Description

Hitachi ZW220,ZW250,ZW310 Wheel Loader Operator’s Manual (EM4GB-1-1, EM4GB-1-2)

Hitachi ZW220,ZW250,ZW310 Wheel Loader  Index:

ENGIN EMISSION CONTROL LABEL
MACHINE NUMBERS
SAFETY
Recognize Safety Information …………………………………………… S-1
Understand Signal Words …………………………………………………… S-1
Follow Safety Instructions ………………………………………………….. S-2
Prepare for Emergencies …………………………………………………….. S-2
Wear Protective Clothing …………………………………………………… S-3
Protect Against Noise …………………………………………………………. S-3
Inspect Machine ………………………………………………………………….. S-3
General Precautions for Cab ………………………………………………. S-4
Use Handholds and Steps ………………………………………………….. S-5
Adjust the Operator’s Seat …………………………………………………. S-5
Ensure Safety Before Rising from or Leaving
Operator’s Seat ………………………………………………………………. S-5
Fasten Your Seat Belt …………………………………………………………… S-6
Move and Operate Machine Safely …………………………………… S-6
Handle Starting Aids Safely ……………………………………………….. S-6
Operate Only from Operator’s Seat ………………………………….. S-7
Jump Starting ………………………………………………………………………. S-7
Investigate Job Site Beforehand ……………………………………….. S-8
Equipment of Head Guard, Rops, Fops ……………………………. S-9
Provide Signals for Jobs Involving Multiple
Numbers of Machines …………………………………………………… S-9
Keep Riders Off Machine ………………………………………………….. S-10
Drive Safely …………………………………………………………………………. S-10
Drive Machine Safely (Work Site) …………………………………….. S-10
Drive Safely with Bucket Loaded …………………………………….. S-11
Drive on Snow Safely ………………………………………………………… S-11
Travel on Public Roads Safely …………………………………………… S-11
Avoid Injury From Rollaway Accidents …………………………… S-12
Avoid Accidents from Backing Up and Turning ……………. S-13
Avoid Positioning Bucket Over Anyone …………………………. S-14
Avoid Tipping ……………………………………………………………………… S-14
Never Undercut a High Bank ……………………………………………. S-15
Dig With Caution ……………………………………………………………….. S-15
Perform Truck Loading Safely ………………………………………….. S-15
Avoid Power Lines ……………………………………………………………… S-16
Precautions for Operation ………………………………………………… S-16
Precautions for Lightening ………………………………………………. S-16
Object Handling ………………………………………………………………… S-16
Protect Against Flying Debris ………………………………………….. S-17
Park Machine Safely …………………………………………………………… S-17
Store Attachments Safely …………………………………………………. S-18
Transport Safely …………………………………………………………………. S-18
Handle Fluids Safely−avoid Fires …………………………………….. S-19
Practice Safe Maintenance ……………………………………………….. S-20
Warn Others of Service Work …………………………………………… S-21
Support Machine Properly ……………………………………………….. S-21
Stay Clear of Moving Parts ……………………………………………….. S-21
Support Maintenance Properly ……………………………………….. S-22
Prevent Parts from Flying …………………………………………………. S-22
Prevent Burns ……………………………………………………………………… S-23
Replace Rubber Hoses Periodically …………………………………. S-23
Avoid High-pressure Fluids ………………………………………………. S-24
Prevent Fires ……………………………………………………………………….. S-25
Evacuating in Case Of Fire ………………………………………………… S-26
Beware of Exhaust Fumes ………………………………………………… S-26
Precautions for Welding and Grinding …………………………… S-26
Avoid Heating Near Pressurized Fluid Lines ………………….. S-27
Avoid Applying Heat to Lines Containing
Flammable Fluids ………………………………………………………… S-27
Remove Paint Before Welding or Heating ……………………… S-27
Beware of Asbestos Dust ………………………………………………….. S-28
Prevent Battery Explosions ………………………………………………. S-28
Service Air Conditioning System Safely …………………………. S-28
Handle Chemical Products Safely ……………………………………. S-29
Dispose of Waste Properly ………………………………………………… S-29
SAFETY SIGNS …………………………………………………………………… S-31
COMPONENTS NAME ……………………………………………………….. 1-1
Components Name …………………………………………………………….. 1-1
OPERATOR’S STATION
