Hitachi ZW 120-6 Wheel Loader Workshop + Troubleshooting + Operational + Electrical-Hudraulic Circuit Manual – PDF Download

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Hitachi ZW 120-6 Wheel Loader Workshop + Troubleshooting + Operational + Electrical-Hudraulic Circuit Manual

FILE DETAILS:

Hitachi ZW 120-6 Wheel Loader Workshop + Troubleshooting + Operational + Electrical-Hudraulic Circuit Manual

This Listing includes all of the manuals mentioned below:

1. ELECTRICAL-HYDRAULIC CIRCUIT DIAGRAM.pdf
2. Hitachi ZW 120-6 Wheel Loader Operational Principle Technical Manual.pdf
3. Hitachi ZW 120-6 Wheel Loader Troubleshooting Technical Manual.pdf
4. Hitachi ZW 120-6 Wheel Loader Workshop Manual.pdf

HITACHI ZW 120-6 WHEEL LOADER WORKSHOP + TROUBLESHOOTING + OPERATIONAL + ELECTRICAL-HUDRAULIC CIRCUIT MANUAL – PDF DOWNLOAD:

SCREENSHOTS OF THE MANUAL:

DESCRIPTION:

Hitachi ZW 120-6 Wheel Loader Workshop + Troubleshooting + Operational + Electrical-Hudraulic Circuit Manual

• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• 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.
• This manual consists the Technical Manual and the Workshop 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.

TABLE OF CONTENTS:

Hitachi ZW 120-6 Wheel Loader 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
SECTION 4 TRAVEL SYSTEM
Group 1 Tire
Group 2 Drive Unit
Group 3 Axle
Group 4 Propeller Shaft
Group 5 Brake Valve
Group 6 Steering Device
Group 7 Missing Number
SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder

