Page 1 PART NO. ENMNSC-NA1-2 Operator's Manual Wheel Loader URL:http://www.hitachi-c-m.com Serial No. 005201 and up This book is printed on recycled paper. PRINTED IN JAPAN (E) 2018, 07...
Page 2 INTRODUCTION Read this manual carefully to learn how to operate and Warranty is provided as a part of Hitachi’s support service your machine correctly. Failure to do so could program for customers who operate and maintain their result in personal injury or machine damage.
Page 3 INDEX MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME GETTING ON/OFF THE MACHINE OPERATOR’S STATION BREAK-IN OPERATING ENGINE DRIVING MACHINE OPERATING MACHINE TRANSPORTING MAINTENANCE MAI N TENANCE UNDER SPECI A L ENVI R ONMENTAL CONDI T I O NS STORAGE TROUBLESHOOTING SPECIFICATIONS OPTIONAL ATTACHMENTS INDEX...
Page 5: Table Of Contents
CONTENTS MACHINE NUMBERS ................1 Evacuating in Case of Fire ............S-31 Beware of Exhaust Fumes............S-31 SAFETY ....................S-1 Precautions for Welding and Grinding ......... S-31 Recognize Safety Information ............S-1 Precautions for DEF/AdBlue® ........... S-32 Understand Signal Words .............S-1 Avoid Heating Near Pressurized Fluid Lines ....... S-33 Follow Safety Instructions ............S-2 Avoid Applying Heat to Lines Containing Flammable Prepare for Emergencies ...............S-3...
Page 6 CONTENTS Control Lever Lock Indicator (Red) ......... 1-17 Armrest Adjust Handle ............... 1-58 Power Mode Indicator (Green) ..........1-17 Traction Control Switch .............. 1-59 Maintenance Indicator (Yellow) ..........1-17 Power Mode Switch ..............1-60 Monitor Display ................1-18 Aftertreatment Device Regeneration Switch ..... 1-61 Forward/Reverse and Shift Position Indicator ....
Page 7 CONTENTS Steps....................1-94 Transporting by Road ..............6-1 Rear Grille ..................1-94 Transporting by Trailer ..............6-1 Opening the rear grille ............1-94 Loading / Unloading on Trailer ...........6-2 Closing the rear grille ............1-94 Fastening Machine for Transporting ........6-4 Grease Gun Box ................1-94 Transporting Wheel Loader (Urgent Situation) ....6-5 Vandal-Proof Devices ..............
Page 8 CONTENTS Inspect the Air Cleaner Element for Clogging ....7-64 Check and Replace EGR Device ........7-102 Clean and Replace Air Cleaner Element ......7-65 Clean EGR Cooler ..............7-102 G. Cooling System ................ 7-66 Check Turbocharger .............7-102 Check Coolant Level .............. 7-67 Check and Clean Injector Nozzle........7-102 Check Drive Belt ..............
Page 9: Machine Numbers
MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request.
Page 10 MACHINE NUMBERS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 11: Safety
SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices. SA-2644 Understand Signal Words ...
Page 12: Follow Safety Instructions
 Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine...
Page 13: Prepare For Emergencies
SAFETY Prepare for Emergencies  Be prepared if a fire starts or if an accident occurs.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly. ...
Page 14: Protect Against Noise
SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. SA-434 Inspect Machine ...
Page 15: General Precautions For Cab
SAFETY General Precautions for Cab  Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.
Page 16: Use Handrails And Steps
SAFETY Use Handrails and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.  Do not use any controls as hand-holds. ...
Page 17: Ensure Safety Before Rising From Or Leaving Operator's Seat
SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open / close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position.
Page 18: Move And Operate Machine Safely
SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped).
Page 19: Operate Only From Operator's Seat
SAFETY Operate Only from Operator’s Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator's seat.  NEVER start the engine while standing on the tire or on ground.
Page 20: Investigate Job Site Beforehand
SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.
Page 21: Equipment Of Head Guard, Rops, Fops
SAFETY Equipment of Head Guard, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) Any modification of the ROPS structure will modify its performances and its certification will be lost.
Page 22: Keep Riders Off Machine
SAFETY Keep Riders Off Machine  Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.  Only the operator should be on the machine. Keep riders off.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.
Page 23: Drive Machine Safely (Work Site
SAFETY Drive Machine Safely (Work Site)  Before driving the machine, always confirm that the steering wheel / and forward / reverse lever (switch) direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions. ...
Page 24: Drive Safely With Bucket Loaded
SAFETY Drive Safely with Bucket Loaded  If the machine is incorrectly operated while driving with the bucket loaded, turning over of the machine may result. Be sure to follow all the instructions indicated below.  When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility.
Page 25: Travel On Public Roads Safely
SAFETY Travel on Public Roads Safely  This machine is not allowed to drive on public roads with the bucket loaded.  Be sure to empty the bucket.  Hold the bucket at mark (A) 350 to 400 mm (14 to 16 in) above the road surface as illustrated.
Page 26: Avoid Accidents From Backing Up And Turning
SAFETY Avoid Accidents from Backing Up and Turning  Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and / or death by being run over or entangled in the machine.
Page 27: Avoid Positioning Bucket Or Attachment Over Anyone
SAFETY Avoid Positioning Bucket or Attachment Over Anyone  Never allow the bucket or attachment to pass over co- workers and / or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket or attachment may cause serious personal accidents and / or damage to the machine.
Page 28: Never Undercut A High Bank
SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death. SA-519 Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and / or fire, possibly resulting in serious injury or death.
Page 29: Avoid Power Lines
SAFETY Avoid Power Lines Serious injury or death can result from contact with electric lines. Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length. SA-455 Precautions for Operation ...
Page 30: Object Handling
SAFETY Object Handling CRANING OPERATION USING THE MACHINE IS NOT ALLOWED.  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. Never attach a sling or chain to the bucket teeth or to the attachment (fork or grapple for example).
Page 31: Park Machine Safely
SAFETY Park Machine Safely To avoid accidents:  Park the machine on a firm, level surface.  Lower bucket to the ground.  Put the forward / reverse lever (switch) in neutral, and turn the parking brake switch (lever) ON (parking brake) position.
Page 32: Transport Safely
SAFETY Transport Safely  Take care that the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.  Observe the related regulations and rules for safe transportation.  Select an appropriate truck or trailer for the machine to Less than 15 °...
Page 33: Handle Fluids Safely−Avoid Fires
SAFETY Handle Fluids Safely−Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and / or a fire may occur, possibly resulting in serious injury or death.  Do not refuel the machine while smoking or when near open flame or sparks.
Page 34: Practice Safe Maintenance
SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the work area clean and dry.  Do not spray water or steam inside cab.  Never lubricate or service the machine while it is moving. ...
Page 35: Warn Others Of Service Work
SAFETY  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.
Page 36: Stay Clear Of Moving Parts
SAFETY Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. SA-026 Support Maintenance Properly ...
Page 37: Prevent Parts From Flying
SAFETY Prevent Parts from Flying  Travel reduction gears are under pressure.  As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.  GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.
Page 38: Replace Rubber Hoses Periodically
SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. ...
Page 39: Prevent Fires
SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.
Page 40 SAFETY Clean up Flammable Materials:  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammable materials may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammable materials immediately.
Page 41: Evacuating In Case Of Fire
SAFETY Evacuating in Case of Fire  If a fire breaks out, evacuate the machine in the following way:  Stop the engine by turning the key switch to the OFF position if there is time.  Use a fire extinguisher if there is time. ...
Page 42: Precautions For Def/Adblue
SAFETY Precautions for DEF/AdBlue®  Although DEF/AdBlue® is minimally hazardous itself and a difficult substance to burn, when heated to 160 °C (320 °F) or higher, such as when there is a fire nearby, it breaks down and generates ammonia gas, so care must be taken. Ammonia gas is toxic, has an extremely irritating odour and is very irritating to the mucous membranes.
Page 43: Avoid Heating Near Pressurized Fluid Lines
 Keep the units away from open flames and fire.  Do not bore a hole, do not cut by torch.  Avoid giving shocks by hitting or rolling the unit.  Before disposing the unit, sealed gas must be released. Consult your nearest Hitachi dealer. S-33...
Page 44: Remove Paint Before Welding Or Heating
 Keep bystanders out of the work site during operation.  Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. S-34...
Page 45: Prevent Battery Explosions
SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. ...
Page 46: Handle Chemical Products Safely
 Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.  Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
Page 47: Notes On Aftertreatment Device
SAFETY Notes on Aftertreatment Device About Aftertreatment Device The aftertreatment device removes particulate matter (PM) and NOx (Nitrogen Oxide) from the exhaust gas. Follow the instructions below to prevent the aftertreatment device from being damaged. WARNING: Exhaust gas from the aftertreatment device, muffler, exhaust piping and tail piping becomes hot during and right after engine running and regeneration of aftertreatment device.
Page 48: Precautions For Communication Terminal
SAFETY Precautions for Communication Terminal Equipment This machine has a communication terminal equipment emitting electrical waves installed inside the rear tray situated at the back of the operator's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, could be affected and malfunction due the electrical waves emitted from the communication terminal equipment.
Page 49 SAFETY  Do not attempt to disassemble, repair, modification and displacement of the communication terminal, antenna and cables. Failure to do so may cause damage or fire on the machine and the communication terminal. (Before removing or installing the communication terminal, consult your authorized dealer.) ...
Page 50: Safety Signs
Always keep the safety signs clean. In case a safety sign is broken or lost, immediately, obtain a new replacement and affix it again in position on the machine. Use the part No. indicated under the right corner of each safety sign illustration when placing an order of it to the Hitachi dealer. SS-4042...
Page 51 SAFETY SIGNS 1. Bucket 21. Hood CAUTION: Sign indicates a fall hazard. Sign indicates a hazard of falling. Do not stand on this place. 4478724370 2. Both Sides of Lift Arm DANGER: Crush Hazard During operation, loads may spill from the bucket and/ or the bucket may suddenly fall.
Page 52 SAFETY SIGNS 5. Cab Inside Right Front Column (3rd safety sign from the top) WARNING: Runover or Entanglement Hazard If the parked machine starts moving unexpectedly, personal injury or death due to entanglement in moving parts or running over by the machine may result. Before leaving the machine, lower the front attachment to the ground, lock the control levers, and remove the key from the key switch.
Page 53 SAFETY SIGNS 9. Hydraulic Oil Tank WARNING: Burn Hazard Sign indicates a burn hazard from compressed air and spurting hot oil if the oil inlet is uncapped during or right after operation. Read the manual for safe and proper handling. 4478725030 10.
Page 54 SAFETY SIGNS 13. Engine Housing 20. Inside Engine Housing WARNING: Burn Hazard Avoid skin contact with highly heated parts such as the engine, muffler, etc. immediately after operation of the machine. Severe burns may result. Do not touch until cool. 4478724990 14.
