Hitachi ZW 65 User manual

65
75
95
EM4L2-EN1-2ZW65 • ZW75 • ZW95 WHEEL LOADER OPERATOR’S MANUAL
URL:http://www.hitachi-c-m.com
EM4L2-EN1-2
PART NO.
Wheel Loader
Operator's Manual
PRINTED IN THE NETHERLANDS 2012, 10
Serial No.
ZW65 000101 and up
ZW75 000101 and up
ZW95 000101 and up

©2012 Hitachi Construction Machinery Co., Ltd.
All rights reserved.
INTRODUCTION
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 standard specification machine can be operated
under the following conditions without being modified.
Atmospheric Temperature: -20 °C to 40 °C (-4 °F to 104 °F)
Altitude: 0 m to 2000 m (0 ft to 6600 ft)
In case the machine is used under conditions other than
described above, consult your nearest Hitachi dealer.
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.
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.
Use only diesel fuel with quality specified in JIS K-2204,
EN-590, ASTM D-975, GOST R52368 or GB252.
Failure to use diesel fuel with quality as specified
above may allow the engine to emit exhaust gas which
cleanness can not conform to the requests in various
relevant regulations. In addition, serious damage to the
engine may result. Consult with your nearest Hitachi
dealer for detailed information.
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 with 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.
The EC Declaration of conformity includes the machine
without equipment unless fitted with equipments
approved by TCM Corporation. Refer to enclosed list for
approved equipments. TCM Corporation will not cover
conformity of machines fitted with OEM equipments.
All information, illustrations and specifications in this manual are based on the latest product information available at the
time of publication. The right is reserved to make changes at any time without notice.
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INDEX
EM4L2-EN1-2
SAFETY SIGNS
COMPONENTS NAME
OPERATOR’S STATION
BREAK-IN
OPERATING ENGINE
DRIVING MACHINE
OPERATING MACHINE
TRANSPORTING
MAINTENANCE
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
STORAGE
TROUBLESHOOTING
SPECIFICATIONS
SAFETY
MACHINE NUMBERS
ENGINE EMISSION CONTROL LABEL
OPTIONAL ATTACHMENT
OTHERS
INDEX
GETTING ON/OFF THE MACHINE
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CONTENTS
ENGINE EMISSION CONTROL LABEL .......................................1
EC Emission Control Label: Engine Label....................................1
MACHINE NUMBERS .......................................................................3
SAFETY ..............................................................................................S-1
Recognize Safety Information ...................................................S-1
Understand Signal Words ............................................................S-1
Follow Safety Instructions ...........................................................S-2
Prepare for Emergencies ..............................................................S-3
Wear Protective Clothing .............................................................S-3
Protect Against Noise ...................................................................S-4
Inspect Machine .............................................................................S-4
General Precautions for Cab .......................................................S-5
Use Handrails and Steps ..............................................................S-6
Never Ride Attachment.................................................................S-6
Adjust Operator’s Seat ..................................................................S-6
Ensure Safety Before Rising from or
Leaving Operator’s Seat ..........................................................S-7
Fasten Your Seat Belt .....................................................................S-7
Move and Operate Machine Safely ..........................................S-8
Handle Starting Aids Safely ........................................................S-8
Operate Only from Operator’s Seat .........................................S-9
Jump Starting ..................................................................................S-9
Investigate Job Site Beforehand ............................................S-10
Equipment of Head Guard, ROPS, FOPS ..............................S-11
Provide Signals for Jobs Involving Multiple Machines ...S-11
Keep Riders Off Machine ..........................................................S-12
Drive Safely .................................................................................... S-12
Drive Machine Safely (Work Site) ........................................... S-13
Drive Safely with Bucket Loaded ........................................... S-14
Drive on Snow Safely .................................................................. S-14
Travel on Public Roads Safely .................................................. S-15
Avoid Injury from Rollaway Accidents .................................S-15
Avoid Accidents from Backing Up and Turning ...............S-16
Avoid Positioning Bucket or Attachment
Over Anyone ............................................................................ S-17
Avoid Tipping ................................................................................S-17
Never Undercut a High Bank ................................................... S-18
Dig with Caution .......................................................................... S-18
Perform Truck Loading Safely ................................................. S-18
Avoid Power Lines .......................................................................S-19
Precautions for Operation ........................................................S-19
Precautions for Lightning ......................................................... S-19
Object Handling .......................................................................... S-20
Protect Against Flying Debris .................................................S-20
Park Machine Safely .................................................................... S-21
Store Attachments Safely .........................................................S-21
Transport Safely ...........................................................................S-22
Handle Fluids Safely−Avoid Fires ...........................................S-23
Practice Safe Maintenance .......................................................S-24
Warn Others of Service Work .................................................. S-25
Support Machine Properly .......................................................S-25
Stay Clear of Moving Parts ....................................................... S-26
Support Maintenance Properly ..............................................S-26
Prevent Parts from Flying ......................................................... S-27
Prevent Burns ................................................................................ S-27
Replace Rubber Hoses Periodically ....................................... S-28
Avoid High-Pressure Fluids ...................................................... S-28
Prevent Fires ..................................................................................S-29
Evacuating in Case of Fire ......................................................... S-30
Beware of Exhaust Fumes .........................................................S-30
Precautions for Welding and Grinding ................................S-30
Avoid Heating Near Pressurized Fluid Lines ......................S-31
Avoid Applying Heat to Lines Containing
Flammable Fluids ................................................................... S-31
Remove Paint Before Welding or Heating ..........................S-31
Beware of Asbestos and Silicon Dust and Other
