Hitachi Authorized

180/220
Dealer Use Only

SALES MANUAL
WHEEL LOADER
Model: ZW180-5A
Engine Power : 128 kW
Operating Weight : 14 370 - 14 860 kg
Bucket Capacity (ISO Heaped): 2.2 - 3.3 m3

Model: ZW220-5A
Engine Power : 144 kW
Operating Weight : 16 810 - 17 450 kg
Bucket Capacity (ISO Heaped): 2.7 - 4.4 m3

*The copyright of this manual belongs to Hitachi Construction Machinery.

Hitachi Construction Machinery Co., Ltd. PL-EN060P 17.03 (- / -) *This manual must never be given to customers. Any use of the drawings etc. or expressions used in this manual cannot be used in any advertisement.
*Photos, names, and data shown in this manual may differ from the final specification of the models.
 Major Sales Points of ZW-5A Series

For Managers and Owners For Operators

Sales Sales
Point 10 % Fuel Saving* Brochure Pg. 4-5
Point Operator-Friendly Features to Improve Operator Comfort Brochure Pg. 8-9

The “Active Engine Control System” is effective especially in sites with “large workloads” or “a long There are a variety of features inside the cab to provide an environment that is comfortable to be in
distance drive”, or sites that are “lacking in experienced operators.” Even if the operator has little preventing operator fatigue.
experience, this system provides assistance to actually run the machine in a way that is closer to that of
an experienced operator, achieving a greater fuel economy.
Cab with clear visibility
Mechanical suspension seat that limits shaking
Quick Power Switch (QPS) Fully automatic air conditioner with bi-level function
10 %* Active Engine A variety of storage spaces
Fuel Saving Control System New Transmission
with 5 Speed Gears A rearview monitor for checking safety (optional)
ROPS/FOPS Cab for increased safety (optional)
* Though 10% fuel saving is confirmed, further fuel saving (17-25%) is anticipated (See the sales manual
Pg.15 for the details).

Sales Sales
Point Simplified Maintenance Brochure Pg. 10
Point Enhanced Controllability Brochure Pg. 6-7

A variety of measures have been taken in order to reduce maintenance costs. Some of these features are ZW's highly-acclaimed operability has been improved further, such as those shown below.
shown below.

Equipment layout for better accessibility

Improvement of fresh air filter function
A frame structure with torsional strength and excellent durability
Powertrain with excellent durability and reliability
Self-reversing cooling fan (optional)
Pre-cleaner to prolong the cleaning interval of air cleaners
(optional)
Wide fin pitch radiator for dusty environment (optional) Increased efficiency with the parallel Speed-responding clutch cut-off for Ride control for reducing pitching and
tandem circuit smooth loading bouncing (optional)

Sales
Point Proven Support System Brochure Pg. 11

HCM provides an excellent support system; our

full-package service menu “ConSite (Consolidated
Solution for Construction Site) allows customers to
select from a variety of service options.

Lift arm restriction valve for reducing Control levers for easy operation Lift arm auto leveler stopping at preset
shocks height (optional)

2 ZW180/220-5A 3
 ZW180/220-5A

CONTENTS

I Introduction

Target-based Sales Points .................................................................... Pg.6

Features of ZW-5A ................................................................................. Pg.8

II Product Features

Chapter 1: Fuel Economy....................................................................... Pg.10

Chapter 2: Operability............................................................................ Pg.14

Chapter 3: Comfort................................................................................. Pg.20

Chapter 4: Maintenance/Durability......................................................... Pg.26

III Appendix

Setting Procedures for Demonstration Ride .......................................... Pg.30

Attachment Data .................................................................................... Pg.36

Photo Comparison between ZW-5A and Conventional ZW ................... Pg.38

Specification Comparison ..................................................................... Pg.40

Demo : Please explain the benefit/function and let customer feel it at a demonstration ride.

4 ZW180/220-5A 5
The photos used in this sales manual may include wheel loaders with optional equipment.
 Target-based Sales Points I. Introduction

This section narrows down important sales points and other sales points that is likely to interest customers according
to machines owned by customers / targets.
In particular, items marked are very important sales points which should be emphasized during sales activities.

Machines Owned by Customers Machines Owned by Customers

Old Models Old Models

Machines Complying Machines Complying
: Major sales point against the machine they currently own (Not complying Page : Major sales point against the machine they currently own (Not complying Page
with Tier 3 * with Tier 3 *
: Sales point that is highly likely to interest customers with Tier 3) : Sales point that is highly likely to interest customers with Tier 3)

Owners Operators Owners Operators Owners Operators Owners Operators

Chapter 1: Fuel Economy Chapter 3: Comfort

1.  Technology to cut fuel consumption Pg.10 1. Accessibility to the cab Pg.20

2. Causes for fuel consumption performance to drop Pg.10 2. Spacious and comfortable cab Pg.21

3. Active engine control Pg.11 3. Excellent visibility Pg.22

4.  New transmission with 5 speed gears Pg.12 4. Fully-automated air conditioning with bi-level function Pg.23

5. Promoting fuel-efficient driving with ECO indicator Pg.13 5. A variety of storage spaces Pg.24

6. Improved fuel consumption Pg.13 Chapter 4: Maintenance/Durability

Chapter 2: Operability 1. Equipment layout for better accessibility Pg.26

1. Power mode for when you need more power Pg.14 2. A frame structure with torsional strength and excellent durability Pg.27

2. Smooth simultaneous operation with parallel tandem Pg.15 3. Powertrain with excellent durability and reliability Pg.27

3. Speed-responding clutch cut-off system Pg.15 4. Non EGR (Exhaust Gas Recirculation) and reliable engine Pg.27

4. Lift arm restriction valve Pg.16 5. Propeller shaft greasing intervals extended to 4 000 hours Pg.27

5. Lift arm auto leveler (optional) Pg.16 6. ROPS/FOPS Cab for safety (optional) Pg.28

6. A “Conventional Differential” that controls tire wear Pg.16 7.  Automatic reversible cooling fan that eliminates the need for cleaning
Pg.28
(optional)
7. Shift change delay mode for fuel efficiency and performance
Pg.17
(optional) 8. Wide fin pitch radiator for dusty sites (optional) Pg.29

8. Ride control system that reduces pitching and bouncing (optional) Pg.17 9.  Pre-cleaner to prolong the cleaning interval of air cleaners (optional) Pg.29

9. Control levers for easy operation Pg.18 *Conventional ZW, CAT H series, Komatsu 6 series, etc.

10. Various lever patterns Pg.19

*Conventional ZW, CAT H series, Komatsu 6 series, etc.