Page 55 SAFETY SIGNS 17. Inside Battery Box WARNING: Explosion Hazard Sign indicates an explosion hazard. Keep fire and open flames away from this area. 4478724340 18. Inside Battery Box CAUTION: Chemical Burn Hazard Skin contact with electrolyte will cause burns. Splashed electrolyte into eyes will cause blindness.
Page 56 SAFETY SIGNS 23. Both Sides of Counterweight WARNING: Runover Hazard Avoid injury from backing-over accident. Keep everyone far away from the machine during operation. 4478724400 24. Both Sides of Front Frame DANGER: Crush Hazard The articulation area becomes a pinch point when steering the machine.
Page 57 SAFETY SIGNS 27. Cab Inside Right Console To those persons fixed with any medical device. Including implantable device such as a cardiac pacemaker. Please read the instruction manual carefully and follow the instructions before using this machine. label 44787-25020 28. Top of Battery Recycle Batteries Batteries contain lead and acid.
Page 58 SAFETY SIGNS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................S-48...
Page 59: Components Name
COMPONENTS NAME Components Name 1- Cutting Edge (BOC) 2- Bucket 3- Bell Crank 4- Bucket Cylinder 5- Front Combination Light (Headlight/Turn Signal/Clearance Light/Hazard Light) 6- Outside Rear View Mirror 7- Front Work Light 8- ROPS Cab 9- Fuel Filler Port MNSC-01-004 10- Battery 11- Rear Fender...
Page 60: Getting On/Off The Machine
GETTING ON/OFF THE MACHINE Getting ON/OFF the Machine Foot holds (1) and handrails (2) are provided in and around the machine. These are used to get on and off the cab safely as well as to do inspection and maintenance of the machine safely. Never jump on or off the machine as it is very dangerous.
Page 61: Operator's Station
Standardization (ISO). If improper liquid (diesel oil, kerosene or gasoline) is refilled in the DEF/AdBlue® tank, fire or system failure may result.  Use only genuine Hitachi engine oil. Using engine oil other than Hitachi genuine oil may result in malfunction of the aftertreatment device.
Page 62 OPERATOR'S STATION  Do not modify the machine without authorization. Never attempt to modify the air inlet and exhaust parts such as the air duct, aftertreatment device and the exhaust piping. Also never attempt to disassemble the aftertreatment device. Avoid giving shocks on the aftertreatment device by striking elements with other objects or dropping the device.
Page 63 OPERATOR'S STATION  If auto regeneration did not complete, an aftertreatment device regeneration request will blink on the monitor. (Refer to the page 1-13) Perform manual regeneration following the specified procedure. (Refer to the page 1-62)  When the machine is operated without performing manual regeneration, the aftertreatment device may be damaged.
Page 64: Cab Features
OPERATOR'S STATION Cab Features 1- Front Defroster 2- Front Console 3- Operator's Seat 4- Right Console 5- Document Holder 6- Hot/Cool Box 7- Rear Defroster 8- Glove Compartment 9- Cup Holder 10- Floor Mat MNEC-01-035...
Page 65: Front Console
OPERATOR'S STATION Front Console 1- Air Conditioner Front Vent 2- Hazard Switch 3- Work Light Switch 4- Parking Brake Switch 5- Neutral Lever Lock (Forward/Reverse Lever) 6- Steering Wheel 7- Monitor Panel 8- Horn Switch MNDB-01-001 9- Accelerator Pedal 10- Brake/Inching Pedal (Both right and left sides are interlocked.) 11- Front/Rear Wiper Switch 12- Forward/Reverse Lever/Shift Switch...
Page 66: Right Console
OPERATOR'S STATION Right Console Multi-Function Joystick Type 1- Forward/Reverse Switch 2- Multi-Function Joystick Lever 3- Quick Shift Switch (QSS) 4- Auxiliary 5- Auxiliary Control Lever (Optional) 6- Control Lever Lock Switch 7- Auxiliary 8- Traction Control Switch MNDB-01-005 9- Power Mode Switch 10- Forward/Reverse Selector Switch 11- Emergency Steering Operation Check Switch (Optional) 12- Auxiliary...
Page 67: Monitor Panel
OPERATOR'S STATION Monitor Panel MPTC-01-019 1- Left Turn Signal Indicator 21- Monitor Display Mode Selector 2- High Beam Indicator 22- Not Used 3- Work Light Indicator 23- Monitor Display Selector (Up) 4- Right Turn Signal Indicator 24- Preheat Indicator 5- Aftertreatment Device Warning Indicator 25- Monitor Display Selector (Down) 6- Not Used 26- Forward/Reverse Selector Switch Indicator...
Page 68: Service Indicator
OPERATOR'S STATION Service Indicator WARNING: Prevent possible casualty and/or machine damage. If the service indicator flashes and the alarm buzzer sounds, immediately stop machine operation. Then, check and service the section displaying the trouble. The service indicator comes ON and the alarm buzzer sounds if one of the following cases below occurs.
Page 69: Parking Brake Indicator (Red)
OPERATOR'S STATION Parking Brake Indicator (Red) The parking brake indicator will light when the parking brake is applied. If the forward/reverse lever is moved to either the forward (F) or the reverse (R) position when the parking brake is applied, the alarm buzzer will sound.
Page 70: Hst Warning Indicator (Red)
OPERATOR'S STATION HST Warning Indicator (Red) If any serious abnormality occurs in the HST and/or HST related parts, the red indicator will light. If the HST warning indicator and the service indicator light, immediately move the machine to a safe area, set the machine in the park position and stop the engine.
Page 71: Overheat Indicator (Red)
OPERATOR'S STATION Overheat Indicator (Red) If the engine coolant temperature increases to the abnormally high range, the red indicator will light, the service indicator will flash, and the alarm buzzer will sound. Stop operation. Run the engine at slow idle speed to lower the coolant temperature.
Page 72: Preheat Indicator (Yellow)
OPERATOR'S STATION Preheat Indicator (Yellow) The engine is being preheated as long as the preheat indicator stays ON. When the preheat indicator goes OFF, engine preheating is completed. M4GB-01-031 HST Oil Temperature Indicator (Red) If the HST oil temperature is kept higher than the specification for a short period of time, both the HST oil temperature indicator and the service indicator come ON.
Page 73: Coolant Temperature Gauge
OPERATOR'S STATION Coolant Temperature Gauge The engine coolant temperature is indicated with a needle. When the needle stays in range (1) during operation, the coolant temperature is normal. If the engine coolant temperature becomes abnormally high, the service indicator will flash and the alarm buzzer will sound.
Page 74: Turn Signal Indicator (Green)
OPERATOR'S STATION Turn Signal Indicator (Green) When the turn signal lever is operated, the turn signal and the turn signal indicator start flashing. M4GB-01-032 High Beam Indicator (Blue) When the head lights are used at the high beam position, the indicator will light.
Page 75: Clearance Light Indicator (Green)
OPERATOR'S STATION Clearance Light Indicator (Green) When the clearance lights are turned ON, this indicator will light. M4GB-01-035 Control Lever Lock Indicator (Red) When the control lever lock switch is in ON position, the control lever lock indicator will light. MNEC-01-004 Power Mode Indicator (Green) When the power mode switch is in ON position, the power...
Page 76: Monitor Display
OPERATOR'S STATION Monitor Display 1- Monitor Display 2- Monitor Display Mode Selector 3- Monitor Display Selector (Up) 4- Monitor Display Selector (Down) 5- Speedometer 6- Information Display 7- Traction Control Indicator MPTC-01-019 8- Forward/Reverse and Shift Position Indicator 9- Ride Control Indicator 10- ECO Indicator 11- DEF/AdBlue®...
Page 77: Forward/Reverse And Shift Position Indicator
OPERATOR'S STATION Forward/Reverse and Shift Position Indicator Forward/Reverse and Shift Position Indicator (1) displays the machine driving status (selected FNR lever and shift positions). MPTC-01-020  FNR (Forward/Reverse) Position Indicator FNR position indicator (2) displays the selected position of forward (F)/neutral (N)/reverse (R) lever (3). (Letters F-N-R are constantly displayed.) MNSC-01-001 MNDB-01-002...
Page 78 OPERATOR'S STATION  Shift Position Indicator When shift switch (4) is in either H or L position, shift position indicator (3) displays the actually selected shift stage.  Forward: 2 stages  Reverse: 2 stages MNSC-01-001 Low Speed (L) High Speed (H) MNDB-01-002 ...
Page 79: Speedometer
OPERATOR'S STATION Speedometer Speedometer (1) indicates the present machine driving speed. While information display (2) is indicating the drive distance, each time monitor display mode selector (3) is pressed, the indicated speed unit alternates between “km/h” and “MPH. ” MPTC-01-019 MPTC-01-020 1-21...
Page 80: Ride Control Indicator (Optional)
OPERATOR'S STATION Ride Control Indicator (Optional) Ride control indicator (1) lights when ride control switch (2) is turned ON. MPTC-01-020 ECO Indicator ECO indicator (3) lights when the engine runs in energy efficient condition. It becomes OFF when the driving speed is 2 km/h (1.24 mph) or lower or under heavy driving load.
Page 81: Def/Scr System Alarm
OPERATOR'S STATION DEF/SCR System Alarm When the DEF/AdBlue® level becomes low and/or the Urea SCR system malfunctions, the engine performance is controlled depending on the status. The operator is alerted with alarm indicators and buzzer. Move and park the machine in a safe place and follow troubleshooting guide for the accompanied alarms.
Page 82: Urea Scr System Malfunction
OPERATOR'S STATION Urea SCR System Malfunction Alarm Indicator Buzzer Status/Inducement Buzzer sounds once. (0.3 seconds) Urea SCR system is broken. (Red, light) (Red, light) Buzzer sounds every 1.2 seconds. (Red, slow blink) Urea SCR system is broken. Engine output and speed are Buzzer sounds every 1.2 seconds.
Page 83: Machine Information Display
OPERATOR'S STATION Machine Information Display When the key switch is turned ON, the machine information area (4) displays the machine information. When the key switch is turned ON, the machine information display indicates engine start-ready screen (5). Each 0.5 seconds, the most left side indication is counted down as shown in display illustration (6).
Page 84: Shifting Item To Be Indicated On Machine Information Display
OPERATOR'S STATION Shifting Item to be Indicated on Machine Information Display Press monitor display selector (2) to shift the display item one a time in order from the clock display on the machine information display. MPTC-01-019  Clock (24H) : When monitor display selector ( )(2) is pressed once: : When monitor display selector ( )(3) is pressed once:...
Page 85 OPERATOR'S STATION IMPORTANT: Each time the oil is changed and/or oil filter is replaced, reset the displayed monitor time by pressing monitor display mode selector (1) for more than 2 seconds. Beware not to press monitor display mode selector (1) when the display is indicating the time to change or replace.
Page 86 OPERATOR'S STATION MPTC-01-019  Transmission Oil Hour Meter : When monitor display selector ( )(2) is pressed once: Screen I and time screen J indicating the remaining hours up : When monitor display selector ( )(3) is pressed once: to transmission oil change are alternately displayed. Transmission Oil When the remaining hour reading becomes 0 hour, Hour Meter...