Hitachi ZW 120-6 Wheel Loader Troubleshooting Manual

Group 1 Diagnosing Procedure
INTRODUCTION…………………………………………………………..T5-1-1
DIAGNOSIS PROCEDURE……………………………………………T5-1-2
ELECTRICAL SYSTEM INSPECTION……………………………T5-1-5
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE……………………………………………………….T5-1-6
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS…………………………………………………………T5-1-8
FUSE INSPECTION……………………………………………………..T5-1-10
FUSE AND FUSIBLE LINK INSPECTION……………………T5-1-13
BATTERY VOLTAGE CHECK……………………………………….T5-1-14
HOW TO CHECK ALTERNATOR…………………………………T5-1-15
CONTINUITY CHECK………………………………………………….T5-1-16
VOLTAGE AND CURRENT MEASUREMENT……………..T5-1-18
CHECK BY FALSE SIGNAL………………………………………….T5-1-26
Test Wire Harness………………………………………………………T5-1-27
Group 2 Monitor
OPERATING PROCEDURES OF SERVICE MENU……….T5-2-3
COOLANT TEMPERATURE GAUGE AND HST OIL TEMPERATURE GAUGE…………………………………………..T5-2-9
FUEL GAUGE AND DEF GAUGE……………………………….T5-2-10
Group 3 e-Service
OVERVIEW…………………………………………………………………….T5-3-1
LIST OF OPERATION DATA………………………………………….T5-3-2
SNAPSHOT DATA…………………………………………………………T5-3-6
COMMUNICATION SYSTEM……………………………………….T5-3-7
Group 4 Component Layout
MAIN COMPONENT (OVERVIEW)………………………………T5-4-1
MAIN COMPONENT…………………………………………………….T5-4-3
ELECTRICAL SYSTEM (OVERVIEW)……………………………T5-4-5
AIR CLEANER, RADIATOR, AND SURROUNDINGS…..T5-4-6
BATTERY BOX……………………………………………………………….T5-4-8
FRAME: REAR RIGHT INSIDE………………………………………T5-4-8
HYDRAULIC OIL TANK…………………………………………………T5-4-9
FUEL TANK………………………………………………………………….T5-4-10
CAB………………………………………………………………………………T5-4-11
FRONT CONSOLE……………………………………………………….T5-4-12
RIGHT CONSOLE………………………………………………………..T5-4-13
REAR CONSOLE………………………………………………………….T5-4-14
CONROL UNIT…………………………………………………………….T5-4-15
ENGINE………………………………………………………………………..T5-4-17
AFTERTREATMENT DEVICE………………………………………T5-4-18
TRANSMISSION/HST MOTOR…………………………………..T5-4-19
PUMP DEVICE…………………………………………………………….T5-4-20
CONTROL VALVE………………………………………………………..T5-4-21
PILOT SHUTOFF SOLENOID VALVE………………………….T5-4-22
RIDE CONTROL VALVE……………………………………………….T5-4-23
DEF TANK……………………………………………………………………T5-4-24
DEF SUPPLY MODULE……………………………………………….T5-4-25
Group 5 Troubleshooting A
TROUBLESHOOTING A (BASE MACHINE
DIAGNOSIS BY USING FAULT CODES)
Procedure………………………………………………………………..T5-5-1
MC FAULT CODE LIST………………………………………………….T5-5-3
HST CONTROLLER FAULT CODE LIST………………………T5-5-11
INFORMATION CONTROLLER FAULT CODE LIST……T5-5-17
COLUMN DISPLAY CONTROLLER FAULT CODE
LIST…………………………………………………………………………T5-5-18
AIR CONDITIONER CONTROLLER FAULT CODE
LIST…………………………………………………………………………T5-5-20
COMMUNICATION TERMINAL FAULT CODE LIST…..T5-5-21
MC FAULT CODES 111000 to 111002……………………..T5-5-22
MC FAULT CODE 111003…………………………………………..T5-5-23
MC FAULT CODES 111006, 111007, 111030………….T5-5-25
CAN1 HARNESS CHECK…………………………………………….T5-5-26
MC FAULT CODES 111008, 111014, 111025………….T5-5-31
CAN2 HARNESS CHECK…………………………………………….T5-5-32
MC FAULT CODES 111103, 111106, 111107………….T5-5-35
MC FAULT CODE 111217…………………………………………..T5-5-37
MC FAULT CODE 111313…………………………………………..T5-5-38
MC FAULT CODE 111422…………………………………………..T5-5-39
MC FAULT CODE 111908…………………………………………..T5-5-40
MC FAULT CODE 111909…………………………………………..T5-5-41
HST CONTROLLER FAULT CODES 111027,
111028……………………………………………………………………T5-5-42
HST CONTROLLER FAULT CODE 111332………………..T5-5-43
HST CONTROLLER FAULT CODES 111330,
111331……………………………………………………………………T5-5-44
HST CONTROLLER FAULT CODES 111430,
111434, 111455…………………………………………………….T5-5-45
HST CONTROLLER FAULT CODE 111457………………..T5-5-46
HST CONTROLLER FAULT CODES 111450,
111451……………………………………………………………………T5-5-47
HST CONTROLLER FAULT CODE 111622………………..T5-5-48
HST CONTROLLER FAULT CODE 111904………………..T5-5-49
HST CONTROLLER FAULT CODE 111905………………..T5-5-50
INFORMATION MONITOR CONTROLLER FAULT
CODE 115001………………………………………………………..T5-5-51