6 ZW180/220-5A 7
 Features of ZW-5A I. Introduction

1. Product concept of ZW-5A

The conventional ZW had problems on powertrain such as transmission and the customers faced troubles with
Low Running Cost
them. Accordingly, we decreased our customers’ credibility and needed to improve them. In order to restore the
credibility, HCM has repeatedly carried out various tests to solve the problems and developed the solutions.

Durability
ZW Restoration: Fuel economy - Durable and Reliable power train
Refresh the image of ZW - Active engine control
- New transmission with 5 speed gears
by ZW-5A

- Robust frame
- Propeller shaft extending the
greasing interval

NEW
2. Appeal on reliability
HCM solved the problems/troubles occurred in the conventional ZW models as follows
Problem/trouble Solution Ref.
Further Refinements
1 Oil leakage

2 Abrasion failure of spline Time-tested transmission is employed

3 Burnt bearing/disk
4 Deterioration of brake disk by heat
Abnormal noise from brake disk/ Scoring on
5 - Lift arm restriction valve
spiral bevel gear or final gear
6 Oil leakage at axle brake piston seal
7 Oil leakage at axle oil seal
8 Corrosion of EGR valve
Heat-resistant disk is employed
Heat-resistant and durable axle is employed
Non EGR and reliable engine is employed
Operability
Comfort
Pg. 27 - Power mode
- Speed responding clutch cut-off - Accessibility to the cab
- Spacious/comfortable cab
- Excellent visibility
- Shift change delay mode (optional)
- Control lever for easy operation - Bi-level auto air conditioner
- Lift arm auto leveler (optional) - A variety of storage space
- Ride control (optional)
Pg. 27

8 ZW180/220-5A 9
 Chapter 1 - Fuel Economy II. Product Features

1. Technology to cut fuel consumption 3. Active engine control NEW Demo

ZW-5A achieved 10% fuel saving through using Active engine control system, Quick power switch (QPS) and the Active engine control on the ZW-5A series detects any excessive pedal depression as shown in the left example and
new transmission with 5 speed gears: Active engine control system can eliminate energy loss by optimizing engine reduces the engine speed.
speed. Using the quick power switch (QPS) enable the operator to use the power mode only when extra power
needed (the efficient standard mode resume after switching forward/reverse or when travel load resume). The new As a result:
transmission select an optimum gear according to the load.
- Fuel consumption can be controlled with minimal impact on the workload.
- Even operators with little experience can run the vehicle in a fuel-efficient way.
Quick Power Switch (QPS)
10 % Fuel Saving = Active engine
control system + New Transmission with 5 speed gears Engine
speed

High-speed travel
2. Causes for fuel consumption performance to drop 100 %
Maximum engine speed enabled for
maximum speed.
Some of the causes of poor fuel consumption in wheel loaders

Acceleration
Up to 90 % for smooth acceleration
better fuel economy.
90 %
(1) Sudden acceleration (2) Excessive pedal depression during excavation
Excavation
Up to 90% engine speed for reduced
traction and for easier arm lift operation..

*The active engine control system function only

when the standard mode is selected.

The active engine control system is effective in following situations

Sudden acceleration during the operation will lead
to poor fuel economy. Fuel consumption can be
controlled simply by reducing the amount of pedal
depression.
Some operators have the bucket dig into the earth
(1) Where there are many dump and hopper loading
and keep the throttle open. Doing this will make
it even more difficult for the lift arm to raise, and (2) Poor fuel economy machines are used
increase the fuel consumption. Reducing the throttle (3) Long travel distances
will enable smoother excavation and better fuel (4) Lack of experienced operators
economy.

(3) Inappropriate gear selection

When traveling and loadering repeatedly in a 2
3
Fixed to 2nd
job site, many operators tend to travel holding gear
4

the gear in 2nd gear with full throttle. Doing so Full throttle
will lead to an increase in fuel consumption.
New transmission with 5 speed gears (Pg.12)
Setting above 3rd gear and adjusting the speed
using the accelerator may improve fuel economy
significantly.

Demo : Please explain the benefit/function and let customer feel it at a demonstration ride.

10 ZW180/220-5A 11
 Chapter 1 - Fuel Economy II. Product Features

4. New transmission with 5 speed gears NEW Demo 5. Promoting fuel-efficient driving with ECO indicator NEW

The new transmission has AUTO1 and AUTO2 that can automatically select an optimum gear according to the load, When driving in a fuel-efficient manner, the ECO indicator will appear on the monitor to let the operator be more
thereby reducing fuel consumption. Furthermore, the new transmission has 5 speed gears which can keep fuel aware about fuel economy. Adhering to this display is equivalent to using the active engine control.
efficient engine speed more easily compared to the conventional transmission with 4 speed gears.

AUTO1
This mode is used to automatically shift between the selected gear and 1st gear according to the load.
Operators do not need to shift down the gear even when requiring large traction.

AUTO2
This mode is used to automatically shift between selected gear and 2nd gear according to the load.

AUTO2 can be useful in the following situations:

- Avoiding automatic gear shift down that causes speed loss during hill climb
- Prevents shift down to 1st gear in operation at slippery surfaces such as snow removal

AUTO1 Automatic gear shift: gears 1-5

6. Improved fuel consumption
AUTO2 1st Automatic gear shift: gears 2-5
Manual 1st 2nd 3rd 4th 5th The graphs below detail fuel consumption levels in the ZW-5B models and the conventional ZW models based on our
Global e-Service data. Compared with the conventional ZW models, the ZW180-5B and ZW220-5B have a reduced
average fuel consumption of 17% and 25% respectively.
With fuel consumption levels in the ZW-5B and the ZW-5A being almost identical, the above fuel savings can also be
expected by upgrading to a ZW-5A model from the conventional ZW models.*
* A 10% fuel saving is listed in the ZW180-5A and ZW220-5A brochures, however as detailed in the data, further fuel
savings can be anticipated for the ZW-5A models compared to the conventional ZW models.