Page 87 OPERATOR'S STATION MPTC-01-019  Engine Oil Filter Hour Meter : When monitor display selector ( )(2) is pressed once: Screen P and time screen Q indicating the remaining hours up : When monitor display selector ( )(3) is pressed once: to engine oil filter replacement are alternately displayed Engine Oil Filter When the remaining hour reading becomes 0 hour,...
Page 88 OPERATOR'S STATION MPTC-01-019  Axle Oil Hour Meter Axle Oil Hour Screen Y and time screen Z indicating the remaining hours up Meter to axle oil change are alternately displayed. Press button (3) When the remaining hour reading becomes 0 hour, Remaining hours Alternate display maintenance indicator (4) will light.
Page 89: Resetting Of Oil Change And Filter Replacement Intervals
OPERATOR'S STATION Resetting of Oil Change and Filter Replacement Intervals Reset oil change and/or oil filter replacement intervals as needed: Hydraulic Oil Change Interval Hour Meter Oil change intervals can be reset to “2000.0”, “1500.0”, or “1000.0”. The interval set when the machine was shipped from the factory is “2000.0”.
Page 90: Hydraulic Oil Filter 1 Replacement Interval Hour Meter
OPERATOR'S STATION Hydraulic Oil Filter 1 Replacement Interval Hour Meter Hydraulic oil filter replacement intervals can be reset to “1000.0” or “500.0”. The interval set when the machine was shipped from the factory is “1000.0”. While displaying the change interval hours, keep pressing switch (1).
Page 91: Hydraulic Oil Filter 3 Replacement Interval Hour Meter
OPERATOR'S STATION Hydraulic Oil Filter 3 Replacement Interval Hour Meter Hydraulic oil filter replacement intervals can be reset to “500.0”, “250.0”, or “100.0”. The interval set when the machine was shipped from the factory is “500.0”. While displaying the change interval hours, keep pressing switch (1).
Page 92: Transmission Oil Change Interval Hour Meter
OPERATOR'S STATION Transmission Oil Change Interval Hour Meter Oil change intervals can be reset to “1000.0”, “500.0”, or “250.0”. The interval set when the machine was shipped from the factory is “1000.0”. While displaying the change interval hours, keep pressing switch (1).
Page 93: Transmission Oil Filter Replacement Interval Hour Meter
OPERATOR'S STATION Transmission Oil Filter Replacement Interval Hour Meter Transmission oil filter replacement intervals can be reset to “500.0”, “250.0”, or “100.0”. The interval set when the machine was shipped from the factory is “500.0”. While displaying the replacement interval hours, keep pressing switch (1).
Page 94: Engine Oil Change Interval Hour Meter
OPERATOR'S STATION Engine Oil Change Interval Hour Meter Oil change intervals can be reset to “500.0”, “250.0”, or “200.0”. The interval set when the machine was shipped from the factory is “500.0”. While displaying the change interval hours, keep pressing switch (1).
Page 95: Engine Oil Filter Replacement Interval Hour Meter
OPERATOR'S STATION Engine Oil Filter Replacement Interval Hour Meter Filter replacement intervals can be reset to “500.0”, “250.0”, or “200.0”. The interval set when the machine was shipped from the factory is “500.0”. While displaying the replacement interval hours, keep pressing switch (1).
Page 96: Fuel Filter Replacement Interval Hour Meter
OPERATOR'S STATION Fuel Filter Replacement Interval Hour Meter Filter replacement intervals can be reset to “1000.0” or “500.0”. The interval set when the machine was shipped from the factory is “1000.0”. While displaying the replacement interval hours, keep pressing switch (1). NOTE: When switch (1) is released, time resetting is completed.
Page 97: Axle Oil Change Interval Hour Meter
OPERATOR'S STATION Axle Oil Change Interval Hour Meter Oil change intervals can be reset to “2000.0”, “1500.0”, or “1000.0”. The interval set when the machine was shipped from the factory is “2000.0”. While displaying the change interval hours, keep pressing switch (1).
Page 98: Clock Setting Mode
OPERATOR'S STATION Clock Setting Mode The clock display on the machine information display screen can be set in the clock setting mode. NOTE: If battery power is interrupted for an extended period of time, the time display screen may indicate “Year of 2000, Month of 1, day of 1, and time of 00:00”...
Page 99: Switches, Steering Wheel And Pedals
OPERATOR'S STATION Switches, Steering Wheel and Pedals 1- Air Conditioner Front Vent 2- Hazard Switch 3- Work Light Switch 4- Parking Brake Switch 5- Neutral Lever Lock (Forward/Reverse Lever) 6- Steering Wheel 7- Monitor Panel 8- Horn Switch MNDB-01-001 9- Accelerator Pedal 10- Brake/Inching Pedal (Both right and left sides are interlocked) 11- Front/Rear Wiper Switch...
Page 100: Forward/Reverse Lever/ Shift Switch
OPERATOR'S STATION Forward/Reverse Lever/ Shift Switch 1, 2 IMPORTANT: The forward/reverse lever and shift switch are designed to operate with low effort. Low Speed (L) Do not press and twist the lever and switch firmly. Damage to the lever and switch may result. High Speed (H) Forward/Reverse Lever Changes the machine drive direction from forward to...
Page 101: Neutral Lever Lock (For The Forward/Reverse Lever)
OPERATOR'S STATION Neutral Lever Lock (for the Forward/Reverse Lever) UNLOCK WARNING: When the machine is parked or serviced, be sure to place neutral lever lock (1) in the LOCK position. The neutral lever lock makes forward/reverse lever (4) immovable so that the machine does not start moving even if a body part comes in contact with forward/reverse lever (4) by mistake.
Page 102: Turn Signal Lever
OPERATOR'S STATION Turn Signal Lever Indicates the drive change direction to persons and/or other vehicles by operating turn signal lever (7). Return turn signal lever (7) to neutral manually. L- Left Turn R- Right Turn MNDB-01-003 1-44...
Page 103: Light Switch
OPERATOR'S STATION Light Switch Light switch (1) has three positions, OFF, Small, and Main. As shown below, each light comes ON ( ) or OFF ( according to the selected position of the light switch. 2- Headlight 3- Turn Signal / Hazard Light / Clearance Light 4- Turn Signal/Hazard Light 5- Brake Light/Tail Light MNDB-01-003...
Page 104: High-Low Beam Switch
OPERATOR'S STATION High-Low Beam Switch Shifts the direction of the headlight beam high and low. CAUTION: Travel the machine with the headlight in the low beam position when other vehicles are present in the vicinity. By bringing down signal lever (7) with the headlight ON, the headlight beam turns upward, and high beam indicator (8) comes ON.
Page 105: Wiper Switch
OPERATOR'S STATION Wiper Switch Wiper Operation IMPORTANT: The windshield surface, the wiper blade, the wiper motor and the relay may be damaged due to dry or frozen condition of the wiper and the windshield.  Before operating the windshield wiper, remove snow or dust from the windshield surface and defrost the frozen windshield.
Page 106: Front/Rear Wiper Switch
OPERATOR'S STATION Front/Rear Wiper Switch Operate wiper switch (1) to move the front and rear windshield wipers. IMPORTANT: The washer motor may become damaged if washer fluid is continuously used for more than 20 seconds or the wiper switch is operated with no fluid in the washer tank.
Page 107: Hazard Switch
OPERATOR'S STATION Hazard Switch IMPORTANT: Do not hold hazard switch (1) in the " " position for a long time with the engine stopped. The batteries will become discharged. When a machine failure occurs, use this switch to inform other vehicles that the machine is in an emergency situation.
Page 108: Work Light Switch
OPERATOR'S STATION Work Light Switch Press the mark on switch (1) while the light switch is in " " or " " position to turn front work lights (2) ON. Rear work lights (3) stay OFF. When the side with mark switch (1) is pressed, both front work lights (2) and rear work lights (3) are turned ON.
Page 109: Parking Brake Switch
OPERATOR'S STATION Parking Brake Switch WARNING:  To prevent accidents due to running away of the machine, after parking the machine or before leaving the machine, be sure to apply the parking brake.  Never apply the parking brake while traveling the machine.
Page 110: Accelerator Pedal
OPERATOR'S STATION Accelerator Pedal When accelerator pedal (3) is stepped on, the engine speed increases. When released, the engine speed decreases. NOTE: The engine speed may change due to the machine control regardless of the operation of the accelerator pedal. Brake/Inching Pedal WARNING: MNDB-01-001...
Page 111: Tilt, Telescopic Lever/Steering Column Tilt Pedal
OPERATOR'S STATION Tilt, Telescopic Lever/Steering Column Tilt Pedal WARNING:  Before operating the machine, be sure that the steering wheel is locked.  Do not operate the tilt, telescopic lever (1) and steering column tilt pedal (2) during operation.  Before operating the machine, adjust the steering column inclination so as to match the operator's physical constitution.
Page 112: Slow Speed (L) Select Switch
OPERATOR'S STATION Slow Speed (L) Select Switch Maximum speed can be selected from 7 km/h to 11.5 km/h range by operating slow speed (L) select switch (2) while shift switch (1) is in the low speed (L) position. MNDB-01-001 LO SPEED MNDF-01-019 1-54...
Page 113: Right Console
OPERATOR'S STATION Right Console Multi-Function Joystick Type 1- Forward/Reverse Switch 2- Multi-Function Joystick Lever 3- Quick Shift Switch (QSS) 4- Auxiliary 5- Auxiliary Control Lever (Optional) 6- Control Lever Lock Switch 7- Auxiliary 8- Traction Control Switch MNDB-01-005 9- Power Mode Switch 10- Forward/Reverse Selector Switch 11- Emergency Steering Operation Check Switch (Optional) 12- Auxiliary...
Page 114: Control Lever
OPERATOR'S STATION Control Lever The control lever is used to operate the lift arm and/or bucket. Lever Bucket Operation Position Float: The lift arm free falls and can be moved as loads are applied. Lift Arm Lower Hold: The lift arm is stopped and held in that position.
Page 115: Control Lever Lock Switch
OPERATOR'S STATION Control Lever Lock Switch WARNING:  Before leaving the operator's seat, be sure to stop the engine. Then, set control lever lock switch (1) to the LOCK ( ) position.  Always check to be sure that the control lever lock switch is set in the LOCK ( ) position before transporting the machine or leaving the machine at the end of the shift.
Page 116: Armrest Adjust Handle
OPERATOR'S STATION Armrest Adjust Handle The armrest is provided so that the operator can operate the lever with an arm on the armrest, for comfort and ease. Loosen handle (1) and position the armrest height to fit the operator's preference, tighten handle (1) to fix the armrest. L : Loosen R : Tighten MNDB-01-005...
Page 117: Traction Control Switch
OPERATOR'S STATION Traction Control Switch When traction control switch (1) is turned ON, indicator (2) is lit. This function prevents tire slip on the slippery road and improves working efficiency by controlling the maximum tractive force when digging load is high. ON : Use for work on slippery road surfaces, such as removing snow.