Hitachi ZW 120-6 Wheel Loader Operational Manual

Group 1 Specifications
Specifications……………………………………………………………… T1-1-1
Group 2 Component Layout
MAIN COMPONENT (OVERVIEW)……………………………… T1-2-1
MAIN COMPONENT……………………………………………………. T1-2-3
ELECTRICAL SYSTEM (OVERVIEW)…………………………… T1-2-5
AIR CLEANER, RADIATOR, AND SURROUNDINGS….. T1-2-6
BATTERY BOX………………………………………………………………. T1-2-8
FRAME: REAR RIGHT INSIDE……………………………………… T1-2-8
HYDRAULIC OIL TANK………………………………………………… T1-2-9
FUEL TANK………………………………………………………………….T1-2-10
CAB………………………………………………………………………………T1-2-11
FRONT CONSOLE……………………………………………………….T1-2-12
RIGHT CONSOLE………………………………………………………..T1-2-13
REAR CONSOLE………………………………………………………….T1-2-14
CONTROL UNIT………………………………………………………….T1-2-15
ENGINE………………………………………………………………………..T1-2-17
AFTERTREATMENT DEVICE………………………………………T1-2-18
TRANSMISSION/HST MOTOR…………………………………..T1-2-19
PUMP DEVICE…………………………………………………………….T1-2-20
CONTROL VALVE………………………………………………………..T1-2-21
PILOT Lock SOLENOID VALVE…………………………………..T1-2-22
RIDE CONTROL VALVE……………………………………………….T1-2-23
DEF Tank……………………………………………………………………..T1-2-24
DEF SUPPLY MODULE……………………………………………….T1-2-25
Group 3 Component Specifications
Engine………………………………………………………………………….. T1-3-1
Engine Accessories…………………………………………………….. T1-3-5
Hydraulic Component……………………………………………….. T1-3-7
Electrical Component……………………………………………….T1-3-12
Group 1 Controller
OVERVIEW…………………………………………………………………….T2-1-1
CAN CIRCUIT………………………………………………………………..T2-1-2
Group 2 Control System
OVERVIEW…………………………………………………………………….T2-2-1
ENGINE CONTROL (ECM)……………………………………………T2-2-4
HST PUMP/MOTOR, TRANSMISSION CONTROL……T2-2-19
VALVE CONTROL………………………………………………………..T2-2-43
OTHER CONTROL………………………………………………………T2-2-47
CONTROL BY ELECTRICAL AND HYDRAULIC
COMBINED CIRCUIT……………………………………………..T2-2-51
Group 3 Engine System
OVERVIEW…………………………………………………………………….T2-3-1
FUEL INJECTION CONTROL………………………………………..T2-3-2
FUEL INJECTION AMOUNT CORRECTION
CONTROL……………………………………………………………….T2-3-10
EGR CONTROL……………………………………………………………T2-3-12
PREHEATING CONTROL…………………………………………….T2-3-14
ALARM CONTROL………………………………………………………T2-3-15
UREA SCR SYSTEM…………………………………………………….T2-3-17
ENGINE OUTPUT RESTRICTION CONTROL
(INDUCEMENT)……………………………………………………..T2-3-32
AFTERTREATMENT DEVICE………………………………………T2-3-37
AFTERTREATMENT DEVICE REGENERATION
CONTROL……………………………………………………………….T2-3-39
Group 4 Hydraulic System
OVERVIEW…………………………………………………………………….T2-4-1
MAIN CIRCUIT………………………………………………………………T2-4-2
OVERVIEW…………………………………………………………………….T2-4-4
STRUCTURE………………………………………………………………….T2-4-5
OPERATION………………………………………………………………….T2-4-7
HST CIRCUIT……………………………………………………………….T2-4-16
PILOT CIRCUIT…………………………………………………………….T2-4-24
TRANSMISSION CIRCUIT…………………………………………..T2-4-31
SERVICE BRAKE CIRCUIT…………………………………………..T2-4-37
Group 5 Electrical System
OVERVIEW…………………………………………………………………….T2-5-1
MAIN CIRCUIT………………………………………………………………T2-5-2
ELECTRIC POWER CIRCUIT (KEY SWITCH: OFF)……….T2-5-4
CAN CIRCUIT………………………………………………………………..T2-5-6
ACCESSORY CIRCUIT (KEY SWITCH: ACC)………………..T2-5-8
STARTING CIRCUIT (KEY SWITCH: START)………………T2-5-10
CHARGING CIRCUIT (KEY SWITCH: ON)………………….T2-5-12
SURGE VOLTAGE PREVENTION CIRCUIT…………………T2-5-16
LOCK CIRCUIT (KEY SWITCH: ON)……………………………T2-5-18
ENGINE STOP CIRCUIT………………………………………………T2-5-20
STEERING COLUMN BOX CIRCUIT…………………………..T2-5-23
HEADLIGHT CIRCUIT…………………………………………………T2-5-24
HAZARD LIGHT CIRCUIT (KEY SWITCH: OFF)…………T2-5-30