The fuel consumption of ZW180 and ZW180-5B The fuel consumption of ZW220 and ZW220-5B
40% 40%
Avg. of ZW180-5B : 10.0 L/h Avg. of ZW220-5B : 11.8 L/h
Travel mode switch
35%
ZW180-5B 35%
ZW180 Number of samples Number of samples
ZW180 : 1 062 ZW220-5B ZW220 : 371
ZW180-5B : 87 ZW220-5B : 186
n Set above 3rd gear 30% 30%

Avg. of ZW180 : 12.1 L/h ZW220

By presetting above 3rd gear 25% 25%

using the shift switch, gear will shift Percent

Percent
20% 20%
between the 1st/2nd gear and the Avg. of ZW220 : 15.8 L/h
preset gear. 15% 15%

10% 10%

17% 25%
5% 5%

0% 0%
1-3 3-5 5-7 7-9 9-11 11-13 13-15 15-17 17-19 19-21 21-23 23-25 25-27 27-29 31-33 1-3 3-5 5-7 7-9 9-11 11-13 13-15 15-17 17-19 19-21 21-23 23-25 25-27 27-29 29-31 31-33
Fuel consumption (L/h) Fuel consumption (L/h)

12 ZW180/220-5A 13
 Chapter 2 - Operability II. Product Features

1. Power mode for when you need more power NEW 2. Smooth simultaneous operation with parallel tandem
ZW-5A features a power mode, which helps bring out the maximum power from the engine. It is particularly useful in ZW-5A is equipped with the parallel tandem circuit,
sites where strong acceleration or traction are required. Parallel tandem circuit which was highly praised in the conventional ZW
series.
ZW hydraulic circuit Conventional hydraulic circuit
Slope climbing Handling Acceleration With the parallel tandem circuit, it is possible to carry
Bucket- out a combined operation of the bucket and the lift
Simultaneous priority
arm. Front work such as excavation and loading can
Power Mode

operation operation
be carried out smoothly.

Control valve Control valve

Bucket Lift Arm

spool spool
Standard Mode

Lift Arm
Bucket
spool
spool

Parallel/ Variable Fixed

tandem displacement displacement
line pump pump

Caution : Reduction in Fuel Efficiency

When set to the power mode, the engine RPM will change according to the operator's
pedal depression input. Make sure you let your customer know that it is likely that the fuel
3. Speed-responding clutch cut-off system NEW Demo
consumption will increase when this mode is used.
The machine features a newly-developed clutch cut-off system, which detects the vehicle speed and the pedal
input levels. It reduces jerkiness to offer smoother operation during loading work. This system also has two different
The new ZW-5A now has only the standard and power modes as compared to the conventional ZW models (3
modes: a flat mode where the clutch is disconnected earlier, and an slope mode where the clutch is disconnected
operation modes and 4 travel modes), making the selection easier. In addition, the machine is equipped with a QPS
later. There is also a mode to disable the clutch cut-off system.
(quick power switch), which enables the operator to switch to the power mode instantly. Fuel consumption can be
reduced by using the power mode only when required and using the standard mode at all other times.*

Flat Mode The clutch is disconnected earlier Slope Mode The clutch is disconnected later
Conventional ZW machine New ZW-5A model (2 modes)
Standard mode

Power mode
3 operation 4 travel
+ Power mode switch Quick power switch
modes modes

Displayed when the

power mode is active

OFF
Clutch cut-off system disabled
Clutch cut
position switch
*When the power mode is selected via QPS, the system will automatically revert back to the standard mode when switching forward/reverse, or when the trav-
el load reduces. When the power mode is selected via the power mode switch, the vehicle will automatically revert to the standard mode upon restart.

14 ZW180/220-5A 15
 Chapter 2 - Operability II. Product Features

4. Lift arm restriction valve Demo 7. Shift change delay mode for fuel efficiency and performance (optional) NEW Demo

The lift arm of ZW-5A has the same lift arm restriction valve as with the conventional models, which reduces the
shocks when stopping the arm. This improves comforts of the operator and avoid load spills.
By using gears that are above 3rd gear and by controlling the vehicle speed through acceleration operation, fuel
consumption during travel can be reduced. However, the vehicle speed may increase excessively if the excavation
and loading work is carried out while the gear is set to 3rd gear or above. For this reason, many operators drive only
in 2nd gear.
In ZW-5A, however, has the "shift change delay mode", where the gear shift timing from 2nd to 3rd gear is delayed in
order to prevent overspeed.

When moving forward with the lift arm up* When reversing

Holds 2nd gear for 4 seconds Holds 2nd gear for 5 seconds
With lift arm restriction value Without lift arm restriction value

5. Lift arm auto leveler (optional)

An auto leveler, which has the ability to preset the lift arm position, is available as an optional. The operator can
concentrate on traveling without worrying about the lift arm height when loading the dump truck or reversing while
lowering lift arm.
*When height of lift arm is lower than pre-set height, shift change delay won’t activate.

8. Ride control system that reduces pitching and bouncing (optional) Demo

This system automatically reduces pitching and

bouncing of the machine during travel. This contributes
to comfort as well as prevention of load tipping out.

Arm lowering auto stop Arm raising auto stop

Vibration without Vibration with
ride control ride control

6. A “Conventional Differential” that controls tire wear

A conventional differential with high durability and less tire wear achieved through a simple configuration. Furthermore,
a limited slip differential (LSD) is optionally available, which effectively transmits driving force to tire on rough terrain.

Ride control activates at 6 km/h or faster

Comparative evaluation of differentials It deactivates at 4 km/h or slower
(The vehicle speed can be adjusted with MPDr. The
Anti-slip Ability Tire Wear Maintenance
ON setting range is 3-18 km/h, and OFF setting range
Conventional Differential is -2 km/h of the set value.)
Monitor display Ride control
Torque Proportioning Differential (TPD) switch

Limited Slip Differential (LSD) ×

: Very Good : Good : Normal ×: Not Good

16 ZW180/220-5A 17
 Chapter 2- Operatability II. Product Features

9. Control levers for easy operation NEW 10. Various lever patterns NEW

Although we received positive feedback about our conventional levers from operators who use only the tip of their In order to offer more efficient operation, we have prepared a variety of lever patterns tailored to suit the different
fingers to operate, the reaction was less positive from operators who grip the lever. We have reworked the lever attachments fitted. Check customer’s operational requirements carefully and recommend the lever pattern
shape for the ZW-5A enabling comfortable operation using either fingertip control or grip control. accordingly.