Page 118: Power Mode Switch
OPERATOR'S STATION Power Mode Switch Operating power mode switch (1) turns the power mode function ON and OFF. Power Mode Material OFF Mode  Crushed Rocks in Smaller (Loading work with Diameter more emphashis on  Gravel fuel consumption)  Stone ...
Page 119: Aftertreatment Device Regeneration Switch
OPERATOR'S STATION Aftertreatment Device Regeneration Switch This switch is for performing manual regeneration of the aftertreatment device. When the need for aftertreatment device regeneration is indicated, press aftertreatment device regeneration switch (1) to start manual regeneration. MNDB-01-005 MNSC-01-011 1-61...
Page 120: Manual Regeneration Procedure
OPERATOR'S STATION Manual Regeneration Procedure IMPORTANT:  Manual regeneration that is performed when the aftertreatment device regeneration request is displayed restores aftertreatment device function. This is not a malfunction.  If the machine is continuously operated despite the aftertreatment device regeneration request is displayed, aftertreatment device alarm and engine trouble alarm will be displayed, and the buzzer sounds.
Page 121 OPERATOR'S STATION CAUTION: The manual regeneration does not start unless the accelerator pedal is OFF, forward/reverse lever is in Neutral, parking switch is ON, and the front attachment lock switch is ON. When touching the accelerator pedal, forward/reverse lever, parking switch and the front attachment lock switch, the regeneration process is aborted.
Page 122: Ride Control Switch
OPERATOR'S STATION Ride Control Switch WARNING:  To ensure safety, operate the ride control switch only after parking the machine with the bucket lowered to the ground.  When operating the machine with the front attachment in the float position (scooping, grading, or snow removal), always turn the ride control switch OFF.
Page 123: Forward/Reverse Selector Switch
OPERATOR'S STATION Forward/Reverse Selector Switch Forward/reverse selector switch (1) is a switch that activates forward/reverse switch (2) on the control lever. When forward/ reverse selector switch (1) is in ON position, the machine travels in forward or reverse direction by pressing (F) or (R) button of forward/reverse switch (2).
Page 124: Cigar Lighter
OPERATOR'S STATION Cigar Lighter Using Cigar Lighter WARNING: Never touch other than the knob part. Otherwise, it may result in severe burns. IMPORTANT: In case the cigar lighter does not pop out automatically 30 seconds after pushing the cigar lighter in, pull out the cigar lighter manually. Then, consult your nearest authorized dealer.
Page 125: Ash Tray
OPERATOR'S STATION Ash Tray WARNING: Take precautions against fires. Use ash tray (1) when smoking in the cab. MNDB-01-003 1-67...
Page 126: Auto Air Conditioner
OPERATOR'S STATION Auto Air Conditioner Feature  Full Auto-Temperature Control: Automatically controls the cab temperature to maintain the temperature set by the temperature control switch regardless of outside air temperature and insolation.  Max. Cooling and Heating: Maximum cooling or heating can be obtained by pressing the top side mark "...
Page 127: Components Name
OPERATOR'S STATION Components Name 1- Control Panel 2- Front Vent 3- Rear Vent 4- Foot Vent 5- Defroster Vent 6- Power OFF Switch 7- Blower Switch MNDB-01-011 8- Liquid-Crystal Display (LCD) 9- Temperature Control Switch 10- Mode Switch 11- AUTO Switch 12- Air Conditioner Switch 13- Circulation/Fresh Air Switch 14- Defroster Switch...
Page 128: Controller Part Name And Function
OPERATOR'S STATION Controller Part Name and Function  Power OFF Switch (6) Stops the blower. When the switch is pressed, all displays (vent mode, set- temperature, and blower speed) on the LCD (8) panel will disappear and the blower stops in both the auto and manual modes.
Page 129 OPERATOR'S STATION  Temperature Control Switch (9) Sets the air temperature in the range of 18 to 32.0 °C (65 to 90 °F) in the MANUAL and AUTO modes. Temperature can be set by 0.5 °C (0.9 °F) increments. The set-temperature is displayed on the LCD (8) center.
Page 130: Mode/Temperature Control Switch
OPERATOR'S STATION Mode/Temperature Control Switch  Mode Switch (10) Selects the air vent. The selected air vent is indicated on LCD (8). Front Vent Mode Front/Rear Vent Mode MNDB-01-011 Front/Rear/Foot Vent Mode Foot Vent Mode Foot/Defroster Vent Mode Defroster Vent Mode Each time mode switch (10) is pressed, the vent location can be changed in 6 stages as illustrated below.
Page 131 OPERATOR'S STATION  AUTO Switch (11) Selects the air conditioner operation mode in either AUTO or MANUAL.  AUTO Operation Mode 15 16 Press AUTO switch (11). When the indicator comes ON, the AUTO operation mode is selected. In response to the set temperature, the blower speed, vent mode, and ventilation mode are automatically controlled.
Page 132: Defroster Operation
OPERATOR'S STATION Defroster Operation 1. Press defroster switch (14) to change defroster vent mode; the fresh air mode and air conditioner will turn 2. Temperature in the cab can be adjusted by operating temperature control switch (9). 3. Operate blower switch (7) to adjust flow. 4.
Page 133: Tips For Optimal Air Conditioner Usage
OPERATOR'S STATION Tips for Optimal Air Conditioner Usage For Rapid Cooling Temperature in the cab may rise over 80°C (176°F) when the machine is exposed to sun light in the summer. For rapid cooling, ventilate air in the cab first. After starting the engine, set the temperature control to maximum cooling (18°C, 65°F) using temperature control switch (9).
Page 134: Adjusting Operator's Seat (Air Suspension Type Seat) (Sears)
OPERATOR'S STATION Adjusting Operator's Seat (Air Suspension Type Seat) (Sears) Adjust the seat for comfort and so that the pedals may be pushed fully down when the operator's back is fully against the seat back. Components Name 1- Armrest Angle Adjustment 2- Lumbar Support Adjustment 3- Reclining Angle Adjustment 4- Damper Adjustment...
Page 135: Rear Tray
OPERATOR'S STATION Rear Tray 1- Document Holder 2- Hot/Cool Box 3- Electric Power Output 4- Tray 5- Fuse Box 6- Cup Holder MNEC-01-046 Electric Power Output 12 V DC electric power is available from electric power output (3). The maximum current is 5A (60W). Use the electric power output to supply power to lighting equipment for servicing the machine.
Page 136: Fuse Box
OPERATOR'S STATION Fuse Box IMPORTANT: If a fuse blows, turn the key switch OFF. After checking and correcting the cause of the trouble, replace the fuse with a new one. The slow blow fuses (1 and 2) function as a safety valve to prevent excess current from flowing in the electrical system.
Page 137: Fuse Box A
OPERATOR'S STATION Fuse Box A 10- PARKING 20- OPTION 4 (10 A) 9- AC 1 19- OPTION 3 10 A (10 A) 8- STOP LAMP 18- DC-DC UNIT (ENGINE) 7- BACK BUZZER 17- SCR SYSTEM 30 A 6- HST 2 16- Ad Blue SENSOR 15 A 5- HEAD LAMP...
Page 138: Hot/Cool Box
OPERATOR'S STATION Hot/Cool Box Cool or warm air from the air conditioner is routed to hot & cool box (1) so that food or a drink can be temporarily stored. Use a container with a tight cap in the hot/cool box. MNEC-01-048 Tray and Drink Holder IMPORTANT: Tray (2) is not a waterproof type.
Page 139: Rops Cab
OPERATOR'S STATION ROPS Cab ROPS cab (1) is standard equipment. 1- ROPS Cab 2- Speakers 3- Front Room Light 4- Sun Visor MNSC-01-010 M4GB-01-113 M4GB-01-114 MNEC-01-052 1-81...
Page 140 OPERATOR'S STATION 5- Radio 6- Cab Switch Panel (Optional) 7- Room Rear View Mirror 8- Rear Room Light 9- Emergency Evacuation Hammer 10- Coat Hook MNEC-01-534 M4GB-01-117 MNEC-01-536 1-82...
Page 141: Front Room Light
OPERATOR'S STATION Front Room Light Press ON side of switch (1) to turn the room light ON. The room light switch has three operation positions. : Light (2) comes and stays ON. Neutral : When the cab door is opened, light (2) comes ON. When closed, light (2) goes OFF.
Page 142: Sun Visor
OPERATOR'S STATION Sun Visor When sunlight is strong, use sun visor (4) by hanging its edge from the cab top down to a desired hook preset. MNEC-01-052 Emergency Evacuation Hammer In case the cab door becomes difficult or impossible to open if an emergency situation occurs, evacuate from the machine by breaking the windowpane using the provided hammer.
Page 143: Upper Switch Panel (Optional)
OPERATOR'S STATION Upper Switch Panel (Optional) 1- Auxiliary 2- Rear View Mirror Heater Switch (Optional) 3- Auxiliary 4- Auxiliary 5- Auxiliary MNEC-01-534 Rear View Mirror Heater Switch IMPORTANT: Do not use for a long time with the engine stopped. Doing so will drain the battery. Once the mirror is defogged, turn OFF the switch.
Page 144: Outside Rear View Mirror
OPERATOR'S STATION Outside Rear View Mirror WARNING: Do not travel the machine in reverse by relying on only the range of vision the rear view mirror (1) provides. Use the rear view mirror only as an assistant during travel operation. Be sure to confirm the safety by using your own visibility when traveling the machine in reverse.
Page 145: Door Lock Knob
OPERATOR'S STATION Door Lock Knob CAUTION: After closing the door, always check that the door lock is securely engaged. Depress door lock knob (5) to engage the door lock. M4GB-01-128 Door Open/Close Lever When opening the door, while lifting door lock knob (5), pull lever (6) to disengage the door lock.
Page 146: When Fully Opening The Left Door
OPERATOR'S STATION When Fully Opening the Left Door WARNING: Before getting on or off the cab using the hand rails, check that the cab door is securely locked. If the hand rails are used without locking the door securely, the door lock may come off, possibly causing falling accident.
Page 147: Battery Disconnect Switch
OPERATOR'S STATION Battery Disconnect Switch IMPORTANT: Never turn the disconnect switch OFF while the engine is running or the key switch is in the position other than OFF. Failure to do so may damage the electrical system. The battery disconnect switch is different from the engine start key switch.
Page 148: Switch Operation
OPERATOR'S STATION Switch Operation 1. Open the cover of the battery box. When lever (1) is vertical to the ground, battery disconnect switch (2) turns ON. The lever can not be removed when lever (1) points downward. When operating the machine with battery disconnect switch (2) ON, close the cover.
Page 149: Articulation Lock Bar
OPERATOR'S STATION Articulation Lock Bar WARNING:  Before servicing or transporting the machine, be sure to engage lock bar (1).  Before driving the machine, be sure to disengage the lock bar (1) from the front frame and fasten the lock bar to the rear frame with pin and β-form lock pin (2).