Contamination......................................................................... S-32
Prevent Battery Explosions ...................................................... S-32
Service Air Conditioning System Safely .............................. S-33
Handle Chemical Products Safely .......................................... S-33
Dispose of Waste Properly ........................................................S-34
SAFETY SIGNS ............................................................................. S-35
COMPONENTS NAME .................................................................1-1
Components Name ........................................................................1-1
Cab Vehicle...................................................................................1-1
GETTING ON/OFF THE MACHINE ...........................................1-2
OPERATOR’S STATION ................................................................1-3
Cab Features......................................................................................1-3
Front Console....................................................................................1-4
Right Console....................................................................................1-5
Multi-function Type...................................................................1-5
Monitor Panel ...................................................................................1-6
STOP Indicator (Red) ......................................................................1-7
Service Indicator (Yellow).............................................................1-7
Parking Brake Indicator (Red)......................................................1-8
Brake Oil Low Level Indicator (Red)..........................................1-8
Seat Belt Indicator...........................................................................1-8
Discharge Warning Indicator (Red)...........................................1-8
Overheat Indicator (Red) ..............................................................1-9
Engine Oil Low Pressure Indicator (Red).................................1-9
Air Filter Restriction Indicator (Red)..........................................1-9
Engine Coolant Temperature Gauge.....................................1-10
Fuel Gauge......................................................................................1-10
Preheat Lamp (Yellow)................................................................1-11
Turn Signal Indicator (Green)...................................................1-11
High-beam Indicator (Blue) ......................................................1-11
Work Light Indicator (Yellow)...................................................1-11
Clearance Light Indicator (Green) ..........................................1-11
Monitor Display.............................................................................1-12
F-N-R and Shift Position Indicator..........................................1-13
F-N-R (Forward / Reverse) Position Indicator................1-13
Shift Position Indicator..........................................................1-13
Speedometer.................................................................................1-14
Ride Control Indicator.................................................................1-14
Information Display.....................................................................1-15
Shifting Item to be Indicated on
Machine Information Display.............................................1-16
Hour Meter................................................................................1-16
Odometer ..................................................................................1-16
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CONTENTS
Fault Code..................................................................................1-17
Switches, Steering Wheel and Pedals....................................1-18
Steering Wheel..............................................................................1-19
Horn Switch....................................................................................1-19
Turn Signal Switch........................................................................1-19
Light Switch....................................................................................1-20
High-low Beam Switch...............................................................1-21
Hazard Switch................................................................................ 1-22
Front Work Light Switch (Optional) .......................................1-23
Rear Work Light Switch ..............................................................1-24
Front Wiper Switch....................................................................... 1-25
Front Washer Switch....................................................................1-25
Rear Wiper / Washer Switch......................................................1-26
Heated Rear Window Switch....................................................1-27
Handling of Heater ......................................................................1-28
Blower Switch ................................................................................1-28
Heater Switch.................................................................................1-28
Front Window Defroster / Front and Foot Air Vent...........1-28
Accelerator Pedal..........................................................................1-29
Brake / Inching Pedal ..................................................................1-29
Steering Column Tilt Lever........................................................ 1-29
Parking Brake Lever.....................................................................1-30
Right Console / Switch Panel ...................................................1-31
Key Switch.......................................................................................1-32
External Power Source................................................................1-32
Ride Control Switch (Optional)................................................1-33
Ride Control Operation.........................................................1-33
Right Console (Front Attachment).........................................1-34
Multi-function Type................................................................1-34
Loader Control Lever (Multi-function Joystick Type).......1-35
F-N-R Switch...................................................................................1-36
Shift Switch.....................................................................................1-36
Loader Control Lever Lock ........................................................ 1-37
Armrest Adjust Handle...............................................................1-37
Adjusting Operator’s Seat (Suspension Type)....................1-38
Components Name................................................................1-38
Seat Belt...........................................................................................1-40
Seat Pocket .....................................................................................1-40
Fuse Box...........................................................................................1-41
Fuse Box A .................................................................................1-42
Fuse Box B..................................................................................1-42
Tray and Drink Holder.................................................................1-43
ROPS Cab.........................................................................................1-44
Room Light ..................................................................................... 1-45
Sun Visor..........................................................................................1-45