Product Name Lever pattern Primary uses

New ZW-5A model
n 2 levers n Fingertip control 2 levers Bucket control lever Standard Specifications
Lift arm control lever - Bucket
- Pallet forks etc.

Multi function lever MF lever

(MF lever)

n Grip control
2 levers & 1 lever Attachment control lever - Log grapple
(inside layout) - Grapple bucket etc.
for 3SP

2 levers & 1 lever Attachment control lever - Angling plow etc.

(outside layout)
for 3SP

Employs the best features of both

(Control levers which are easily operable
by fingertip or grip)
2 levers & 2 levers - Multi-plow
Conventional ZW machine (outside layout) -S ide slide-angling plow etc.
for 4SP
n Standard levers n Optional lever (Double valve two levers; DSS*on the knob)
/ Suited to fingertip control / Suited to grip control

Narrow
Attachment control lever

2 levers & 1 lever Attachment control lever (joy stick)

for 4SP

*DSS: Down-Shift Switch

18 ZW180/220-5A 19
 Chapter 3-Comfort II. Product Features

1. Accessibility to the cab 2. Spacious and comfortable cab Demo

The sloped ladder with slip-resistant steps, and conveniently placed handrails within easy grasp are designed for The cab interior allows the positioning of the seat/steering wheel/side controls to be adjusted according to the
easier operator access. operator body shape and preference. In addition, the mechanical suspension seat that limits vehicle vibration
transmitted to the operator. These features help reduce operator fatigue.

n Slip-resistant steps

n Sloped ladder and hand rail

n A range of adjustable items

Seat Side console Arm rest

Reclining
Vertical slide
Slide
Tilt

Angle
adjustment

Forward/backward slide (Bolt adjustment type)

20 ZW180/220-5A 21
 Chapter 3-Comfort II. Product Features

3. Excellent visibility Demo 4. Fully-automated air conditioning with bi-level function

Forward visibility As with conventional models, fully-automated air conditioning with bi-level function comes standard. Adjustment
control is easy using the controller with its LCD monitor.
The cab of ZW-5A has more rigid console yet offers the same superior levels of visibility offered by conventional ZW
models.

Rear visibility
ZW-5A model uses a complex and curved engine cover in order to improve rear visibility. The counterweight can now
be checked visually. In addition, a rearview camera and rearview monitor are available as options to cover blind
spots such as the back of the machine.
In addition to the above, we have improved the functions detailed below.
Improved airflow
The airflow is improved with the revised duct shape for better comfort.

Optional NEW

Rearview camera
Improving fresh air filter function
We have improved the air-tightness of the fresh air inlet ensuring all the air passes through the filter. This
inhibits dust from entering the cab, thus reduces time spent on maintenance. Optional (double) filter is
also available for dusty work sites.

Rearview monitor Improved maintainability

At very dusty sites, cleaning and replacement of evaporators cannot be avoided. On ZW-5A, the
evaporator can be cleaned and replaced while the air-conditioning unit remains fitted to the vehicle.
Thus, maintenance time is reduced considerably.

Improved corrosion resistance

We have increased the thickness of the sacrificial layer (the layer in which corrosion does not matter)
for the ZW-5A models. In addition, we have changed the coating method for an even sacrificial layer, it is
twice more corrosion resistant than before.

22 ZW180/220-5A 23
 Chapter 3-Comfort II. Product Features

Air-conditioner duct Air-conditioner duct MEMO

Beneath the
cab floor

Conventional model air-conditioner duct ZW-5A Air-conditioner duct ZW-5A Evaporator

The air duct can now passes inside the cab, preventing dust The cladded evaporator (zinc-aluminum alloy) is
penetration. twice more corrosion resistant than before.

We have reduced the dust entering the air-conditioner unit by reviewing the piping route and the inside/outside air
filters. Moreover, corrosion resistance of the evaporator has been doubled.
The evaporator can easily be replaced by opening the cover on the back of the seat, thereby reducing maintenance
time.

5. A variety of storage spaces

We have prepared a variety of spaces tailored in size and shape to hold everyday items used by the operator.

Glove compartment Ash tray

Document holder

Storage for small items Front console for small items Lunch box & document holder

Magazine holder

Digital audio player holder Hot & cool box Drink holder

24 ZW180/220-5A 25
 Chapter 4-Maintenance/Durability II. Product Features

1. Equipment layout for better accessibility 2. A frame structure with torsional strength and excellent durability
We have increased the service space to the engine room for easy inspections and maintenance. The frame which is inherited from conventional ZW models has
demonstrated its high durability on work sites around the world. It
can cope with heavier counterweights.

3. Powertrain with excellent durability and reliability Improved

This model employs the highly durable and reliable transmission

that has proven itself on sites in Europe where travel carrying
load is common. The axle is designed to withstand harsh road
environments through a combination of design optimization and
material selection. Additionally, ZW-5A uses heat-resistant discs for
the brakes, thus improving brake feeling.

4. Non EGR (Exhaust Gas Recirculation) and reliable engine Improved

The conventional ZW engine had a problem with the corrosion of Fuel Filter Common Rail Pressure Sensor
Common Rail
EGR valve because the exhaust contained sulfur and it affected Fuel Pump

the valve. ZW-5A employs the non EGR and reliable engine which
has been already used in various places in the world. Furthermore,
the engine is clean and fuel efficient because of the common rail
D
system that enables optimum combustion to generate large horse
A power and reduce PM (Particulate Matter) and fuel consumption.
B
C
C Coolant
Engine Oil Filter

Right side Left side

Fuel Tank Control Unit Injector
A Fuel Pre-Filter C Engine Oil Gauge

B Main Fuel Filter D Window Washer Tank

5. Propeller shaft greasing intervals extended to 4 000 hours

The greasing interval for the propeller shaft universal joint is
extended from 2 000 hours to 4 000 hours.