Page 150: Towing Pin
OPERATOR'S STATION Towing Pin WARNING: Since towing is a potentially dangerous operation, perform only when there is an emergency and crisis situation. IMPORTANT: Available towing forces by machine model are as follows. To prevent excessive wear of tires, avoid towing operation requiring more than the available towing force.
Page 151: Inspection/Maintenance Side Access Cover
OPERATOR'S STATION Inspection/Maintenance Side Access Cover CAUTION:  Always close side covers (1) during traveling and/or working operation.  Do not keep the side cover open on a slope or when a strong wind is blowing. Failure to do so may be dangerous because the side cover may unexpectedly close.
Page 152: Steps
OPERATOR'S STATION Steps WARNING: When getting on and off the machine, use steps and hand rails to support your body with at least three points. Getting on and off the machine with less than three support points may cause you to slip, possibly resulting in a falling accident.
Page 153: Vandal-Proof Devices
OPERATOR'S STATION Vandal-Proof Devices A lock key can be installed to battery cover (1), DEF/AdBlue® tank (2) and grease gun box (3). Fuel tank cap (4), side covers (5), rear grille (6), air conditioner fresh air filter (7) and expansion tank cap (8) can be locked with the keys.
Page 154: Seat Belt
OPERATOR'S STATION Seat Belt WARNING: Always use the seat belt when operating the machine. Before operating the machine, be sure to examine the seat belt and attaching hardware for any failure. If any damage and/or wear is found, replace the part concerned.
Page 155: Break-In
BREAK-IN Break-in Operation for New Machine IMPORTANT: If the machine is heavily loaded without performing break-in operation, damage to the machine such as seizure and/or scoring may result by which the machine life will be remarkably shortened. Be sure to sufficiently perform break-in operation. Machine life and performance will be greatly affected by the extent of operation and maintenance of the machine during the initial operation.
Page 156 BREAK-IN MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 157: Operating Engine
OPERATING ENGINE Inspect Machine Daily Before Starting IMPORTANT: Make sure there are no oil and water leaks on the ground under the machine. If there is oil and water leakage, it may cause damage. Please check the cause immediately, and perform the maintenance. Perform the required daily check before starting the engine.
Page 158 OPERATING ENGINE Check Points Check Contents 8. Chassis 1. Oil leaks of the transmission and the axle 2. Level, leaks and contamination of the fuel tank. Drain fuel tank sump. 3. Fuel leaks and damage of the fuel hoses and pipe lines 4.
Page 159: Check Before Starting
OPERATING ENGINE Check Before Starting CAUTION: In the interest of safety, put Forward/ Reverse selector switch (5) in its OFF position prior to starting the engine. 1. Ensure that the battery disconnect switch is in the ON position. 2. Check that both forward/reverse lever (2) and forward/ reverse switch (6) are in the neutral (N) position and neutral lever lock (3) is in the LOCK position.
Page 160 OPERATING ENGINE 5. Check that control lever lock switch (7) is in the LOCK ( ) position. MNDB-01-005 6. Adjust the position of outside rear view mirror (8) and room rear view mirror (9) so that the best rear visibility can be obtained.
Page 161: Starting Engine
OPERATING ENGINE Starting Engine Follow the steps below to start the engine without depressing accelerator pedal (3). 1. Check that both forward/reverse lever (8) and forward/ reverse switch (9) are in the neutral (N) position and neutral lever lock (10) is in the LOCK position. 2.
Page 162 OPERATING ENGINE IMPORTANT: Never operate the starter for more than 10 seconds at a time. If the engine fails to start, return key switch to OFF. Wait for more than 30 seconds, then try again. Failure to do so may damage the starter or discharge the batteries.
Page 163: Starting In Cold Weather
OPERATING ENGINE Starting in Cold Weather Preheating 1. Turn the key switch (1) ON. The coolant temperature sensor is activated so that the engine is automatically preheated. 2. Preheat indicator (2) comes ON. As long as the preheat indicator stays ON, the engine is being heated. MNDB-01-053 NOTE: Preheating time varies depending on the coolant temperature.
Page 164: Check After Starting
OPERATING ENGINE Check After Starting IMPORTANT: If any abnormality is found in the monitor functions, immediately stop the engine and investigate the cause of the trouble. Check the monitor operation: 1. Check that discharge warning indicator (1) is OFF. In case the discharge warning indicator stays ON, immediately stop the engine.
Page 165: Using Booster Batteries
OPERATING ENGINE Using Booster Batteries IMPORTANT: The machine electrical system is a 24 volt negative (-) ground. Use only 24 volt booster batteries with sufficient capacity. WARNING:  An explosive gas is produced while batteries are in use or being charged. Keep open flames and sparks away from the battery area.
Page 166: Machine
OPERATING ENGINE 1. Connecting the booster batteries 1.1 Stop the engine on the booster battery mounted machine. 1.2 Connect one end of red booster cable (1) to the positive (+) terminal of the machine battery, and the other end to the positive (+) terminal of the booster battery.
Page 167: Warming Up Operation
OPERATING ENGINE Warming Up Operation WARNING: After starting the engine, start the machine operation only after confirming that the engine speed changes by operating accelerator pedal (3). Otherwise, the machine or the front attachment may unexpectedly start moving, possibly causing accidents such as a crash.
Page 168: Warming Up Operation In Cold Weather
OPERATING ENGINE Warming Up Operation in Cold Weather WARNING: After starting the engine, start the machine operation only after confirming that the engine speed changes by operating accelerator pedal (3). Otherwise, the machine or the front attachment may unexpectedly start moving, possibly causing accidents such as a crash.
Page 169 OPERATING ENGINE 2. Run the engine at slow idle speed for more than 5 minutes. NOTE: At this time, do not operate the engine in slow or fast speed. 3. Slowly raise the bucket 1 m off the ground. 4. Slowly extend the bucket cylinder to stroke end. NOTE: Do not continuously operate the control lever for more than 10 seconds at this time.
Page 170: Stopping Engine
OPERATING ENGINE Stopping Engine Stop the engine in the following manner. IMPORTANT: Never stop the engine while traveling the machine. If the engine stops, the steering system may become inoperable, or it may cause other malfunctions or seizure of parking brake. MNDB-01-053 1.
Page 171: Driving Machine
DRIVING MACHINE Driving the Machine Correct operation will result in extending the service life of each part and component as well as saving fuel and oil. Always be sure to safely and efficiently operate the machine while paying attention to the following points. Precautions for starting to move 1.
Page 172: Starting To Move
DRIVING MACHINE Starting to Move WARNING: Start to move the machine only after checking that no personnel and/or obstacles are present around the machine. Never turn ride control switch (3) (optional) to ON position when traveling the machine or raising the bucket.
Page 173 DRIVING MACHINE 3. Turn neutral lever lock (4) to the UNLOCK ( ) position. 4. Step on brake pedal (6) and press parking brake switch 10, 11 (7) to the OFF position to release the parking brake. Check that at this time parking brake indicator (1) goes OFF.
Page 174: Parking Brake Switch
DRIVING MACHINE Parking Brake Switch WARNING:  To prevent accidents due to running away of the machine, after parking the machine or before leaving the machine, be sure to apply the parking brake.  Never apply the parking brake by operating parking brake switch (1) while traveling the machine except in an emergency.
Page 175: Drive Speed Change
DRIVING MACHINE Drive Speed Change The transmission gear range can be selected by turning shift switch (1). Low speed (L) : To be used for excavation and loading work High speed (H) : To be used for traveling operation. NOTE: Avoid rapid gear changes using shift switch (1) while traveling at high speed.
Page 176: Steering Wheel
DRIVING MACHINE Steering Wheel WARNING:  Avoid quick steering while driving the machine at high speeds, while driving on a steep slope, or while raising the lift arms. Failure to do so may cause the machine to turn over.  Never attempt to stop the engine while steering the machine.
Page 177: Stop And Restart Of Driving
DRIVING MACHINE Stop and Restart of Driving Follow the tips described below when required to stop or restart driving. 1. Slowly release the accelerator pedal. Depress the brake pedal to stop the machine. 2. Slowly depress the accelerator pedal to move the machine again.
Page 178 DRIVING MACHINE Precautions for driving During drive operation, observe the general operating manners beside the precautions described below to ensure safe and correct operation. WARNING:  In case a tire is punctured while driving, securely hold the steering wheel and slowly reduce the drive speed.
Page 179 DRIVING MACHINE Driving in Water or on Soft Ground IMPORTANT: If the axles, transmission, etc. should become submerged, they must be reconditioned immediately, otherwise the inner gears may wear excessively, or the machine may become damaged. Consult your nearest authorized dealer for inspection and maintenance.
Page 180: Precautions For Driving On Slopes
DRIVING MACHINE Precautions for Driving on Slopes WARNING:  When descending a slope, use engine braking. Apply the brakes only when absolutely required. If the brake is continuously used while descending a slope, the brake temperature will increase, possibly decreasing the braking performance. If overheating of the brake system is recognized, immediately park the machine in a safe location.
Page 181: Precautions For Driving Speeds
DRIVING MACHINE Precautions for Driving Speeds CAUTION: Descend the machine on a steep slope with the shift switch in the slow drive gear range while depressing the brake pedal (normal brake) if necessary as well as applying engine brake sufficiently. Traveling for a long time without reducing the speed will create the causes of various machine troubles.
Page 182: Precautions To Be Taken If Machine Failure Occurs
DRIVING MACHINE Precautions to be Taken if Machine Failure Occurs  Keep alert. While paying attention to the vehicles following you, slowly reduce the travel speed and park the machine on the road shoulder as closely to the shoulder edge as possible.
Page 183: Stop The Machine
DRIVING MACHINE Stop the Machine 1. Avoid sudden deceleration. Smoothly reduce the drive speed. Release accelerator pedal (1) and step on brake pedal (2) to stop the machine on level surface. 2. Return forward/reverse lever (3) and forward/reverse switch (7) to neutral (N). Place neutral lever lock (4) to the LOCK position.
Page 184 DRIVING MACHINE IMPORTANT: Do not leave the machine by turning key switch (9) in ACC position. Failure to do so may discharge the batteries. Be sure to turn key switch to OFF position before leaving the machine. 7. Turn key switch (9) to OFF position to stop the engine. Remove the key from the switch.
Page 185: Parking
DRIVING MACHINE Parking IMPORTANT: When parking the machine with cab door and windows open, cab electrical components may be damaged by bad weather. Always close windows, roof vent and cab door when parking the machine. 1. Stop and park the machine on level surface. Lower the bucket to the ground.
Page 186: Emergency Evacuation
DRIVING MACHINE Emergency Evacuation When the engine has stalled during driving: Pressurized oil in the master cylinder acts on the brake when the brake pedal is depressed. Immediately park and stop the machine in a safe location. At this time, do not repeat to pat the brake pedal.
Page 187: Operating Machine
OPERATING MACHINE Control Lever The control lever is used to operate the lift arm and/or bucket. Lever Lift Arm/Bucket Operation Position Float: The lift arm free falls and can be moved as loads are applied. Lift Arm Lower Hold: The lift arm is stopped and held in that position.