Coat Hook .......................................................................................1-45
Outside Rear View Mirror...........................................................1-45
Cab Door..........................................................................................1-46
Left Door Open / Close Lever................................................... 1-46
Right Door Open / Close Lever................................................ 1-46
When Fully Opening Door ........................................................1-47
Door Lock Disengage Lever......................................................1-47
Articulation Lock Bar...................................................................1-48
Towing Pin ......................................................................................1-48
Engine Hood ..................................................................................1-49
Step ...................................................................................................1-49
Tool Box............................................................................................1-50
Vandal-proof Devices..................................................................1-51
BREAK-IN .........................................................................................2-1
Observe Engine Operation Closely...........................................2-1
OPERATING ENGINE ...................................................................3-1
Inspect Machine Daily Before Starting....................................3-1
Check Before Starting....................................................................3-3
Starting Engine ................................................................................3-5
Check After Starting .......................................................................3-7
Using Booster Batteries.................................................................3-8
Warming Up Operation..............................................................3-10
Warming Up Operation in Cold Weather.............................3-11
Stopping Engine...........................................................................3-12
DRIVING MACHINE ......................................................................4-1
Driving Machine ..............................................................................4-1
Starting to Move..............................................................................4-2
Parking Brake Lever........................................................................4-4
Drive Speed Change.......................................................................4-5
Changing Forward / Reverse Drive Direction........................4-5
Steering...............................................................................................4-6
Provisional Stop and Restart of Driving ..................................4-7
Precautions for Driving on Slopes..........................................4-10
Precautions to be Taken If Machine
Failure Occurs...........................................................................4-11
Stop ...................................................................................................4-12
Parking ............................................................................................. 4-13
Emergency Evacuation...............................................................4-15
OPERATING MACHINE ................................................................5-1
Loader Control Lever (Multi-function Type) ..........................5-1
Loader Control Lever Lock ...........................................................5-2
Hydraulic Quick Coupler Operation .........................................5-3
Before Operation.............................................................................5-6
Precautions for Operation............................................................5-6
Ensure Safety when Operating on Road Shoulders............5-6
Avoid Overloading..........................................................................5-7
Avoid Rapid Steering Changes
and / or Sudden Braking .........................................................5-7
Avoid Operation with Biased Loads .........................................5-7
Excavation..........................................................................................5-8
Grading ............................................................................................5-10
Loading............................................................................................ 5-11
Dozing..............................................................................................5-14
Scooping .........................................................................................5-14
Removing Snow............................................................................5-15
Lifting Wheel Loader...................................................................5-15
Precautions for After Operations............................................5-16
TRANSPORTING ............................................................................6-1
Transporting by Road ....................................................................6-1
Transporting by Trailer ..................................................................6-1
Loading / Unloading on Trailer...................................................6-1
Transporting......................................................................................6-3
Transporting (Urgent Situation).................................................6-4
Towing Method................................................................................6-7
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CONTENTS
Lifting Machine ................................................................................6-8
MAINTENANCE ..............................................................................7-1
Correct Maintenance and Inspection Procedures ..............7-1
Check Hour Meter Regularly ......................................................7-2
Use Correct Fuels and Lubricants .............................................7-2
Layout .................................................................................................7-3
Maintenance Guide Table ............................................................7-4
Preparations for Inspection and Maintenance ....................7-5
Lock Frames ......................................................................................7-6
Maintenance Side Cover ..............................................................7-7
Engine Hood ....................................................................................7-8
Periodic Replacement of Parts ...................................................7-9
Maintenance Guide ....................................................................7-10
Kind of Oils ..................................................................................... 7-16
A. Greasing ..................................................................................... 7-19
B. Engine .........................................................................................7-22
Check Engine Oil Level .........................................................7-22
Change Engine Oil .................................................................7-23
Replace Engine Oil Filter ......................................................7-25
C. Power Train ...............................................................................7-26
Change Transmission Oil .....................................................7-26
Change Axle Oil ......................................................................7-27