26 ZW180/220-5A 27
 Chapter 4-Maintenance/Durability II. Product Features

6. ROPS/FOPS Cab for safety (optional) 8. Wide fin pitch radiator for dusty sites (optional) NEW

To protect the operator in case of accident, ROPS* and FOPS** cab Wide fin pitch radiator reduces clogging and
which conform to ISO standards, ensuring safety is optionally available. overheating problems. This is an effective
* ROPS (Roll-Over Protective Structures) option for sites where there are large amounts
: Structures that protect operators who are wearing seat belts when the of powder dust and radiator clogging occurs
machine rolls over. frequently.
** FOPS (Falling-Object Protective Structures)
: Structures that protect operators from falling objects. Standard fin pitch radiator Wide fin pitch radiator

Caution

• This won’t completely prevent clogging. Please recommend regular cleaning.

• The heat dissipation is inferior when compared with standard fin pitch radiator. On sites such as
indoor sites that reach high temperatures, there is potential for overheating even if the radiator is
not clogged.

7. Automatic reversible cooling fan that eliminates the need for cleaning (optional) NEW • T his feature is not effective in reducing clogging caused by large items of trash such as paper,
plastic, or grass. We suggest fitting a radiator dust screen.

The automatic reversible cooling fan is optionally available to keep the radiator clean at all times. With the fan, hands-free
automated cleaning is realized, and it has three modes which can be selected to suit the site.

9. Pre-cleaner to prolong the cleaning interval of air cleaners (optional)

Fan reverse rotation switch (3 modes)
For the ZW-5A, which is often used on very dusty sites, we have added the option of a cyclone-type pre-cleaner that
MANU (Manual mode) will extend cleaning intervals required for the air cleaner. Because the internal blades expel suspended particles
Same as conventional models
such as large pieces of dust, there is no need to carry out regular maintenance.
Off mode
For use on sites where reversing
fan is not desirable - i.e. industrial Standard/optional equipment : Standard, l: Optional, -: Not applicable
waste sites, etc.
Features External View ZW-5A
AUTO (Auto mode)
Self-reversing every 30 minutes
Generates a vortex and
separate large particles.
Cyclone-type The dust which is caught l
Cooling fan by the blades is expelled
automatically.

Pre-cleaners
Generates a vortex and
Conventional
separate large particles.
model l
The bowl requires regular
(bowl type)
cleaning.

A cap designed to prevent

Rain cap water rain water from entering
When the automatic reversible fan cannot remove dirt well, it is possible to clean them away by inserting
the air filter directly.
an air nozzle through the side of the fan cover.

28 ZW180/220-5A 29
 Setting Procedures for Demonstration Ride III. Appendix

Although several years have passed since HCM launched the ZW wheel loader in the market, our market share and the n Operation for AUTO1 and AUTO2
credibility of the products are not high yet. That’s why customers are likely to hesitate to purchase our wheel loaders.
AUTO 1 Normal operation (digging/traveling etc.) AUTO 2 Operation of slippery place (snow removal etc.)
Demonstration ride is a good way to fully realize the performance of ZW-5A and convince of the validity of the purchase.
So, please invite your potential customer to take a demonstration ride explaining the below procedure and the function.
Moreover, when you deliver the ZW-5A, we also recommend you to let operators and managers to take a demonstration
ride for confirmation so that they can get a high performance out of the machine and are satisfied with it.

1. Mode settings
a. Standard/power mode setting
Please let operator try standard mode which is fuel efficient and sufficient for normal operation at first. Then let him try
powerful power mode by pressing the power mode switch when power is needed. c. Clutch cut-off mode settings
Select the appropriate mode using the clutch cut position switch. Please try with loading work on flat ground and
Monitor display Mode explanation slopes.

This is standard mode

No display Mode Display Mode explanation
Use this for normal situations.
Flat The clutch is cutoff at a fast timing.
This is power mode. Select this when a strong
mode Road condition: suited to flat grounds
traction is required.
Power mode switch
Clutch cut-off not carried out.
OFF LED is OFF
Road condition: suited to steep slopes
n Operation for power mode
Slope The clutch is cutoff at a slower timing.
Steep slope climbing Strong traction power Swift acceleration
Clutch cut position switch mode Road condition: suited to slops
Power Mode

n Operation for clutch cut-off mode

Flat Mode Slope Mode

b. Travel mode/shift switch setting

Select the appropriate travel mode using the travel mode selector and the maximum gear speed using the shift
switch.

Mode Mode explanation

Automated shifting between 1st gear and the
AUTO1 selected gear speed.
Use this for normal situations.
MANUAL Travels at the gear speed selected
Automated shifting between 2nd gear and the
AUTO2

+
Travel mode selector selected gear speed.

Caution

If you wish to lock the transmission in 1st gear, stop the

vehicle and place the forward/reverse travel lever in neutral,
then press the 1st speed fixed switch on the right console.
1st speed fixed switch
Shift switch

30 ZW180/220-5A 31
 Setting Procedures for Demonstration Ride III. Appendix

2. Other settings c. Lift arm auto leveler (optional)

The lift arm auto leveler is a device that automatically stops the lift arm at preset lowering and raising heights.
a. Shift change delay mode (optional)
The timing of shift up to 3rd gear is delayed
at following 3 setting;
- Shift change delay mode switch is ON Setting Method
- Travel mode is set to AUTO1 or AUTO2
l Lower height position
- Shift switch is set in 3rd gear or higher
(1) Hold the lift arm in the position at which the
Shift change delay mode ON Shift change delay mode OFF lowering lift arm is desired to stop.
(2) Release the "lock switch" of the lift arm auto
leveler switch (lower) and press the "SET
switch".
n Operation for shift change delay mode: Digging and loading
l Upper height position
(1) Hold the lift arm in the position at which the
Lower setting Upper setting
switch switch raising lift arm is desired to stop.
(2) Release the "lock switch" of the lift arm auto
Lift arm auto leveler switch leveler switch (raise) and press the "SET
switch".

n Operation for lift arm auto leveler

Loading with lifting the arm

b. Ride control (optional)

The ride controls can be selected using the switch on the right console. Use ride control with a load on the
bucket.

Reversing with lowering the arm

Vibration without Vibration with
Monitor display ride control ride control

No display
Ride control switch

32 ZW180/220-5A 33
 Setting Procedures for Demonstration Ride III. Appendix

3. Introduction of operator’s station

For more details refer to the operator’s manual.

