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Hitachi
Compact Loader
ZW220
Hitachi ZW220 User Manual
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1-2
1-
Fr
ont Console
2-
Operator’
s S
eat
3-
Right Console
4-
F
use Box
5-
12
V elec
tric P
ower Output
T
erminal (Optional)
6-
Hot & Cool Box
7-
Rear Defroster
8-
T
ray
9-
Cup Holder
10-
F
loor Mat
11-
Air C
onditioner Foot
Vent
12-
F
ront Defrost
er
M4GB-01-003
53
55
Table of Contents
Table of Contents
9
Safety
13
Recognize Safety Information
13
Understand Signal Words
13
Follow Safety Instructions
14
Prepare for Emergencies
14
Wear Protective Clothing
15
Protect against Noise
15
Inspect Machine
15
General Precautions for Cab
16
Use Handholds and Steps
17
Adjust the Operator's Seat
17
Ensure Safety before Rising from or Leaving Operator's Seat
17
Fasten Your Seat Belt
18
Move and Operate Machine Safely
18
Handle Starting Aids Safely
18
Operate Only from Operator's Seat
19
Jump Starting
19
Investigate Job Site Beforehand
20
Equipment of Head Guard, Rops, Fops
21
Provide Signals for Jobs Involving Multiple Numbers of Machines
21
Keep Riders off Machine
22
Drive Safely
22
Drive Machine Safely (Work Site
23
Drive Safely with Bucket Loaded
23
Drive on Snow Safely
24
Travel on Public Roads Safely
24
Avoid Injury from Rollaway Accidents
25
Avoid Accidents from Backing up and Turning
26
Avoid Positioning Bucket over Anyone
27
Avoid Tipping
27
Never Undercut a High Bank
28
Dig with Caution
28
Perform Truck Loading Safely
28
Avoid Power Lines
29
Precautions for Operation
29
Precautions for Lightening
29
Object Handling
29
Protect against Flying Debris
30
Park Machine Safely
30
Store Attachments Safely
31
Transport Safely
31
Handle Fluids Safely−Avoid Fires
32
Practice Safe Maintenance
33
Warn Others of Service Work
34
Support Machine Properly
34
Stay Clear of Moving Parts
34
Support Maintenance Properly
35
Prevent Parts from Flying
35
Prevent Burns
36
Replace Rubber Hoses Periodically
36
Avoid High-Pressure Fluids
37
Prevent Fires
38
Evacuating in Case of Fire
39
Beware of Exhaust Fumes
39
Precautions for Welding and Grinding
39
Avoid Heating Near Pressurized Fluid Lines
40
Avoid Applying Heat to Lines Containing Flammable Fluids
40
Remove Paint before Welding or Heating
40
Beware of Asbestos Dust
41
Prevent Battery Explosions
41
Service Air Conditioning System Safely
41
Handle Chemical Products Safely
42
Dispose of Waste Properly
42
Safety Signs
43
Components Name
53
Operator's Station
54
Cab Features
54
Front Console
55
Right Console
56
Monitor Panel
57
Stop Indicator
58
Service Indicator
58
Parking Brake Indicator
59
Brake Oil Low Pressure Indicator
59
Brake Oil Low Level Indicator
59
Emergency Steering Indicator (Optional)
59
Low Steering Oil Pressure Indicator (Optional)
60
Seat Belt Indicator
60
Discharge Warning Indicator
60
Engine Warning Indicator
60
Overheat Indicator
61
Engine Oil Low Pressure Indicator
61
Fuel Filter Restriction Indicator
61
Air Filter Restriction Indicator
61
Transmission Warning Indicator
62
Transmission Oil Filter Restriction Indicator
62
Hydraulic Oil Temperature Indicator
62
Transmission Oil Temperature Indicator
62
Engine Coolant Temperature Gauge
63
Transmission Oil Temperature Gauge
63
Fuel Gauge
63
Preheat Lamp
64
Turn Signal Indicator
64
High Beam Indicator
64
Work Light Indicator
64
Clealance Light Indicator
64
Lever Steering Indicator (Optional)
65
Maintenance Indicator
65
Forward/Reverse Selector Switch Indicator
65
Monitor Display
66
FNR (Forward/Reverse) Position Indicator
67
Hold Indicator
68
Shift Position Indicator
68
Speedometer
69
Automatic Mode Indicator
70
Ride Control Indicator
71
Clutch Cut Position Indicator
71
Machine Information Display
72
Clock Setting Mode
