Hitachi ZW120-6 Wheel Loader Repair Manuals

Service Repair Manual (Troubleshooting) : Vol. No.TTSA60-E-00 (424 Pages)
Operation Manual : Vol. No.TTSA60-E-00 (398 Pages)
Workshop Manual : Vol. No.WNSA60-E-00 (821 Pages)
Circuit diagram: 15 Pages
Hitachi ZW120-6 Wheel Loader Service Manual
The manual is applicable for the Hitachi ZW120-6 Wheel Loader Model
Service Manual consists of the following:
For Model ZW120-6 as mentioned above:
Service Manual (Troubleshooting) : Vol. No.TTSA60-E-00 (424 Pages)

Table of Content of the Workshop Manual

SECTION 1 GENERAL INFORMATION

Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
Group 5 Preparation

SECTION 2 MAINTENANCE STANDARD

Group 1 Body
Group 2 Travel System
Group 3 Front Attachment

SECTION 3 VEHICLE

Group 1 Cab
Group 2 Counterweight
Group 3 Center Hinge
Group 4 Engine
Group 5 Radiator Assembly
Group 6 Hydraulic Oil Tank
Group 7 Fuel Tank
Group 8 Pump Device
Group 9 Control Valve
Group 10 Pilot Valve
Group 11 Missing Number
Group 12 Missing Number
Group 13 Solenoid Valve
Group 14 Priority Valve
Group 15 Missing Number
Group 16 Ride Control Device
Group 17 Battery Disconnect Switch
Group 18 Aftertreatment Device
Group 19 DEF Tank
Group 20 Coolant Control Valve
Group 21 DEF Supply Module
Group 22 Exterior Components

Table of Content of the Technical Manual

Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
Group 5 Component Test
Group 6 Adjustment

SECTION 5 TROUBLESHOOTING

Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Troubleshooting C
Group 8 Air Conditioner

Table of Content of the Operation Manual

SECTION 1 GENERAL

Group 1 Specifications
Group 2 Component Layout
Group 3 Component Specifications

SECTION 2 SYSTEM

Group 1 Controller
Group 2 Control System
Group 3 ECM System
Group 4 Hydraulic System
Group 5 Electrical System

SECTION 3 COMPONENT OPERATION

Group 1 Pump Device
Group 2 Control Valve
Group 4 Steering Valve
Group 5 HST Motor
Group 6 Pilot Valve
Group 8 Transmission
Group 9 Axle
Group 10 Brake Valve
Group 11 Priority Valve
Group 12 Ride Control Valve
Group 13 Others
Manual guide composition
Hitachi ZAXIS ZW120-6 service manual consists of the Troubleshooting and the Workshop Manual.

Information included in the Service 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.

ENGINE OUTPUT RESTRICTION CONTROL (INDUCEMENT)
Purpose:

When DEF level becomes low, or malfunction occurs on the urea SCR system or EGR system, the engine output restriction control displays the alarm on the monitor and sounds the buzzer. When the machine is continuously operated under this state, the engine output restriction control gradually decreases the engine torque and speed.

Operation:
1. The urea SCR system signal (a) are sent to ECM (18).
2. When any of the following condition is met, ECM (18) decreases the engine torque and the engine speed.
Condition:
– DEF Level: 10 minutes after the level reaches 5 % or less
– Urea SCR System: Abnormal, and a certain period of time has passed
– EGR System: Abnormal, and a certain period of time has passed

3. In addition, ECM (18) further decreases the engine torque and sets the engine speed to the slow idle position according to the level of DEF and the elapsed time from the system error occurrence.

4. When the machine recovers to the normal condition, ECM (18) controls the engine torque and speed according to the other engine controls.