Front console Right console

1 Air-conditioner front vent

1 2 3 4 5 6 7 8 1 1 Bucket control lever*
3 2* 4 5 6 7 8
2 Hazard switch 2 Lift arm control lever*
2 1* 9
3 Work light switch 3 Auxiliary control lever (optional)*

4 Control lever lock switch 1 3* 10

4 Parking brake switch
5 Auxiliary 11
5 Neutral lever lock (forward/reverse lever)
6 Auxiliary 12
6 Steering wheel
7 Power mode switch 13
7 Monitor panel
8 Forward/reverse selection switch (optional) 14
8 Horn switch
9 Fan reverse rotation switch (optional) 15
9 Accelerator pedal
10 11
10 Back buzzer switch (optional) 16
10 Brake/clutch cut-off pedal 11 Auxiliary 19 18 17
9
11 Brake/clutch cut-off pedal (optional) 12 Emergency steering check switch (optional)
12 13
12 Front/rear wiper switch 13 Lift arm auto-leveler switch (raise) (optional)
20
13 Forward/reverse lever/shift switch 14 Lift arm auto-leveler switch (lower) (optional)

14 Tilt lever 15 1st speed fixed switch 21

15 Turn signal lever/light switch/dimmer switch 16 Ride control switch (optional) 22

17 Armrest adjust handle
16 Key switch
18 Armrest adjustment
17 Travel mode selector
19 Hold switch
18 Auxiliary
20 DSS (Down shift switch)
19 Clutch cut position switch
21 Horn switch
20 Shift change delay mode switch (optional)
22 Quick Power Switch (QPS)
21 Ash tray 14
* The location of control levers may be changed depending on the specification.
22 Cigar lighter
15 16 17
Operator seat (mechanical suspension seat)
18
1 Suspension handle (height adjustment)
19
2 Slide lever (seat fore-aft adjustment)
20 3 Arm rest (angle adjustment)

4 Reclining adjustment lever

5 Indicator (weight adjustment) 3

22 21
4

1 5
34 ZW180/220-5A 35
 Attachment Data III. Appendix

1. Joint between lift arm and bucket 3. Bucket selection guide

Unit: mm
ZW180-5A ZW180 LX130-7/L27-3 ZW220-5A ZW220 LX160-7/L32-3 Bucket capacity m3
Materials to be handled
Pin diameter A 75 85 ZW180-5A ZW220-5A
Pin diameter B 75 85
C 887 882 2.8 3.2
D 109 114
Sand/gravel/crushed stone (under 40 mm)
E 113 118 Bolt-on
F 113 118 cutting 3.0 3.4
edge
G 250 280 260
H 382 395 General
3.3 − Industrial waste (wood scrap etc.)
I − 20 − 20 purpose
J 233 241 258
K 221 258 232
2.7 3.1
Bolt-on
Materials (crushed stone etc.) with lumps
teeth
2.9 3.3

Bolt-on
Rock bucket 2.2 2.7 Rocks/concrete debris
teeth

Side view of bucket Bucket bracket − 4.0

Arm top Bolt-on
Coal bucket cutting Coal/snow/woodchip
edge
− 4.4

2. Interchangeability of components
: Interchangeable ×: Not Interchangeable
ZW180-5A ZW180 ZW220-5A ZW220
Bucket

BOC

Teeth

Lift arm

Lift-arm cylinder
(The dust seal on the ZW180-5A is improved) (The dust seal on the ZW220-5A is improved)

Bucket cylinder
(The dust seal on the ZW180-5A is improved) (The dust seal on the ZW220-5A is improved)
Tire (rim) × ×
Quick couplers (hydraulic)

Hydraulic Attachments

Bucket for the quick coupler

BOC: Bolt On Cutting Edge

36 ZW180/220-5A 37
 Photo Comparison between ZW-5A and Conventional ZW III. Appendix

The followings are the comparisons between the ZW-5A and the conventional ZW.

ZW-5A ZW ZW-5A ZW

Ample foot space

(30 mm extended compared with conventional ZW)

Lever for easy operation

(Suited to both fingertip control and grip control)

Sophisticated design

Large capacity for drink

Wide visibility Large storage space behind the seat

38 ZW180/220-5A 39
 Specification Comparison III. Appendix

n ZW180 class specification comparison

Manufacturer Hitachi HITACHI CAT CAT KOMATSU KOMATSU KOMATSU KOMATSU VOLVO VOLVO HYUNDAI
WA320-7
Model ZW180-5A ZW180 938K 938H WA 320-6 WA 320-5 WA 320-3 L 90 G L 90 F HL757-9S
North America
Engine maker Cummins Cummins Caterpillar Caterpillar Komatsu Komatsu Komatsu Komatsu Volvo Volvo Cummins
Engine model QSB6.7 QSB6.7 C7.1 ACERT C6.6 ACERT SAA6D107E-2 SAA6D107E-1 SAA6D102E-2 S6D114E-1 D6H D6E LAE3 QSB6.7
Displacement (L) 6.69 6.69 7.0 6.6 6.69 6.69 5.88 8.27 5.7 5.7 5.7
Engine output (SAE J1995 gross / ISO 9249, SAE J1349 net) (kW) 128 / 125 128 / / 136 147 / 134 127 / 123 127 / 125 /124 129/121 129 / 129 129 / 128 129 / 122
ENGINE

Engine output (SAE J1995 gross/ISO 9249, SAE J1349 net) (HP) 172 / 168  171 / / 182 197 / 180 170 / 165 171 / 167 /166 173/162 173 / 173 173 / 172 173 / 164
Engine output at (rpm) 2 200 2 200 1 800 2 100 2 100 2 000 2 000 2 380 1 700 1 700 2 100
Engine max. torque (SAE J1995 gross / ISO 9249, SAE J1349 net) (Nm) 763 / 753 N.A / 874 / 840 N.A N.A N.A N.A 880 / 880 770 / 736 814
Engine max. torque at (min-1) 1 400 N.A 1 400 1 400 N.A N.A N.A N.A 1 400 1 600 1 400
Exhaust emissions EU directive 97/68/EC Stage IIIA Stage IIIA Stage IIIA Stage IIIA Stage IIIB Stage IIIA N.A N.A Stage IIIB Stage IIIA Stage IIIA
Main pump type Variable piston pump Variable piston pump Variable piston pump  Variable piston pump  Variable piston pump Gear pump N.A N.A Variable piston pump Variable piston pump Gear pump
Hydraulic cycle time
HYDRAULIC SYSTEM

