety measures for backing up and turning to prevent collisions.

Avoid Positioning Bucket Over Anyone

Warning against placing the bucket over people or equipment.

Avoid Tipping

Procedures to prevent the machine from tipping over, especially on grades.

Never Undercut a High Bank

Warning against undercutting high banks due to collapse risk.

Dig With Caution

Pre-digging checks for underground utilities like cables and lines.

Perform Truck Loading Safely

Safety measures for loading trucks, avoiding involuntary movement and free-fall.

Avoid Power Lines

Safety distances and precautions when working near electric lines.

Precautions for Operation

Avoiding contact with overhead obstacles during operation.

Precautions for Lightening

Procedures to follow during electrical storms.

Object Handling

Safe practices for lifting and handling loads.

Protect Against Flying Debris

Protection from flying objects and debris, use of safety glasses.

Park Machine Safely

Step-by-step procedure for parking the machine safely.

Store Attachments Safely

Safe storage of machine attachments to prevent falling.

Transport Safely

Precautions for loading and transporting the machine onto trucks or trailers.

Handle Fluids Safely-Avoid Fires

Precautions for handling flammable fluids to prevent fires.

Practice Safe Maintenance

General safety procedures and precautions before performing maintenance.

Warn Others of Service Work

Procedures for warning others before starting service work.

Support Machine Properly

Safe methods for supporting lifted machines or attachments.

Stay Clear of Moving Parts

Warning about entanglement with moving machine parts.

Support Maintenance Properly

Safety precautions related to tire and rim maintenance.

Prevent Parts From Flying

Precautions against flying parts during maintenance, especially from gears and oil plugs.

Prevent Burns

Warnings about hot fluids, steam, and surfaces.

Replace Rubber Hoses Periodically

Importance of periodic replacement of rubber hoses.

Avoid High-Pressure Fluids

Hazards of high-pressure fluids penetrating skin and eyes.

Prevent Fires

Measures to prevent fires, including checks for leaks, shorts, flammables, and key switch function.

Evacuating in Case of Fire

Procedures for safely evacuating the machine in case of fire.

Beware of Exhaust Fumes

Hazards of exhaust fumes and ventilation requirements.

Precautions for Welding and Grinding

Safety measures for welding and grinding operations.

Avoid Heating Near Pressurized Fluid Lines

Warnings about heating near pressurized fluid lines and fire risk.

Avoid Applying Heat to Lines Containing Flammable Fluids

Safety when applying heat to lines containing flammable fluids.

Remove Paint Before Welding or Heating

Precautions for removing paint before welding or heating due to fumes.

Beware of Asbestos Dust

Health risks associated with asbestos dust and precautions.

Prevent Battery Explosions

Safety procedures to prevent battery explosions.

Service Air Conditioning System Safely

Safe practices for servicing air conditioning systems.

Handle Chemical Products Safely

Safe handling of chemicals, MSDS information, and recommended equipment.

Dispose of Waste Properly

Guidelines for proper disposal of waste materials and refrigerants.

Before Returning the Machine to the Customer

Final checks before returning the machine after maintenance.

Workshop Manual

Section 1 General Information

General information and precautions for disassembling and assembling.

Section 1 General Information

Group 1 Precautions for Disassembling and Assembling

Precautions for disassembling and assembling machine components.

Group 2 Tightening

Specifications and procedures for tightening bolts and nuts.

Group 3 Painting

Information regarding painting specifications and procedures.

Group 4 Bleeding Air from Hydraulic Circuit

Procedures for bleeding air from the hydraulic circuit.

Group 5 Hydraulic Circuit Pressure Release Procedure

Steps to release pressure in the hydraulic circuit.

Group 6 Preparation

Preparations required before inspection and maintenance.

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