77
Switches, Steering Wheel and Pedals
78
Forward/Reverse Lever/Shift Switch
79
Neutral Lever Lock (Forward/Reverse Lever)
80
Horn Switch
80
Turn Signal Lever
80
Light Switch
81
High-Low Beam Switch
82
Key Switch
82
Windshield Wiper Switch
83
Rear Window Wiper Switch
83
Hazard Switch
84
Work Light Switch
85
Driving Mode Switch (ZW180)
86
Clutch Cut Position Switch
88
Work Mode Switch
88
Parking Brake Switch
89
Accelerator Pedal
90
Brake Pedal
90
Steering Column Tilt & Telescopic Lever
90
Air Conditioner Operation
91
Auto Air Conditioner
92
Defroster Operation
97
Tips for Optimal Air Conditioner Usage
98
Right Console/Switches
99
Loader Control Lever
100
Front Control Lever Lock
103
Armrest Adjust Handle
103
Finger Type
104
Hold Switch
104
DSS/USS (down Shift/ up Shift) Switch
104
DSS (down Shift) Switch
104
Multi-Function Type
105
Hold Switch
105
DSS (down Shift) Switch
105
USS (up Shift) Switch
105
Right Console Switch Panel
106
Quick Coupler Switch (Optional)
106
Lift Arm Auto Lever Switch (Optional)
107
Forward/Reverse Selector Switch
108
Ride Control Switch (Optional)
109
Fog Lamp Switch (Optional)
110
Fan Reversing Switch
110
Emergency Steering Operation Check Switch
111
Cigarette Lighter
111
Ashtray
111
Section 1
112
1- Weight Support Adjustment
112
2- Height Adjustment
113
3- Damper Adjustment
113
4- Fore-Aft Position Adjustment
113
5- Inclination Adjustment
114
6- Seat Depth Adjustment
114
7- Armrest Angle Adjustment
114
8- Reclining Angle Adjustment
114
10- Lumbar Support Adjustment
115
11- Seat Heater
115
12- Headrest
115
9- Armrest Adjustment
115
Section 2
116
Adjusting Operator's Seat (Mechanical Suspension Type Seat)
116
2- Height Adjustment
116
3- Inclination Adjustment
117
4- Fore-Aft Depth Adjustment
117
5- Fore-Aft Position Adjustment
117
6- Armrest Angle Adjustment
117
7- Armrest Adjustment
118
8- Reclining Angle Adjustment
118
Seat Belt
119
Rear Tray
120
Fuse Box
121
Hot&Cool Box
123
Tray and Drink Holder
123
ROPS Cab
124
Front Room Light
126
Rear Room Light
126
Coat Hook
127
Emergency Evacuation Hammer
127
Sun Visor
127
AM/FM Radio Operation
128
Digital Clock Setting Procedure
129
Upper Switch Panel (Optional)
130
Front Hot-Wire Heater Switch (Optional)
130
Rear Hot-Wire Heater Switch (Optional)
130
Rotary Light Switch (Optional)
130
Cab Door
131
Door Lock Knob
132
Rear View Mirror
131
Room Mirror
131
Door Open/Close Lever
132
Window Open/Close Lever
132
Door Lock Disengage Lever
133
When Fully Opening the Door
133
Articulate Lock Bar
134
Seat Pocket
135
Tool Box
135
Towing Pin
135
Inspection/ Maintenance Side Access Cover
136
Rear Grille
137
Steps
137
Vandal-Proof Devices
138
Break-In
141
Observe Engine Operation Closely
141
Check before Starting
143
Operating the Engine
143
Starting Engine
145
Check after Starting
147
Using Booster Batteries
148
Finger Type
150
Multi-Function Type
150
Warming up Operation
150
Steering
160
Provisional Stop and Restart of Driving
161
Precautions for Driving on Slopes
163
Precautions to be Taken if the Machine Failure Occurs
164
Stop/Parking
165
Loader Control Lever
169
Operating the Machine
169
Front Control Lever Lock
172
Clutch Cut Position Switch
173
Adjustment of Loader Front
174
Lift Arm Auto Lever Switch (Optional)
175
Adjustment of Bucket Auto Leveler
176
Adjustment of Lift Arm Auto Leveler (Optional)
177
Adjustment of Lift Arm Kick out
177
Before Operation
178
Ensure Safety When Operating on Road Shoulders
178
Precautions for Operation
178
Avoid Overloading
179
Avoid Rapid Steering Changes And/Or Sudden Braking
179
Excavation
180
Digging and Loading Level Ground
181
Grading
182
Loading
183
Dozing
185
Scooping
185
Lifting Wheel Loader
186
Removing Snow
186
Precautions for after Operations