Clean Transmission Air Breather .......................................7-29
Check Surrounding Areas Around Axles and
Covers for Oil Leaks ..........................................................7-30
Clean Axle Housing Air Breather ......................................7-30
D. Hydraulic System ....................................................................7-31
Inspection and Maintenance of Hydraulic Equipment ..7-31
Check Hydraulic Oil Level ...................................................7-32
Change Hydraulic Oil / Clean Hydraulic Oil Tank ........7-33
Clean Suction Filter ...............................................................7-35
Replace HST Oil Filter Element ..........................................7-36
Replace Return Filter .............................................................7-38
Check Hoses and Lines ........................................................7-40
E. Fuel System ............................................................................... 7-43
Check Fuel Level .....................................................................7-43
Drain Water and Sediment from Fuel Tank ...................7-44
Check and Drain Water from Fuel Pre-Filter .................7-45
Clean Fuel Pre-Filter Element ............................................7-46
Replace Fuel Filter Element ................................................7-47
Check Fuel Hose .....................................................................7-48
F. Air Cleaner ..................................................................................7-49
Clean and Replace Air Cleaner Element ........................7-49
G. Cooling System .......................................................................7-50
Check Coolant Level ............................................................. 7-52
Check Fan Belt ......................................................................... 7-53
Check Fan Belt Tension ........................................................7-53
Adjust Fan Belt Tension ........................................................7-53
Change Coolant ......................................................................7-54
Clean Radiator and Oil Cooler ...........................................7-55
H. Electrical System ..................................................................... 7-56
Check Monitor Function and All Other Instrument
Operation ............................................................................7-56
Check Work Lights .................................................................7-57
Check Horn and Backup Buzzer.........................................7-57
Check Electrical Harnesses and Fuses ............................7-58
Check Electrolyte Level ........................................................7-64
Check Electrolyte Specific Gravity ................................... 7-65
I. Brake System ..............................................................................7-66
Check Brake Oil Level ...........................................................7-66
Check Right and Left Brake Interlocking
Performance .......................................................................7-67
Check Parking Brake Force .................................................7-68
Check Service Brake...............................................................7-68
Change Brake Oil ....................................................................7-68
J. Tire .................................................................................................7-69
Check and Adjust Tire Pressure .........................................7-69
Check Tire for Damage .........................................................7-70
Check Wheel Bolt Torque ....................................................7-70
Removal and Installation of Tire........................................7-73
Tire Wheel .................................................................................7-74
K. Heater .........................................................................................7-75
Check Heater for Any Damage ..........................................7-75
Check Heater Piping .............................................................7-75
L. Miscellaneous ...........................................................................7-76
Check Bucket Teeth for Tightness and / or Wear ........7-76
Check and Replace Seat Belt ..............................................7-77
Check Cab for Damage and Mounting Bolts
for Tightness .......................................................................7-77
Check Windshield Washer Fluid Level
(Cab Vehicle) .......................................................................7-77
Check Play in Steering Wheel Stroke ..............................7-78
Check Accelerator Pedal Operation, and
Exhaust Gas Color and Noise .......................................7-79
Check Rearview Mirror and Inside Rearview Mirror .. 7-80
Check Steps and Handrails for Damage
and Tightness .....................................................................7-80
Clean Engine Compartment and Hood ......................... 7-80
Check and Adjust Valve Clearance ...................................7-81
Check Sound Absorbing Mat Around Engine .............7-81
Check Fuel Injection Timing ...............................................7-81
Check Engine Compression Pressure ............................. 7-82
Check and Clean Starter and Alternator ........................7-82
Retighten Front Axle, Rear Axle and Transmission
Mounting Nuts .................................................................. 7-82
Tightening and Retightening Torque of Nuts
and Bolts ................................................................................... 7-83
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL
CONDITIONS ...................................................................................9-1
Maintenance Under Special Environmental
Conditions....................................................................................9-1
Precautions for Maintenance During
Cold Weather Season................................................................9-2
STORAGE .......................................................................................10-1
Storing the Machine....................................................................10-1
Removing the Machine from Storage...................................10-2
TROUBLESHOOTING ................................................................11-1
Troubleshooting ........................................................................... 11-1
SPECIFICATIONS ........................................................................12-1
Specifications.................................................................................12-1
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CONTENTS
Sound Level Results (2000/14/EC) .........................................12-2
Vibration Level...............................................................................12-2
OPTIONAL ATTACHMENT ......................................................13-1
Specifications (With Fork Attachment).................................13-1
OTHERS ..........................................................................................14-1
Pallet Forks (ZW65, 75, 95) ........................................................14-1
INDEX ..............................................................................................15-1
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1
EC Emission Control Label: Engine Label
M4FG-00-003
ZW65/ZW75
ZW95
ENGINE EMISSION CONTROL LABEL
M4L2-00-002
M4L2-00-003
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ENGINE EMISSION CONTROL LABEL
2
MEMO
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