Cab Features …………………………………………………………………………. 1-2
Monitor Panel ………………………………………………………………………. 1-5
Stop Indicator ………………………………………………………………… 1-6
Service Indicator ……………………………………………………………. 1-6
Parking Brake Indicator ………………………………………………… 1-7
Brake Oil Low Pressure Indicator ………………………………… 1-7
Brake Oil Low Level Indicator ………………………………………. 1-7
Emergency Steering Indicator (Optional) ………………….. 1-7
Low Steering Oil Pressure Indicator (Optional) ………… 1-8
Seat Belt Indicator …………………………………………………………. 1-8
Discharge Warning Indicator ………………………………………. 1-8
Engine Warning Indicator …………………………………………….. 1-8
Overheat Indicator ………………………………………………………… 1-9
Engine Oil Low Pressure Indicator ………………………………. 1-9
Water Separator Indicator ……………………………………………. 1-9
Air Filter Restriction Indicator ……………………………………… 1-9
Transmission Warning Indicator …………………………………1-10
Transmission Oil Filter Restriction Indicator …………….1-10
Hydraulic Oil Temperature Indicator …………………………1-10
Transmission Oil Temperature Indicator …………………..1-10
Engine Coolant Temperature Gauge …………………………1-11
Transmission Oil Temperature Gauge ……………………….1-11
Fuel Gauge ……………………………………………………………………1-11
Preheat Lamp ………………………………………………………………..1-12
Turn Signal Indicator ……………………………………………………1-12
High Beam Indicator ……………………………………………………1-12
Work Light Indicator …………………………………………………….1-12
Clealance Light Indicator …………………………………………….1-12
Lever Steering Indicator (Optional) …………………………..1-13
Maintenance Indicator ………………………………………………..1-13
Forward/reverse Selector Switch Indicator ………………1-13
Monitor Display …………………………………………………………………..1-14

Forward/Reverse and Selection Gear Indicator ……….1-15
FNR(Forward/Reverse) Position Indicator …………………1-15
Hold Indicator ……………………………………………………………….1-16
Selection Gear Indicator ……………………………………………..1-16
Speedometer ………………………………………………………………..1-17
Automatic Mode Indicator ………………………………………….1-18
Ride Control Indicator ………………………………………………….1-19
Clutch Cut Position Indicator ……………………………………..1-19
Machine Information Display ……………………………………..1-20
Clock Setting Mode …………………………………………………………..1-25
Switches, Steering Wheel and Pedals ………………………………1-26
Forward/Reverse Lever/Shift Switch …………………………1-27
Neutral Lever Lock (Forward/Reverse Lever) ……………1-28
Horn Switch ………………………………………………………………..1-28
Turn Signal Lever ………………………………………………………….1-28
Light Switch …………………………………………………………………..1-29
High-low Beam Switch ………………………………………………..1-30
Key Switch ……………………………………………………………………..1-30
Windshield Wiper Switch …………………………………………….1-31
Rear Window Wiper Switch …………………………………………1-31
Hazard Switch ……………………………………………………………….1-32
Work Light Switch ………………………………………………………..1-33
Driving Mode Switch ……………………………………………………1-34
Clutch Cut Position Switch ………………………………………….1-35
Work Mode Switch ……………………………………………………….1-35
Parking Brake Switch ……………………………………………………1-36
Accelerator Pedal ………………………………………………………………..1-37
Brake Pedal ………………………………………………………………………….1-37
Steering Column Tilt & Telescopic Lever …………………………1-37
Air Conditioner Operation ………………………………………………..1-38
Auto Air conditoner ……………………………………………………………1-39
Defroster Operation …………………………………………………………..1-44
Tips for Optimal Air Conditioner Usage ………………………….1-45
Right Console/Switches …………………………………………………….1-46
Loader Control Lever ………………………………………………………….1-47
Front Control Lever Lock ……………………………………………………1-50
Armrest Adjust Handle ………………………………………………………1-50
Finger Type ………………………………………………………………………….1-51
Hold Switch ……………………………………………………………………1-51
DSS/USS (Down Shift/ Up Shift) Switch …………………….1-51
DSS (Down Shift) Switch ……………………………………………..1-51
Multi-function Type ……………………………………………………………1-52
Hold Switch ……………………………………………………………………1-52
DSS (Down Shift) Switch ……………………………………………..1-52
