Hitachi ZW220, ZW250, ZW310 Serial No. 005101 and up Wheel Loader Operator's Manual EM4GB-1-1

CONTENTS

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

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