Raise (sec) 5.9 5.7 5.5 5.4 6.1 6.1 6.1 5.8 5.4 5.4 6.0
Dump, loaded, max lift (sec) 3.6 2.9 1.5 1.4 1.9 1.2 1.2 1.2 1.9 2.1 1.2
Lower, empty, float down (sec) 1.4 1.2 2.7 2.7 3.5 3.3 3.3 3.3 3.2 2.5 3.1
Total 10.9 9.8 9.7 9.5 11.5 10.6 10.6 10.3 10.5 10.0 10.3
AXLES TRANSMISSION

Number of forward / reverse speeds 5/3 4/4 4/4 4/3 4/4 4/4 4/4 4/4 4/4 4/4 4/3

Max. forward speed std. / opt. (km/h) 39 38 40 43 38 38 38 34 46 46 36

Front Differential Type STD / OPT Conventional / LSD TPD / LSD Open / Diff Lock Diff Lock / TPD / LSD TPD / LSD TPD / LSD TPD/LSD Diff Lock / Diff Lock / Conventional / LSD
Rear Differential Type STD / OPT Conventional / − TPD / LSD Openl / LSD  Open / Diff Lock TPD / LSD TPD / LSD TPD / LSD TPD/LSD Conventional / LSD Conventional / LSD Conventional / LSD
CAPACITIES

Fuel Tank (L) 235 230 195 247 245 245 228 248 219 224 246

Hydraulic tank (L) 100 100 90 89 90 89 89 116 90 90 155

Loader type Double arm Double arm Double arm Double arm Double arm Double arm Double arm Double arm Double arm Double arm Double arm
Geometry Z bar - 1 Z bar - 1 Z bar - 1 Z bar - 1 Z bar - 1 Z bar - 1 Z bar - 1 Z bar - 1 TP linkage TP linkage Z bar - 1
Bucket mounting Direct Direct Direct Direct Direct Direct Direct Direct Direct Direct Direct
Bucket type GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/BOC
Capacity heaped (m³) 2.8 2.8 2.5 2.8 2.8 2.8 2.8 2.7 2.8 2.5 2.7
Bucket width (mm) 2 690 2 690 2 750 2 700 2 740 2 740 2 740 2 740 2 750 2 650 2 740
Hinge pin height (mm) 3 920 3 920 3 969 3 843 4 005 3 905 3 905 3 885 3 970 3 960 3 910
Dump angle full height 45 45 49 50  45 45 45 45 45 44 47
LOADER

Dump clearance at full lift and 45°discharge (teeth / edge) (mm) 2 800 2 790 2 869 2 771 2 880 2 850 2 850 2 850 2 820 2 850 2 860
Dump reach at full height and 45°discharge (teeth / edge) (mm) 1 070 1 070 1 108 1 077 1 000 1 035 1 035 1 035 1 120 1 090 1 040
Crowd angle carry position °  50 50 45 50 N.A 47 49 N.A 53 49 46
Crowd angle ground ° 44 N.A N.A 42 N.A N.A N.A N.A 47 44 41
Breakout force kN 117 119 135 123 162 129 129 123 136 119 125
Operating weight kg 14 430 14 280 15 146 15 059 15 300 13 850 13 520 14 150 15 020 14 980 14 000
Turn radius over bucket mm 6 200 6 100 6 117 N.A 6 310 6 260 6 090 6 080 5 975 5 920 6 175
Tipping load straight kg 11 560 11 480 11 385 11 593 11 630 11 520 11 250 12 560 11 150 11 210 11 100
Tipping load FTTL ° / kg 40 / 9 960 40 / 9 910 40 / 9 698 40 / 10 076 40 / 9 610 40 / 10 270 40 / 9 800 40 / 10 910 40 / 9 500 40 / 9570 40 / 9 730
Length with bucket on ground mm 7 790 7 610 7 604 7 343 7 635 7 515 7 455 7 555 7 600 7 510 7 540
Wheelbase mm 3 100 3 050 3 050 3 020 3 030 3 030 3 030 3 030 3 000 3 000 3 050
Tread mm 2 050 2 050  2 065 N.A 2 050 2 050 2 050 2 050 1 960 1 960 N.A
DIMENSIONS

Height over cab mm 3 280 3 280 3 340 3 356 3 200 3 200 3 200 3 315 3 280 3 280 3 400
Tire size std 20.5-25-12PR(L3) 20.5-25-12PR(L3) 20.5 R25(L3) 20.5 R25(L3) 20.5 R25(L3) 20.5-25-12PR(L3) 20.5-25-12PR(L3) 20.5-25-12PR(L3) 20.5 R25(L3) 20.5 R25(L2) 20.5-25-16PR(L3)
Width over tires std mm 2 610 2 610 2 675 2 674 2 590 2 590 2 585 2 585 2 490 2 490 2 580
Ground clearance std mm  395 395 286 397 425 425 425 400 450 460 410

* The data is for net(The data for gross is 2 000).

40 ZW180/220-5A 41
 Specification Comparison III. Appendix

n ZW220 class specification comparison

Manufacturer Hitachi HITACHI CAT CAT KOMATSU KOMATSU KOMATSU KOMATSU VOLVO VOLVO HYUNDAI
Model ZW220-5A ZW220 950K 950 H WA380-7 WA 380-6 WA 380-5 WA 380-3 L 110 G L 110 F HL760-9S
Engine maker Cummins Isuzu Caterpillar Caterpillar Komatsu Komatsu Komatsu Komatsu Volvo Volvo Cummins
Engine model QSB6.7 AH-8HK1X C7.1 ACERT C7 ACERT SAA6D107E-2 SAA6D107E-1 SAA6D114E-2 S6D108 D8H D7E LB E3 6C8.3
Displacement (L) 6.69 7.79 7.01 7.20 6.69 6.69 8.27 7.15 7.75 7.10 8.30
Engine output (SAE J1995 gross / ISO 9249, SAE J1349 net) (kW) 145 / 144 / 164 173 / 157 162 / 147 143 / 142 143 / 142 N.A/140 N.A/140 191 / 190 170 / 169 160 / 152
ENGINE

