Hitachi ZW220-250 Wheel Loader Workshop +Operational Principle+Troubleshooting+Parts Catalog Manual
FILE DETAILS:
Hitachi ZW220-250 Wheel Loader Workshop +Operational Principle+Troubleshooting+Parts Catalog Manual
This Listing includes all of the manuals mentioned below:
1.Hitachi ZW220 250 Wheel Loader Troubleshooting Technical Manual
2.Hitachi ZW220 250 Wheel Loader (Standard Specification) Workshop Manual
3.Hitachi ZW220 250 Wheel Loader (EU Specification) Workshop Manual
4.Hitachi ZW 220 Wheel Loader Parts Catalog Manual
5.Hitachi ZW 220 Equipment Components Parts Catalog Manual
6.Hitachi ZW 220 250 Wheel Loader Operational Principle Technical Manual
7.Hitachi ZW 220 250 310 Wheel Loader Operator’s Manual
8.Hitachi ZW 220 250 310 Transmission Control (TCM Transmission)
9.Hitachi ZAxis 200.200LC 200E.200LC-E 210.210LC 210H.210LCH 240 Excavator Parts Catalog Manual
10.Hitachi ZW 250 Wheel Loader Parts Catalog Manual
11.Hitachi ZW220 250 Wheel Loader (EU Specification) Workshop Manual w4GB-E-00
DESCRIPTION:
Hitachi ZW220-250 Wheel Loader Workshop +Operational Principle+Troubleshooting+Parts Catalog Manual
INTRODUCTION:
TO THE READER:
• 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.
ADDITIONAL REFERENCES:
• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION:
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for 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 ZW220-250 Wheel Loader Workshop +Operational Principle+Troubleshooting+Parts Catalog Manual
Hitachi ZW 220 250 310 Wheel Loader Operator’s Manual
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
CONTENTS
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
CONTENTS
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 ZW 220 250 Wheel Loader Operational Principle Technical Manual
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic
Oil Tank
SECTION 2 BASE MACHINE (UPPER
STRUCTURE)
Group 1 Cab
Group 2 Counterweight
Group 3 Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Pilot Valve
Group 7 Ride Control Valve
Group 8 Pilot Shutoff Valve
Group 9 Hydraulic Fan Motor
SECTION 3 BASE MACHINE (TRAVEL
SYSTEM)
Group 1 Tire
Group 2 Drive Unit
Group 3 Axle
Group 4 Propeller Shaft
Group 5 Brake Valve
Group 6 Charging Block
Group 7 Steering Pilot Valve
Group 8 Steering Valve
Group 9 Steering Cylinder
Group 10 Emergency Steering Pump Unit
(Optional)
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
Hitachi ZW 220 Wheel Loader Parts Catalog Manual
MEMORANDAM
FOREWORD
CONTENTS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
EXHAUST SYSTEM
ELECTRICAL
DRIVE AXLE
PROPELLER SHAFT
TRANSMISSION
TORQUE CONVERTER
STEERING COLUMN
TIRE
POWER STEERING
BRAKE
FRAME
COUNTER WEIGHT
COVER
FLOOR BOARD
AIR CONDITIONER
CAB
SEAT
COCKPIT
MAIN PUMP
VALVE
PILOT PIPING
OIL TANK
MAIN PIPING
GREASE PIPING
TORQUE CONVERTER PIPING
LIFT ARM CYLINDER
BUCKET CYLINDER
LIFT ARM
BUCKET
DECAL
TOOLS
ROAD HOMOLOGATION SPECIFICATION
PARTS INDEX
Hitachi ZW220 250 Wheel Loader (EU Specification) Workshop Manual w4GB-E-00
SECTION 1 GENERAL
Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
Group 2 ECM System
Group 3 Hydraulic System
Group 4 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Control Valve
Group 3 Hydraulic Fan Motor
Group 4 Steering Pilot Valve
Group 5 Steering Valve
Group 6 Pilot Valve
Group 7 Charging Block
Group 8 Ride Control Valve
Group 9 Drive Unit
Group 10 Axle
Group 11 Brake Valve
Group 12 Others
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PERFORMANCE
TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Wheel Loader Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Dr. ZX
Group 3 e-Wheel
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Troubleshooting C
Group 8 Electrical System Inspection
Hitachi ZW220 250 Wheel Loader Troubleshooting Technical Manual
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil
Tank
SECTION 2 BASE MACHINE (UPPER
STRUCTURE)
Group 1 Cab
Group 2 Counterweight
Group 3 Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Pilot Valve
Group 7 Ride Control Valve
Group 8 Pilot Shutoff Valve
Group 9 Hydraulic Fan Motor
SECTION 3 BASE MACHINE (TRAVEL
SYSTEM)
Group 1 Tire
Group 2 Drive Unit
Group 3 Axle
Group 4 Propeller Shaft
Group 5 Brake Valve
Group 6 Charging Block
Group 7 Steering Pilot Valve
Group 8 Steering Valve
Group 9 Steering Cylinder
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
VIDEO PREVIEW OF THE MANUAL:
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PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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Josue Jon –
I have only had one issue with a manual and that was it downloaded in Spanish. Not much good to me but I did get the English version at no charge.
Foster –
Looks good….haven’t used it yet