Hitachi ZW 220 250 310 Wheel Loader Operator’s Manual
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Hitachi ZW 220 250 310 Wheel Loader Operator’s Manual
Language : English
Pages : 330
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Part No : EM4GB-1-1
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Table of Contents:
Hitachi ZW 220 250 310 Wheel Loader Operator’s Manual
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
Description:
Hitachi ZW 220 250 310 Wheel Loader Operator’s Manual
- Read this manual carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or machine damage. This manual should be considered a permanent part of your machine and should remain with the machine when you sell it. This machine is of metric design. Measurements in this manual are metric. Use only metric hardware and tools as specified.
- • SI Units (International System of Units) are used in this manual. For reference MKS system units and English units are also indicated in parentheses after the SI units. Example : 24.5 MPa (250 kgf/cm2, 3560 psi) Right-hand and left-hand sides are determined by facing in the direction of forward travel. Write product identification numbers in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts.
- If this manual is kept on the machine, also file the identification numbers in a secure place off the machine. Warranty is provided as a part of Hitachi’s support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate which you should have received from your dealer.
- This warranty provides you the assurance that Hitachi will back its products where defects appear within the warranty period. In some circumstances, Hitachi also provides field improvements, often without charge to the customer, even if the product is out of warranty. Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.
- Only qualified, experienced operators officially licensed (according to local law) should be allowed to operate the machine. Moreover, only officially licensed personnel should be allowed to inspect and service the machine.
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
Kace Kenzo –
Very good experience.