USS (Up Shift) Switch …………………………………………………..1-52
Right Console Switch Panel ………………………………………………1-53
Quick Coupler Switch (Optional) ……………………………….1-53
Lift Arm Auto Lever Switch (Optional) ………………………1-54
Forward/Reverse Selector Switch ………………………………1-55
Ride Control Switch (Optional) …………………………………..1-56
Fog Lamp Switch (Optional) ……………………………………….1-57
Fan Reversing Switch …………………………………………………..1-57
Emergency Steering Operation Check Switch
(Optional) ………………………………………………………………………1-57
Cigarette Lighter …………………………………………………………..1-58
Ashtray …………………………………………………………………………………1-58
Adjusting Operator’s Seat (Air Suspension Type Seat) ….1-59
Adjusting Operator’s Seat (Mechanical
Suspension Type Seat) …………………………………………………1-63
Adjusting Operator’s Seat …………………………………………………1-66
Seat Belt ……………………………………………………………………………….1-68
Rear Tray ………………………………………………………………………………1-69
Fuse Box ……………………………………………………………………………….1-70
Fuse Box A ……………………………………………………………………………1-71
Fuse Box B ……………………………………………………………………………1-71
Hot&Cool Box ……………………………………………………………………..1-72
Tray and Drink Holder ………………………………………………………..1-72
Rops Cab ………………………………………………………………………………1-73
Front Room Light ……………………………………………………………….1-75
Rear Room Light …………………………………………………………………1-75
Sun Visor ………………………………………………………………………………1-76
Emergency Evacuation Hammer ……………………………………..1-76
Coat Hook ……………………………………………………………………………1-76
AM/FM Radio Operation …………………………………………………..1-77
Digital Clock Setting Procedure ……………………………………….1-78
Upper Switch Panel (Optional) …………………………………………1-79
Front Hot-Wire Heater Switch (Optional) ………………………..1-79
Rear Hot-Wire Heater Switch (Optional) …………………………1-79
Rotary Light Switch (Optional) …………………………………………1-79
Rear View Mirror ………………………………………………………………….1-80
Room Mirror ………………………………………………………………………..1-80
Cab Door ………………………………………………………………………………1-80
Door Lock Knob ………………………………………………………………….1-81
Door Open/Close Lever ……………………………………………………..1-81
Window Open/Close Lever ……………………………………………….1-81
When Fully Opening the Door ………………………………………….1-82
Door Lock Disengage Lever ……………………………………………..1-82
Articulate Lock Bar ……………………………………………………………..1-83
Towing Pin …………………………………………………………………………..1-84
Seat Pocket ………………………………………………………………………….1-84
Tool Box ………………………………………………………………………………..1-84
Inspection/ Maintenance Side Access Cover …………………1-85
Rear Grille …………………………………………………………………………….1-86
Steps …………………………………………………………………………………….1-86
Vandal-Proof Devices …………………………………………………………1-87
BREAK-IN
Observe Engine Operation Closely …………………………………… 2-1
OPERATING THE ENGINE
Check Before Starting ………………………………………………………… 3-1
Starting Engine ……………………………………………………………………. 3-3
Check After Starting …………………………………………………………… 3-5
Using Booster Batteries ………………………………………………………. 3-6
Warming Up Operation ………………………………………………………. 3-8
Warming Up Operation In Cold Weather …………………………. 3-8
Stopping Engine ………………………………………………………………….. 3-9
DRIVING THE MACHINE
Driving Machine ………………………………………………………………….. 4-1
Starting to Move ………………………………………………………………….. 4-2
CONTENTS
Parking Brake Switch …………………………………………………………… 4-5
Drive Speed Change …………………………………………………………… 4-6
Changing Forward/Reverse Drive Direction ……………………. 4-6
Finger Type …………………………………………………………………………… 4-7
Multi-function Type …………………………………………………………….. 4-7
Steering …………………………………………………………………………………. 4-8
Provisional Stop and Restart of Driving ………………………… 4-9
Precautions for Driving on Slopes ……………………………………4-11
Precautions to be Taken if the Machine Failure Occurs ..4-12
Stop/Parking ……………………………………………………………………….4-13
OPERATING THE MACHINE
Loader Control Lever …………………………………………………………… 5-1
Front Control Lever Lock …………………………………………………….. 5-4