TURN SIGNAL LIGHT CIRCUIT………………………………….T2-5-32
HORN CIRCUIT (KEY SWITCH: OFF)…………………………T2-5-34
BACK BUZZER, REVERSE LIGHT CIRCUIT………………..T2-5-36
BRAKE LIGHT CIRCUIT……………………………………………….T2-5-38
PARKING BRAKE CIRCUIT………………………………………….T2-5-40
ACCESSORY CIRCUIT…………………………………………………T2-5-45
WORK LIGHT CIRCUIT……………………………………………….T2-5-46
WIPER CIRCUIT…………………………………………………………..T2-5-48
CAB LIGHT CIRCUIT…………………………………………………..T2-5-54
Group 1 Pump Device
OVERVIEW……………………………………………………………………. T3-1-1
ROTARY GROUP………………………………………………………….. T3-1-4
DISPLACEMENT CYLINDER……………………………………….. T3-1-6
DA VALVE…………………………………………………………………….T3-1-10
FORWARD/REVERSE SELECTOR CONTROL
SOLENOID VALVE………………………………………………….T3-1-11
CUTOFF VALVE…………………………………………………………..T3-1-13
TRAVEL RELIEF VALVE……………………………………………….T3-1-15
CHARGE RELIEF VALVE………………………………………………T3-1-15
HST CHARGE PUMP…………………………………………………..T3-1-17
MAIN PUMP, BRAKE/TRANSMISSION PUMP………….T3-1-18
Group 2 Control Valve
Overview……………………………………………………………………… T3-2-1
Hydraulic Circuit…………………………………………………………. T3-2-5
Main Relief Valve………………………………………………………… T3-2-7
Overload Relief Valve (with Make-Up Function)……. T3-2-9
Make-Up Valve…………………………………………………………..T3-2-15
Group 4 Steering Valve
OVERVIEW……………………………………………………………………. T3-4-1
STRUCTURE…………………………………………………………………. T3-4-2
OPERATION…………………………………………………………………. T3-4-3
Group 5 HST Motor
OVERVIEW……………………………………………………………………. T3-5-1
ROTARY GROUP………………………………………………………….. T3-5-3
REGULATOR…………………………………………………………………. T3-5-5
MOTOR DISPLACEMENT ANGLE CONTROL……………. T3-5-6
MOTOR DISPLACEMENT ANGLE CONTROL
SOLENOID VALVE…………………………………………………… T3-5-6
TRAVEL RESTRICTION SOLENOID VALVE………………..T3-5-10
FLUSHING VALVE……………………………………………………….T3-5-12
Group 6 Pilot Valve
OVERVIEW (JOYSTICK TYPE PILOT VALVE FOR
FRONT ATTACHMENT)………………………………………….. T3-6-1
OPERATION…………………………………………………………………. T3-6-3
ELECTROMAGNETIC DETENT…………………………………..T3-6-10
Group 8 Transmission
Outline…………………………………………………………………………. T3-8-1
Transmission Part……………………………………………………….. T3-8-3
Travel Mode Selector Solenoid Valve Unit…………….T3-8-10
Accumulator………………………………………………………………T3-8-14
SOLENOID VALVE………………………………………………………T3-8-15
Parking Brake……………………………………………………………..T3-8-16
Group 9 Axle
OVERVIEW……………………………………………………………………. T3-9-1
DIFFERENTIAL……………………………………………………………… T3-9-2
TORQUE PROPORTIONING DIFFERENTIAL (TPD)…… T3-9-6
LIMITED SLIP DIFFERENTIAL (LSD) (OPTIONAL)…….. T3-9-8
SERVICE BRAKE………………………………………………………….T3-9-10
FINAL DRIVE / AXLE SHAFT………………………………………T3-9-12
Group 10 Brake Valve
OVERVIEW…………………………………………………………………..T3-10-1
STRUCTURE………………………………………………………………..T3-10-2
OPERATION………………………………………………………………..T3-10-4
Group 11 Priority Valve
OVERVIEW…………………………………………………………………..T3-11-1
STRUCTURE………………………………………………………………..T3-11-2
OPERATION………………………………………………………………..T3-11-4
Group 12 Ride Control Valve
Outline………………………………………………………………………..T3-12-1
Charge-Cut Spool……………………………………………………..T3-12-6
Overload Relief Valve………………………………………………..T3-12-8
Drain Plug……………………………………………………………….. T3-12-12
Group 13 Others
PROPELLER SHAFT…………………………………………………….T3-13-1
RIDE CONTROL ACCUMULATOR……………………………..T3-13-2
INCHING VALVE………………………………………………………….T3-13-3
PILOT SHUT-OFF SOLENOID VALVE…………………………T3-13-4
SOLENOID VALVE………………………………………………………T3-13-6
FILTER………………………………………………………………………….T3-13-8

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]