Page 188: Control Lever Lock Switch
OPERATING MACHINE Control Lever Lock Switch WARNING:  Ensure that control lever lock indicator (2) on the monitor panel is ON when control lever lock switch (1) is in LOCK ( ) position, and indicator (2) is OFF when control lever lock switch (1) is in UNLOCK ( ) position.
Page 189: Ride Control Switch (Optional)
OPERATING MACHINE Ride Control Switch (Optional) WARNING:  To ensure safety, operate the ride control switch only after parking the machine with the bucket lowered to the ground.  When operating the machine with the front attachment in the float position (scooping, grading, or snow removal), always turn the ride control switch OFF.
Page 190 OPERATING MACHINE AUTO When ride control switch (1) is turned to AUTO, the drive speed sensor and the controller is activated. Then, when the drive speed becomes faster than the preset travel speed, the ride control system automatically operates. When the drive speed becomes slower than the preset travel speed, the ride control system becomes inoperable.
Page 191: Lift Arm Kick Out
OPERATING MACHINE Lift Arm Kick Out WARNING:  Take extra care to prevent personal injury and/or death when adjusting the lift arm kick out system.  Apply the parking brake to prevent the machine from moving unexpectedly. Wedge the wheels with blocks.
Page 192: Bucket Auto Leveler
OPERATING MACHINE Bucket Auto Leveler WARNING:  Pay attention to safety to avoid personal injury and/ or death when adjusting the bucket auto leveler.  Stop the engine. Lower the loader front on the ground to release oil pressure.  Apply the parking brake to prevent the machine from moving unexpectedly.
Page 193 OPERATING MACHINE Adjustment Procedures IMPORTANT: Do not operate the machine with the bucket dumped more than 10°. Avoid applying great towing force to the bucket cutting edge. 1. After moving the bucket to the desired digging angle, stop the engine. 2.
Page 194: Before Operation
OPERATING MACHINE Before Operation WARNING:  Be sure to install only authorized buckets and other work tools on the front attachment.  Never modify or increase the capacity of the bucket or other work tools without first receiving authorization. Do not overload the machine by installing additional counterweights.
Page 195: Avoid Overloading
OPERATING MACHINE Avoid Overloading WARNING:  Do not penetrate the bucket into piles of soil and/ or gravel at fast travel speed to avoid personal accidents.  Avoid excavating or scooping loads when the machine is articulated, which could possibly cause the machine to turn over.
Page 196: Excavation
OPERATING MACHINE Excavation Loading Accumulated Soil IMPORTANT: Avoid operating the machine with the front wheels raised off the ground. Machine traction force is reduced and excessive loads are applied to the undercarriage. M4GB-05-003 Scoop load while driving the machine forward as described below.
Page 197 OPERATING MACHINE Digging and Loading Level Ground IMPORTANT: While excavating with the bucket or fork, never apply excessive traction force to the tooth tips with the bucket or fork tilted more than 10°. Failure to do so may result in cracks or damage to the front attachment.
Page 198: Grading
OPERATING MACHINE Grading WARNING: When operating the machine with the front attachment control lever in the float position when performing such works as soil scooping, land grading, or snow removal, be sure to turn the ride control switch OFF. Failure to do so may allow the ride control system to operate so that the front attachment M4GB-05-011 may automatically move up and down.
Page 199: Loading
OPERATING MACHINE Loading IMPORTANT:  Always maintain a clean surface for machine operation. Cleaning of materials such as soil spilled on the driving surface will reduce wear and/or damage on tires.  When carrying loads in the bucket, pay attention to the travel road surface conditions.
Page 200 OPERATING MACHINE Load and Carrying Method WARNING:  Be sure to provide tire stopper (1) in front of the dumping port.  Before raising the lift arm, slightly tilt the bucket back and forth to stabilize the load in the bucket to avoid personal injury or damage to the machine due to falling of the load.
Page 201 OPERATING MACHINE Loader and Dump Truck Combination Method WARNING:  Always maintain a flat work site surface. Avoid rapid turns and/or sudden braking while raising the lift arm with the bucket loaded to prevent the machine from tipping over.  Do not penetrate the bucket into a loading face at fast travel speeds, possibly resulting in personal accident.
Page 202: Dozing
OPERATING MACHINE Dozing IMPORTANT:  Never attempt to forcibly push piled material higher than the bucket capacity. Premature wear of the tires due to slipping and/or waste of fuel may result.  Do not perform dozing with the bucket dumped. Abnormal excessive stress will be applied on the front attachment.
Page 203: Removing Snow
OPERATING MACHINE Removing Snow WARNING: When operating the machine with the front attachment control lever in the float position when performing such works as soil scooping, land grading, or snow removal, be sure to turn the ride control switch OFF. Failure to do so may allow the ride control system to operate so that the front attachment may automatically move up and down.
Page 204: Precautions For After Operations
OPERATING MACHINE Precautions for After Operations 1. After finishing the day's operation, drive the machine to a firm, level ground where no possibility of falling stones, ground collapse, or floods are present. (Park the machine referring to the "Parking" in the "DRIVING THE MACHINE"...
Page 205 OPERATING MACHINE 5. Maintenance for long term machine storage after Ground Side +24V engaging in snow removal. (Refer to STORAGE section.) (Black Vinyl Cap) (Red Vinyl Cap) Anti-freeze agents such as salt (sodium chloride or calcium chloride) are scattered on snow roads. When the machine is stored for a long time after engaging in snow removal work, perform the following maintenance to protect the machine from being corroded and/or...
Page 206 OPERATING MACHINE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5-20...
Page 207: Transporting
TRANSPORTING Transporting by Road When transporting the machine on public roads, be sure to first understand and follow all local regulations. 1. For transporting using a trailer, check the width, height, length and weight of the trailer when the machine is loaded.
Page 208: Loading / Unloading On Trailer
TRANSPORTING Loading / Unloading on Trailer WARNING: Be sure to use a loading dock or a ramp for loading/unloading. Always load and unload the machine on a firm, level surface. Ramp/Loading Dock: 1. Before loading, thoroughly clean the ramps, loading dock and flatbed.
Page 209 TRANSPORTING Loading / Unloading on Trailer WARNING:  Never steer while driving up or down a ramp as it is extremely dangerous and may cause the machine to turnover. Never attempt to steer the machine on a ramp. If the travel direction must be changed on a slope, move back the machine to the flat ground.
Page 210: Fastening Machine For Transporting
TRANSPORTING Fastening Machine for Transporting WARNING: Fasten the machine frame to the deck securely with chains and cables. While traveling, loads may shake around, move forward or backward or to the sides. 1. Apply the parking brake. Slowly rest the bucket on the trailer deck or load-carrying platform.
Page 211: Transporting Wheel Loader (Urgent Situation)
TRANSPORTING Transporting Wheel Loader (Urgent Situation) The following procedures shall only be applied to cases when urgently moving the wheel loader a short distance is required. When required to transport the wheel loader long distance, use a trailer. Precautions for Self-Traveling Avoid driving the wheel loader long distances at high-speed as much as possible as it may overheat the tires, possibly resulting in premature tire damage and/or wear.
Page 212 TRANSPORTING Precautions for Towing WARNING: Never attempt to tow the machine if the brake system is in need of repair. Ask your nearest authorized dealer to repair the machine. Operate the machine only after repair is completed. Avoid towing the machine as much as possible. If the machine is to be unavoidably towed, beware of the following points.
Page 213 TRANSPORTING Releasing Parking Brake WARNING:  Once the parking brake is released, the machine becomes impossible to stop with the brake system, possibly resulting in personal injury or death.  Before releasing the parking brake or connecting the brake system, be sure to lock tires with wheel stoppers.
Page 214 TRANSPORTING Procedures WARNING:  Once the parking brake is released, the machine becomes impossible to stop with the brake system.  Wedge wheel stoppers to all tires to prevent the machine from moving.  Before restarting to operate the machine, consult your nearest authorized dealer to have the parking brake adjusted.
Page 215: Towing Method
TRANSPORTING Towing Method CAUTION:  Use wire rope with a towing strength of at least 150 % of the machine weight.  Towing from the front side of the machine When using wire ropes, be sure to attach wire ropes to the front axle.
Page 216: Lifting Machine
TRANSPORTING Lifting Machine WARNING:  The lifting tools are optional. Install specified lifting tools at your nearest authorized dealer.  Use lifting wire ropes and other lifting tools being free from any damage and/or aging, and having sufficient strength.  Consult your nearest authorized dealer for correct lifting procedures, and size and types of lifting wire ropes and tools.
Page 217 TRANSPORTING Lifting 1. Straighten the machine and position the front attachment horizontally as illustrated to the right. 2. Move the control lever lock switch in the LOCK ( ) position. 3. Rigidly secure the front and rear frames using the articulation lock bar.
Page 218 TRANSPORTING MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................6-12...
Page 219: Maintenance
IMPORTANT:  Use only recommended fuel and lubricants.  Be sure to use only genuine Hitachi parts. Failure to do so may result in serious injury or death and/or machine breakdown.  Failure to use recommended fuel, lubricants, and genuine Hitachi parts will result in loss of Hitachi product warranty.
Page 220 MAINTENANCE  Body Information Controller This machine provides a body information controller that stores machine operation information for preventive maintenance. When maintaining the machine, our authorized service man may down load the stored information. Consult with your nearest authorized dealer for detailed function of this device. ...
Page 221: Check The Hour Meter Regularly
MAINTENANCE Check the Hour Meter Regularly Refer to the List of Check and Maintenance for information about lubricants, check and adjustment intervals. The maintenance guide table is affixed in to the inside of left step. Refer to page 7-5. This manual recommends grouping the intervals into three categories as follows: Daily Check : To be conducted daily before operation...
Page 222: Layout
MAINTENANCE Layout 9 10 11 13 14 MNSC-07-010 1. Bucket 19. Rear Combination Lamp 2. Bucket Cylinder Pin 20. Engine 3. Bell Crank Pin 21. DEF/AdBlue® Tank 4. Bucket Cylinder 22. Rear Axle 5. Front Work Light 23. Rear Propeller Shaft 6.
Page 223 MAINTENANCE Maintenance Guide Table The maintenance guide table is affixed to the inside of left side step. Lubricate and/or service the parts at the intervals as instructed in the table so that all necessary maintenance can be performed regularly.  Symbol Marks The following marks are used in the maintenance guide table.
Page 224 MAINTENANCE  Maintenance Guide Table 4, 6 SSYA00051048 Lubrication Interval Item Page Item Page Grease (Front Joint Pins) 7-21, 22 Axle Gear Oil (Final drive, Differential gear) 7-36 Grease (Center Hinge Pins) 7-23 Transmission Oil 7-32 Transmission Oil Filter 7-34 Engine Oil Filter 7-30 Hydraulic Oil Filter (Suction)
Page 225: Preparations For Inspection And Maintenance
MAINTENANCE Preparations for Inspection and Maintenance WARNING: If ride control switch (3) is in the AUTO position, the lift arm may unexpectedly rise. To avoid an accident due to unexpected movement of the lift arm, always turn ride control switch (3) OFF before beginning the inspection and/or maintenance of the machine.