Clutch Cut Position Switch …………………………………………………. 5-5
Adjustment of Loader Front ………………………………………………. 5-6
Lift Arm Auto Lever Switch (Optional) ……………………………… 5-7
Adjustment of Bucket Auto Leveler ………………………………….. 5-8
Adjustment of Lift Arm Kick Out ……………………………………….. 5-9
Adjustment of Lift Arm Auto Leveler (Optional) …………….. 5-9
Before Operation ………………………………………………………………..5-10
Precautions for Operation …………………………………………………5-10
Ensure Safety When Operating on Road
Shoulders ………………………………………………………………………5-10
Avoid Overloading ……………………………………………………………..5-11
Avoid Rapid Steering Changes And/or
Sudden Braking …………………………………………………………….5-11
Excavation ……………………………………………………………………………5-12
Digging and Loading Level Ground ………………………………..5-13
Grading ………………………………………………………………………………..5-14
Loading ………………………………………………………………………………..5-15
Dozing ………………………………………………………………………………….5-17
Scooping ……………………………………………………………………………..5-17
Removing Snow …………………………………………………………………5-18
Lifting Wheel Loader ………………………………………………………….5-18
Precautions for after Operations ………………………………………5-19
TRANSPORTING
Transporting by Road …………………………………………………………. 6-1
Transporting by Trailer ……………………………………………………….. 6-1
Loading/Unloading on Trailer ……………………………………………. 6-1
Transporting …………………………………………………………………………. 6-3
Transporting Wheel Loader (Urgent Situation) ………………. 6-4
Towing Method ……………………………………………………………………. 6-7
Lifting Machine ……………………………………………………………………. 6-8
MAINTENANCE
Correct Maintenance and Inspection Procedures ………….. 7-1
Check The Hour Meter Regularly ………………………………………. 7-2
Use Correct Fuels and Lubricants ……………………………………… 7-2
Layout (ZW220, ZW250) ……………………………………………………… 7-3
Layout (ZW310) ……………………………………………………………………. 7-4
Maintenance Guide Table …………………………………………………… 7-5
Preparations for Inspection and Maintenance ……………….. 7-7
Lock Frames ………………………………………………………………………….. 7-8
Inspection/Maintenance Access Side Cover ……………………. 7-9
Rear Grille …………………………………………………………………………….7-10
Periodic Replacement Of Parts …………………………………………7-11
Maintenance Guide ……………………………………………………………7-12
Kind of Oils …………………………………………………………………………..7-18
A. Greasing …………………………………………………………………………..7-21
B. Engine ……………………………………………………………………………..7-26
Check Engine Oil Level ……………………………………………….7-26
Change Engine Oil ……………………………………………………….7-26
Replace Engine Oil Filter ……………………………………………..7-28
C. Power Train ……………………………………………………………………..7-30
Check Transmission Oil Level ……………………………………..7-30
Change Transmission Oil and Transmission Oil Filter …..7-31
Clean Transmission Oil Strainer ………………………………….7-31
Change Axle Oil …………………………………………………………….7-33
Clean Torque Converter Air Breather …………………………7-35
Clean Axle Housing Air Breather ………………………………..7-36
D. Hydraulic System ……………………………………………………………7-37
Inspection and Maintenance of Hydraulic Equipment … 7-37
Check Hydraulic Oil Level ……………………………………………7-38
Change Hydraulic Oil …………………………………………………..7-39
Clean suction filter ……………………………………………………….7-42
Replace Pilot Oil Filter …………………………………………………7-43
Replace Hydraulic Tank Oil Filter ………………………………..7-44
Check Hoses and Lines ………………………………………………..7-45
Service Recommendations for Hydraulic Fittings …..7-48
E. Fuel System …………………………………………………………………….7-50
Check Fuel Level …………………………………………………………..7-50
Drain Water and Sediment from Fuel Tank ……………….7-51
Check and Drain Water Separator ……………………………..7-51
Replace Water Separator Element ……………………………..7-54
Replace Fuel Filter ………………………………………………………..7-56
Clean Fuel Solenoid Pump Strainer …………………………..7-58
Check Fuel Hoses ………………………………………………………….7-59
F. Air Cleaner ………………………………………………………………………..7-60
Clean and Replace Air Cleaner Element ……………………7-60
G. Cooling System ………………………………………………………………7-61
Check Coolant Level …………………………………………………….7-62