Engine output (SAE J1995 gross/ISO 9249, SAE J1349 net) (HP) 194 / 193 / 220 232 / 211 220 / 200 192 / 191 192 / 191 N.A/187 N.A/187 260 / 258 231 / 230 215 / 205
Engine output at (rpm) 1 800* 2 000 1 900 1 800 2 100 2 100 2 000 2 200 1 700 1 700 2 200
Engine max. torque (SAE J1995 gross / ISO 9249, SAE J1349 net) (Nm) 931 / 921 981 / 1 054 / 988 / 907 941 963 N.A N.A 1 255 / 1 248 1 065 / 1 059 971
Engine max. torque at (min-1) 1 400 1 400 1 300 1 400 1 450 1 500 N.A N.A 1 400 1 500 1 400
Exhaust emissions EU directive 97/68/EC Stage IIIA Stage IIIA Stage IIIB Stage IIIA Stage IIIB Stage IIIA Stage II N.A Stage IIIB Stage IIIA Stage II
Main pump type Variable piston pump Variable piston pump N.A Variable piston pump Variable piston pump Piston pump Gear pump Gear pump Variable piston pump Variable piston pump Gear pump
Hydraulic cycle time
HYDRAULIC SYSTEM

Raise (sec) 5.9 5.6 5.9 6.2 5.9 5.9 5.7 5.9 5.4 5.4 6.2
Dump, loaded, max lift (sec) 1.2 1.4 1.8 2.0 1.8 1.8 1.4 1.4 2.1 2.1 1.4
Lower, empty, float down (sec) 3.3 3.5 2.5 2.5 3.3 3.3 3.3 3.3 2.5 2.5 3.0
Total 10.4 10.5 10.2 10.7 11.0 11.0 10.4 10.6 10.0 10.0 10.6
AXLES TRANSMISSION

Number of forward / reverse speeds 5/3 4/4 4/4 4/4 4/4 4/4 4/4 4/4 4/4 4/4 4/3

Max. forward speed std. / opt. (km/h) 37.4 34.5 37.9 38.0 36.1 31.1 31.5 31.5 40.0 37.0 38.4

Front Differential Type STD / OPT Conventional / LSD TPD / LSD Conventional / LSD Conventional / LSD Conventional / LSD Conventional / LSD Conventional / LSD TPD/ Diff Lock / Diff Lock / Conventional / LSD
Rear Differential Type STD / OPT Conventional / − TPD / LSD Conventional / LSD Conventional / LSD Conventional / LSD Conventional / LSD Conventional / LSD TPD/ Conventional / LSD Conventional / LSD Conventional / LSD
CAPACITIES

Fuel Tank (L) 255 285 314 264 300 300 300 287 269 269 263

Hydraulic tank (L) 114 114 189 110 142 139 129 138 133 133 163

Loader type Double arm Double arm Double arm Double arm Double arm Double arm Double arm Double arm Double arm Double arm Double arm
Geometry Z bar - 1 Z bar - 1 Z bar - 1 Z bar - 1 Z bar - 1 Z bar - 1 Z bar - 1 Z bar - 1 TP linkage TP linkage Z bar - 1
Bucket mounting Direct Direct Direct Direct Direct Direct Direct Direct Direct Direct Direct
Bucket type GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/ BOC GP w/BOC
Capacity heaped (m³) 3.2 3.2 3.1 3.1 3.35 3.3 3.3 3.2 3.4 3.1 3.1
Bucket width (mm) 2 910 2 910 2 927 2 927 2 990 2 905 2 905 2 905 2 880 3 000 2 900
Hinge pin height (mm) 4 090 4 090 4 021 3 992 4 095 4 030 4 030 4 030 4 030 4 020 4 105
Dump angle full height 50 50 51 48 N.A N.A N.A 45 50 50 47
Dump clearance at full lift and 45°discharge (teeth / edge) (mm) 2 920 2 910 2 876 2 791 2 895 2 885 2 885 2 925 / 2 790 2 860 3 000
LOADER

Dump reach at full height and 45°discharge (teeth / edge) (mm) 1 110 1 120 1 429 1 319 1 110 1 210 1 210 1 170 / 1 200 1 110 1 190
Crowd angle carry position ° 50 50 51 49 50 50 50 48 45 46 47
Crowd angle ground ° 43 N.A 46 41 N.A N.A N.A N.A 40 41 42
Breakout force kN 149 156 161 150 N.A 158 148 148 158 157 156
Operating weight kg 16 890 17 330 19 425 18 320 18 625 16 610 16 230 16 480 18 480 18 300 17 600
Turn radius over bucket mm 6 590 6 600 6 056 N.A 7 265 N.A 6580 6 430 6 330 6 350 6 560
Tipping load straight kg 13 650 13 750 12 740 12 515 14 290 13 880 12 880 12 630 13 230 13 120 13 950
35 / 11 750 35 / 11 690
Tipping load FTTL ° / kg 40 / 11 800 40 / 11 900 N.A/ 11 008 N.A/ 10 811 40 / 12 635 40 / 12 000 40 / 11 200 40 / 10 935 40 / 12 060
37 / 11 320 40 / 11 270
Length with bucket on ground mm 8 200 8 200 8 162 8 061 8 380 8 195 8 195 7 965 8 010 7 890 8 100
Wheelbase mm 3 300 3 300 3 350 3 350 3 300 3 300 3 300 3 200 3 200 3 200 3 300
Tread mm 2 160 2 160 N.A N.A 2 160 2 160 2 160 2 160 2 070 2 070 N.A
DIMENSIONS

Height over cab mm 3 375 3 375 3 356 3 461 3 395 3 325 3 315 3 315 3 380 3 360 3 485
Tire size std 23.5-25-16PR(L3) 23.5-25-16PR(L3) 23.5 R25 23.5 R25 23.5 R25 20.5-25-16PR(L3) 20.5-25-16PR(L3) 20.5-25-16PR(L3) 23.5 R25(L3) 23.5 R25(L3) 23.5-25-20PR(L3)
Width over tires std mm 2 785 2 785 2 719 2 784 2 765 2 695 2 695 2 695 2 670 2 670 2 770
Ground clearance std mm 455 450 397 397 450 390 390 390 430 420 420

* The data is for net(The data for gross is 2 000).

42 ZW180/220-5A 43