Page 226 MAINTENANCE 8. Be sure to place control lever lock switch (2) to the lock ( ) position. 9. Turn key switch (7) OFF and remove the key. 10. Start working only after putting an "UNDER INSPECTION/ MAINTENANCE" tag in a highly visible place such as on the cab door or the control lever.
Page 227: Lock Frames
MAINTENANCE Lock Frames WARNING: Before beginning to work near the frames (3) and (4) center hinge, install articulation lock bar (1) to securely lock and prohibit movement between the front (4) and rear frames (3). Avoid accidents due to unexpected movement of the machine. 1.
Page 228: Inspection/Maintenance Access Side Cover
MAINTENANCE Inspection/Maintenance Access Side Cover CAUTION:  Always close side cover (1) during driving and operation.  Do not keep side cover (1) open on a slope or when a strong wind is blowing. Failure to do so may be dangerous because side cover (1) may unexpectedly close.
Page 229: Rear Grille
MAINTENANCE Rear Grille WARNING: Open or close rear grille (2) only after the stopping the engine. Before driving the machine, always check that rear grille (2) will not open. Push rear grille (2) open/close button (1) to open rear grille (2) to side so that refilling the fuel tank or cleaning of the cooling fan can be conducted.
Page 230: Inspection And Maintenance Table
MAINTENANCE Inspection and Maintenance Table Check and/or carry out the maintenance at intervals of the specified operating hours below or the calender date, whichever comes first. IMPORTANT: Severe applications require more frequent maintenance. Severe conditions include heavy dust, extremely abrasive material, caustic chemicals, extremely wet conditions or abnormally hot or cold ambient temperatures.
Page 231 MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 3000 4500 Replace Fuel Pre-Filter Element  7-62 Replace Drive Belt  7-68 Replace Automatic Tensioner 7-68  Engine Check and Replace EGR Device ...
Page 232 MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 3000 4500 Check Brake Oil Level  7-79 Check Parking Brake Force  7-81 Check Right and Left Brake Interlocking 7-80 ...
Page 233 MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 3000 4500 Check Rearview Mirror and Inside 7-99  Rearview Mirror Check ROPS Cab Mounting Bolts 7-96  Check and Replace Seat and Seat Belt ...
Page 234: Kind Of Oils
Products IMPORTANT:  Hitachi Genuine Greases are specially designed and tested to provide optimum performance for Hitachi construction machinery, hence we recommend to use Hitachi Genuine Greases.  Do not use greases which do not meet the above specification or requirements. Use of unsuitable grease may lead to damage which is excluded from Hitachi Warranty Policy.
Page 235 Specification JASO DH-2 IMPORTANT:  Hitachi Genuine Engine Oils are specially designed and tested to provide optimum performance for Hitachi construction machinery, hence we recommend to use Hitachi Genuine Engine Oils.  Do not use oils which do not meet the above specification or requirements. Use of unsuitable oil may lead to engine damage which is excluded from Hitachi Warranty Policy.
Page 236  Hitachi Genuine Axle Oils are specially designed and tested to provide optimum performance for Hitachi construction machinery, hence we recommend to use Hitachi Genuine Axle Oils. If other oil is used, which may lead to damage on the machine.
Page 237: List Of Consumable Parts
MAINTENANCE List of Consumable Parts 1. Filter Elements Part No. Engine Oil Filter YA00031035 Fuel Main Filter YA00031036 Fuel Pre-Filter Element YA00031040 Air Cleaner Element (outer) 263A237011 Air Cleaner Element (inner) 263A237001 Suction Filter 4305118 Hydraulic Tank Oil Filter 4129280 Transmission Oil Filter 4630525 Hydraulic Tank Air Breather Element...
Page 238 MAINTENANCE 4. Combination Light and Other Light Part No. Front Combination Light Assembly (Right) YA00018873 Front Combination Light Assembly (Left) YA00018872 YA00020460 Head Light (24V 75/70W) Front Combination Light 263G247101 Bulb Clearance Light (24V 75/70W) 263G247091 Turn Signal Light (24V 75/70W) Rear Combination Light Assembly (Right) (LED) YA00044902 Rear Combination Light Assembly (Left) (LED)
Page 239: Greasing
MAINTENANCE A. Greasing WARNING: Apply the parking brake and the articulation lock bar. NOTE:  Until break-in operation is performed for more than 50 hours, lubricate the machine every day to get initial operational concordance.  In case excavation is made in mud, water or snow, lubricate the machine after operation is complete.
Page 240 MAINTENANCE 5. One point each to right and left lift arm cylinder rod pins (7). --- every 500 hours (250 hours at first time only) One point each to right and left lift cylinder pins (8). --- every 500 hours (250 hours at first time only) 6.
Page 241 MAINTENANCE 8. One point each to right and left steering cylinder rod 12, 13 pins (12 and 13). --- every 500 hours (250 hours at first time only) Left rear (12) Right rear (13) MNSC-07-003 9. One point each to upper and lower frame center hinge pins (14 and 15).
Page 242 MAINTENANCE 10. One point each to front and rear axle support pins (16 and 17). --- every 10 hours Front (16) Rear (17) MNSC-07-004 11. One point to front propeller shaft universal (18). --- every 2000 hours NOTE: When the machine is continuously operated under severe conditions for a long time, shorten the greasing intervals.
Page 243 MAINTENANCE 13. One point to center propeller shaft universal front (20). --- every 2000 hours One point to center propeller shaft universal rear (22). --- every 2000 hours M4FJ-07-003 14. One point to center propeller shaft splines (21). --- every 2000 hours M4FJ-07-004 15.
Page 244 MAINTENANCE 16. Two points to brake pedal (24) --- every 1000 hours M4FC-07-014 17. One point to brake pedal linkage (25) --- every 1000 hours M4FC-07-015 7-26...
Page 245: Engine
MAINTENANCE B. Engine Check Engine Oil Level --- every 10 hours (before starting the engine) IMPORTANT: Incorrect engine oil level may cause engine trouble (The oil level should be between the upper and lower marks on oil level gauge (1)). If the engine oil level is too high, control the oil level to the proper quantity before starting the engine.
Page 246: Change Engine Oil
MAINTENANCE Change Engine Oil --- every 500 hours WARNING: Immediately after the machine has been operated, all engine parts are hot. Wait for the engine to cool before starting any maintenance work. Failure to do so may cause severe burns. NOTE: Improper disposal of waste oil can threaten the earth's environment and ecology.
Page 247 MAINTENANCE 9. Remove oil filler cap (3). Supply the specified amount of engine oil. Engine oil amount: 10.5 L (2.8 US gal) 10. Securely tighten oil filler cap (3). 11. Check for looseness of other oil filler cap (4). 12. Check that the oil level is between the maximum and minimum level scales on oil level gauge (5).
Page 248: Replace Engine Oil Filter
MAINTENANCE Replace Engine Oil Filter --- every 500 hours (each time when engine oil is changed) WARNING: Immediately after the machine has been operated, all engine parts are hot. Wait for the engine to cool before starting any maintenance work. Failure to do so may cause severe burns.
Page 249: Power Train
MAINTENANCE C. Power Train Check Transmission Oil Level --- every 10 hours WARNING: Check the oil level while running the engine with care about the following points.  Move forward/reverse lever to neutral and turn parking brake switch ON.  After leveling the bucket on the ground, move the control lever lock switch to the lock ( ) position.
Page 250: Change Transmission Oil
MAINTENANCE Change Transmission Oil --- every 1000 hours (250 hours at first time only) Clean Transmission Strainer ---every 1000 hours WARNING:  Unexpected movement of the machine may cause a serious accident. When parking the machine, place F-N-R lever (1) in neutral and neutral lever lock (3) in the lock ( ) position.
Page 251 MAINTENANCE 5. Prepare a container of more than 20 L (5.3 US gal) capacity to receive the drain oil. NOTE: Drain plug (5) is magnetized. If excessive amount of metal pieces are found adhered to drain plug (5), consult your nearest authorized dealer.
Page 252: Replace Transmission Oil Filter
MAINTENANCE Replace Transmission Oil Filter --- every 500 hours (250 hours at first time only) WARNING: Take care about the following points.  Starting repair work immediately after operation may cause burns. Wait for the oil to cool before starting any maintenance work. ...
Page 253 MAINTENANCE 5. Pour new hydraulic oil into cartridge type element (5). 6. Coat O-ring (7) on new cartridge type element (5) with hydraulic oil. Install cartridge type element (5) to filter head (6) by turning the hexagonal section on the bottom of cartridge type element (5) with a spanner.
Page 254: Change Axle Oil
MAINTENANCE Change Axle Oil --- every 2000 hours (250 hours at first time only) WARNING: Take care about the following points.  Starting repair work immediately after operation may cause burns. Wait for the oil to cool before starting any maintenance work. ...
Page 255 MAINTENANCE Check Oil Level 1. Park the machine following the same procedures as described on page 7-7 for preparation of inspection/ maintenance work. 2. Install articulation lock bar to the front and rear of the frame by following the procedures described on page 7-9.
Page 256: Check Surroundings Around Axle And Covers For Oil Leaks
MAINTENANCE Check Surroundings Around Axle and Covers for Oil Leaks --- every 1000 hours Check the surroundings around the axle and covers for oil leaks. If any oil leaks are found, check the bolts in the oil leaking area for looseness. Retighten as needed. M4GB-07-159 Clean Transmission Air Breather --- every 1000 hours...
Page 257: Hydraulic System
MAINTENANCE D. Hydraulic System Inspection and Maintenance of Hydraulic Equipment CAUTION: When checking and/or servicing the hydraulic components, pay special attention to the following points. During operation, the parts of the hydraulic system become very hot. Allow the machine to cool down before beginning inspection or maintenance.
Page 258 MAINTENANCE IMPORTANT:  When connecting hydraulic hoses and pipes, take special care to keep seal surfaces free from dirt and to avoid damaging them. Keep these precautions in mind.  Wash hoses, pipes, and the tank interior with a washing liquid and thoroughly wipe it out before reconnecting them.
Page 259: Check Hydraulic Oil Level
MAINTENANCE Check Hydraulic Oil Level --- every 10 hours IMPORTANT: If the oil level is not viewed in the level gauge, immediately refill hydraulic oil up to the appropriate level. Failure to do so may result in a serious failure in the hydraulic system. If the oil level is higher than the level gauge, drain oil down to the appropriate level using a pump.
Page 260: Change Hydraulic Oil/Clean Hydraulic Oil Tank
MAINTENANCE Change Hydraulic Oil/Clean Hydraulic Oil Tank --- every 2000 hours Clean Suction Filter ---each time when hydraulic oil is changed Changing and cleaning procedure WARNING: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if the skin comes in contact with escaping hydraulic oil immediately after operation.