Check Fan Belt ………………………………………………………………7-63
Check Fan Belt Tension ………………………………………………..7-63
Adjust Fan Belt Tension ……………………………………………….7-63
Change Coolant ……………………………………………………………7-64
Clean Radiator/Oil Cooler Cores and Other Cooling 7-66
H. Electrical System …………………………………………………………….7-67
Replace Batteries ………………………………………………………….7-70
Check Monitor Functions and All Other
Instrument Operation ………………………………………………….7-71
Check Work Lights ………………………………………………………..7-72
Check Horn and Reverse Buzzer ………………………………..7-72
Check Electrical Harnesses And Fuses ………………………7-73
Fuse Box A ……………………………………………………………………..7-74
Fuse Box B ……………………………………………………………………..7-74
I. Brake System …………………………………………………………………….7-75
Check Right and Left Brake
Interlocking Performance …………………………………………..7-75
Check Parking Brake Force ………………………………………….7-75

Check Accumulator Function, Gas Leakage,
Looseness, And Damage …………………………………………….7-76
Check Gas Pressure In Accumulator ………………………….7-76
Check Brake Disks (Service And Paring) ……………………7-77
J. Tire ……………………………………………………………………………………..7-78
Check And Replace Tire (Tire Pressure)check ………….7-78
Check Tire for Damage ………………………………………………..7-79
Check Wheel Bolt Torque …………………………………………….7-79
K. Air Conditioner ……………………………………………………………….7-83
Clean/Replace Air Conditioner Circulation/Fresh
Air Filters ………………………………………………………………………..7-83
Clean Circulation Air Filter …………………………………………..7-84
Check Air Conditioner ………………………………………………….7-85
Check Air Conditioner Piping ……………………………………..7-85
Check Air Conditioner Condenser ……………………………..7-86
Check Air Conditioner Fan Belt …………………………………..7-86
Check Refrigerant …………………………………………………………7-87
Check Compressor and Pulley ……………………………………7-87
Check Switch Operation ……………………………………………..7-87
L. Miscellaneous ………………………………………………………………….7-88
Check Bucket Teeth and Cutting Edge ……………………..7-88
Check and Replace Seat Belt ………………………………………7-89
Check ROPS Cab, Resin Cab Roof, and Roof
Mounting Bolts …………………………………………………………….7-89
Check Windshield Washer Fluid Level ……………………….7-89
Check Play Amount in Steering Wheel Stroke …………7-90
Check Accelerator Pedal Operation, and
Exhaust Gas Color and Noise ………………………………………7-91
Check Rearview Mirror and Inside Rearview Mirror .7-92
Check Turbocharger Bearing ………………………………………7-92
Check Engine Cylinder Head and Manifold ……………..7-92
Check and Adjust Valve Clearance …………………………….7-92
Check Fuel Injection Timing ……………………………………….7-93
Check Engine Compression Pressure ………………………..7-93
Check and Clean Starter and Generator …………………..7-93
Retighten front Axle and Rear
Axle Support Mounting Bolts ……………………………………7-93
MAINTENANCE UNDER SPECIAL
ENVIRONMENTAL CONDITIONS
Maintenance Under Special Environmental Conditions …….. 9-1
STORAGE
Storing the Machine …………………………………………………………..10-1
Removing the Machine from Storage ……………………………..10-2
TROUBLESHOOTING
Troubleshooting …………………………………………………………………11-1
SPECIFICATIONS
Specifications ………………………………………………………………………12-1
OPTIONAL ATTACHMENTS
Hydraulic Type Quick Coupler Operation ……………………….13-1
Log Grapple Operation ……………………………………………………..13-4
Loading and Unloading …………………………………………………….13-5
Working Position ………………………………………………………………..13-7
Carrying Position ………………………………………………………………..13-7
Picking Up Operation (One Log) ………………………………………13-8
Truck Loading ……………………………………………………………………..13-9
Specifications (Bolt-on Cutting Edge) ………………………….. 13-10
Specifications (Bucket With Teeth) ……………………………….. 13-11
Specifications (Rock Bucket With Teeth) ……………………… 13-12
Specifications (Bolt-on Cutting Edge (Hight-lift Arm)) … 13-13
Specifications (Log Grapple) …………………………………………. 13-14
INDEX …………………………………………………………………………………..14-1

Hitachi