187
Loading/Unloading on Trailer
189
Transporting
189
Transporting by Road
189
Transporting by Trailer
189
Transporting
190
Transporting Wheel Loader (Urgent Situation)
192
Towing Method
198
Lifting Machine
199
Correct Maintenance and Inspection Procedures
201
Maintenance
201
Check the Hour Meter Regularly
202
Use Correct Fuels and Lubricants
202
Layout
203
Maintenance Guide Table
206
Preparations for Inspection and Maintenance
208
Lock Frames
209
Inspection/Maintenance Access Side Cover
210
Rear Grille
211
Periodic Replacement of Parts
212
Maintenance Guide
213
Kind of Oils
219
Greasing
222
Engine
228
Check Engine Oil Level
228
Change Engine Oil
228
Replace Engine Oil Filter
230
Power Train
233
Check Transmission Oil Level
233
Change Transmission Oil and Transmission Oil Filter
234
Clean Transmission Oil Strainer
234
Change Axle Oil
236
Clean Torque Converter Air Breather
238
Clean Axle Housing Air Breather
239
Hydraulic System
240
Inspection and Maintenance of Hydraulic Equipment
240
Check Hydraulic Oil Level
241
Change Hydraulic Oil
242
Clean Suction Filter
245
Replace Pilot Oil Filter
246
Replace Hydraulic Tank Oil Filter
247
Check Hoses and Lines
248
Service Recommendations for Hydraulic Fittings
251
Fuel System
253
Check Fuel Level
253
Drain Water and Sediment from Fuel Tank
254
Check and Drain Water Separator
254
Replace Fuel Main Filter
258
Replace Fuel Pre-Filter
260
Clean Fuel Solenoid Pump Strainer
262
Check Fuel Hoses
263
Air Cleaner
264
Clean and Replace Air Cleaner Element
264
Cooling System
265
Check Coolant Level
267
Check Fan Belt
268
Check Fan Belt Tension
268
Adjust Fan Belt Tension
268
Change Coolant
269
Clean Radiator/Oil Cooler Cores and Other Cooling System
273
Electrical System
274
Replace Batteries
277
Check Monitor Functions and All Other Instrument Operation
278
Check Work Lights
279
Check Horn and Reverse Buzzer
279
Check Electrical Harnesses and Fuses
280
Brake System
282
Check Right and Left Brake Interlocking Performance
282
Check Parking Brake Force
282
Check Accumulator Function, Gas Leakage, Looseness, and Damage
283
Check Gas Pressure in Accumulator
283
Check Brake Disks (Service and Paring)
284
Tire
285
Check and Replace Tire (Tire Pressure) Check
285
Check Tire for Damage
286
Check Wheel Bolt Torque
286
Air Conditioner
290
Clean/Replace Air Conditioner Circulation/Fresh Air Filters
290
Check Air Conditioner
292
Check Air Conditioner Piping
292
Check Air Conditioner Condenser
293
Check Air Conditioner Fan Belt
293
Check Refrigerant
294
Check Compressor and Pulley
294
Check Switch Operation
294
Miscellaneous
295
Check Bucket Teeth and Cutting Edge
295
Check and Replace Seat Belt
296
Check ROPS Cab, Resin Cab Roof, and Roof Mounting Bolts
296
Check Windshield Washer Fluid Level
296
Check Play Amount in Steering Wheel Stroke
297
Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise
298
Check Rearview Mirror and Inside Rearview Mirror
299
Check Turbocharger Bearing
299
Check Engine Cylinder Head and Manifold
299
Check and Adjust Valve Clearance
299
Check Fuel Injection Timing
300
Check Engine Compression Pressure
300
Check and Clean Starter and Generator
300
Retighten Front Axle and Rear Axle Support Mounting Bolts
300
Tightening and Retightening Torque of Nuts and Bolts
301
Maintenance under Special Environmental Conditions
315
Storing the Machine
319
Removing the Machine from Storage
320
Troubleshooting
321
Specifications
325
Sound Level Results (2000/14/Ec)
326
Optional Attachments
327
Specifications
327
Index
331
5
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Hitachi ZW220 Specifications
General
Brand
Hitachi
Model
ZW220
Category
Compact Loader
Language
English
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