Page 261 MAINTENANCE 8. Supply hydraulic oil through cover (3) hole on the hydraulic oil tank while checking the oil level at level gauge (8). Capacity of hydraulic oil tank : 50 liters (13.2 US gal) Total capacity in the hydraulic system : 75 liters (19.8 US gal) 9.
Page 262: Replace Hydraulic Tank Oil Filter
MAINTENANCE Replace Hydraulic Tank Oil Filter --- every 1000 hours Replace WARNING: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
Page 263 MAINTENANCE 10. After replacing the filter, bleed air from the hydraulic pump and check the oil level in the hydraulic oil tank. (Refer to the descriptions for "Bleed air from the hydraulic system" in item If the machine is operated without bleeding the air mixed in the hydraulic circuit, damage to the hydraulic pump may result.
Page 264: Replace Hst Charge Filter
MAINTENANCE Replace HST Charge Filter --- every 500 hours Replace WARNING: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
Page 265 MAINTENANCE 6. Pour new hydraulic oil into cartridge type element (4). 7. Coat O-ring (6) on new cartridge type element (4) with hydraulic oil. Install cartridge type element (4) to filter head (5) by turning the hexagonal section on the bottom of cartridge type element (4) with a spanner.
Page 266: Replace Air Breather Element
MAINTENANCE Replace Air Breather Element --- every 2000 hours WARNING: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
Page 267: Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, And Damage
MAINTENANCE Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, and Damage --- every 2000 hours WARNING:  Allow only qualified personnel to handle the accumulator.  High-pressure nitrogen gas is enclosed in the accumulator. Caution is required to prevent fires from occurring.
Page 268: Replace Pilot Circuit Accumulator
MAINTENANCE Replace Pilot Circuit Accumulator --- every 4000 hours or once every two years whichever comes first. Consult your nearest authorized dealer for replace. Check Ride Control Accumulator Function, Gas Leakage, Looseness, and Damage --- every 500 hours WARNING:  Allow only qualified personnel to handle the accumulator.
Page 269: Check Hoses And Lines
MAINTENANCE Check Hoses and Lines --- every 10 hours / every 250 hours WARNING: Escaping fluid under pressure can penetrate the skin causing serious injury. To avoid this hazard, search for leaks with a piece of cardboard. Take care to protect hands and body from high-pressure fluids.
Page 270 MAINTENANCE Hose Interval Check Points Abnormalities Remedies (hours) Hose covers Leak (1) Replace Hose ends Leak (2) Replace Every 10 hours Fittings Leak (3) Retighten or replace hose or O-ring M137-07-008 Hose covers Leak (4) Replace Hose ends Leak (5) Replace Hose covers Exposed reinforcement...
Page 271 MAINTENANCE Interval Check Points Abnormalities Remedies (hours) Contact surfaces of Leak (11) Replace flange joints Bolts Loose or leak (11) Retighten or replace Daily Check O-ring Welded surfaces on Leak (12) Replace M4GB-07-059 flange joints Flange joint neck Crack (13) Replace Welded surfaces on Crack (12)
Page 272 MAINTENANCE Service Recommendations for Hydraulic Fittings Two hydraulic fitting designs are used on this machine. Flat Face O-ring Seal Fitting (ORS Fitting) An O-ring is used on the sealing surfaces to prevent oil leakage. 1. Inspect fitting sealing surfaces (6). They must be free of M104-07-033 dirt or defects.
Page 273 MAINTENANCE Metal Face Seal Fittings Fittings are used on smaller hoses and consist of metal flare (9) and metal flare seat (10). 1. Tighten fitting (7) by hand. 2. Tighten fitting (7) or nut (8) to the torque values shown. Do not allow hose (5) to twist when tightening fittings.
Page 274: Fuel System
MAINTENANCE E. Fuel System Check Fuel Level --- every 10 hours (daily) DANGER: Beware of fire Fuel is flammable. Keep fuel away from fire hazards. IMPORTANT: Always fill the fuel tank with the specified diesel fuel. Failure to do so may cause engine trouble and also making it difficult for the engine to start.
Page 275 MAINTENANCE Refueling 1. Park the machine following the same procedures as described on page 7-7 for preparation of inspection/ maintenance work. IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down. DANGER: Handle fuel carefully. Shut the engine off before fueling.
Page 276: Drain Water And Sediment From Fuel Tank
MAINTENANCE Drain Water and Sediment from Fuel Tank --- every 1000 hours Before starting to operate the machine, remove plug (2) from the tip of drain valve (1) on the fuel tank bottom and open drain valve (1) to drain water and/or sediment from the fuel tank.
Page 277: Drain Fuel Pre-Filter
MAINTENANCE Drain Fuel Pre-Filter --- daily IMPORTANT: Drain fuel filter daily before starting operation. The engine may be damaged if you do not drain fuel filter daily. Fuel pre-filter (1) has water separator functions. When the engine trouble indicator blinks, drain the water accumulated in the filter.
Page 278 MAINTENANCE Bleed Air from the Fuel System Air in the fuel system may make the engine hard to start or make it run irregularly. After draining water and sediment from the fuel pre-filter, replacing the fuel main filter or the fuel pre-filter, or running the fuel tank dry, be sure to bleed the air from the fuel system.
Page 279: Replace Fuel Main Filter Element
Replace Fuel Main Filter Element ---every 1000 hours IMPORTANT:  Be sure to use only genuine Hitachi elements for the fuel main filter element and the pre-filter element. Failure to do so may deteriorate the engine performance and/or shorten the engine service life.
Page 280: Replace Fuel Pre-Filter Element
Replace Fuel Pre-Filter Element ---every 3000 hours IMPORTANT:  Be sure to use only genuine Hitachi elements for the main fuel filter and the pre-filter. Failure to do so may deteriorate the engine performance and/ or shorten the engine service life. Please be noted...
Page 281: Check Fuel Hoses
MAINTENANCE Check Fuel Hoses --- every 10 hours / every 250 hours WARNING: Fuel leaks can lead to fires that may result in serious injury. Check for kinked hoses, hoses that rub against each other, and any fuel leaks. M4GB-07-071 Repair or replace any loose or damaged hoses.
Page 282: Air Cleaner
MAINTENANCE F. Air Cleaner Inspect the Air Cleaner Element for Clogging --- every 10 hours Perform before starting work. Look at visual dust indicator (2) of air cleaner (1) to check whether the element is clogged. If the centre of dust indicator (2) (clear part) appears red, clean or replace the element.
Page 283: Clean And Replace Air Cleaner Element
MAINTENANCE Clean and Replace Air Cleaner Element Clean --- every 250 hours (clog may be detected even before that) Replace --- after cleaning six times or after one year. Air cleaner (1) is comprised of double elements, the outer element (6) and inner element (5). Cleaning is of outer element (6), so do not remove inner element (5).
Page 284: Cooling System
Use fresh water or normal tap water as a coolant. Do not use strong acid or alkaline water. Use the coolant with genuine Hitachi Long-Life Coolant (LLC) mixed by 30 to 50 %. If the air temperature is expected to fall below 0 °C (32 °F), fill the cooling system with a genuine Hitachi Long-Life Coolant (LLC) and soft water mix.
Page 285: Check Coolant Level
MAINTENANCE Check Coolant Level --- every 10 hours WARNING: Do not remove cap (2) until the coolant temperature in the radiator is cool. Hot steam may spout out, possibly causing severe burns. After the coolant temperature cools, slowly loosen cap (2) to release the inside air pressure before removing cap (2).
Page 286: Check Drive Belt
MAINTENANCE Check Drive Belt --- every 10 hours Check the drive belt for any abnormality. If any cracks are found, replace the belt with a new one. Replace Drive Belt --- every 3000 hours Consult your nearest authorized dealer for repair. Replace Automatic Tensioner --- every 3000 hours MNSC-07-022...
Page 287: Change Coolant
(1) to release the inside air pressure before removing cap (1). IMPORTANT:  Use genuine Hitachi long-life coolant. Change the coolant every two years or 2000 hours whichever comes first. 1. Park the machine following the same procedures as...
Page 288: Clean Radiator/Oil Cooler And Other Cooling System
MAINTENANCE Clean Radiator/Oil Cooler and Other Cooling System --- every 500 hours or when the core is clogged. CAUTION: Wear goggles or safety glasses when using compressed air [less than 0.2 MPa (2 kgf/cm IMPORTANT: If compressed air with the pressure of more than 0.2 MPa (2 kgf/cm ) or tap water with high delivery pressure is used for cleaning, damage to the...
Page 289: Electrical System
MAINTENANCE H. Electrical System IMPORTANT:  Improper radio communication equipment and associated parts, and/or improper installation of radio communication equipment affects the machine's electronic parts, causing involuntary movement of the machine. Also, improper installation of electrical equipment may cause machine failure and/or a fire on the machine.
Page 290 MAINTENANCE Avoid hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Using proper booster battery starting procedures. If you spill acid on yourself: 1.
Page 291 MAINTENANCE Electrolyte Level Check --- every 100 hours 1. Check the electrolyte level at least once a month. 2. Park the machine on level ground and stop the engine. 3. Check the electrolyte level. 3.1 When checking the level from the battery side: Clean around the level check lines with a wet towel.
Page 292 MAINTENANCE Check Electrolyte Specific Gravity --- every 250 hours WARNING: If you spill acid on yourself:  Battery gas can explode. Keep sparks and flames 1. Flush your skin with water. away from batteries. 2. Apply baking soda or lime to help neutralize the acid.
Page 293: Check Monitor Functions And All Other Instrument Operation
MAINTENANCE Replace Batteries IMPORTANT: Before adjusting the electrical system or welding on the machine, turn the disconnect switch OFF. Your machine has two 12-volt batteries with negative (-) ground. If one battery in a 24-volt system has failed but the other is still good, replace the failed battery with one of the same type.
Page 294: Check Lights
MAINTENANCE Check Lights --- every 10 hours CAUTION: If any burned-out light is found, immediately replace it with a new one. Visually check all lights that they normally light and/or flash from the front and rear sides of the machine. MNSC-07-024 MNSC-01-032 Check Horn and Reverse Buzzer...
Page 295: Check Electrical Harnesses And Fuses
MAINTENANCE Check Electrical Harnesses and Fuses --- every 50 hours CAUTION: If dirt or dust is adhered on the wirings or relays, it may cause fire on the machine. Check the electrical harness and terminals of the batteries, starter motor, and alternator for loose connection and/or short circuit (broken shield).
Page 296 MAINTENANCE Fuse Box A 10- PARKING 20- OPTION 4 (10 A) 9- AC 1 19- OPTION 3 10 A (10 A) 8- STOP LAMP 18- DC-DC UNIT (ENGINE) 7- BACK BUZZER 17- SCR SYSTEM 30 A 6- HST 2 16- Ad Blue SENSOR 15 A 5- HEAD LAMP 15- AC 2...
Page 297: Brake System
MAINTENANCE I. Brake System Check Brake Oil Level --- every 10 hours (daily) Indicator comes ON WARNING: In case brake oil level indicator (1) comes ON, immediately stop machine operation and stop the engine. Inspect brake oil tank (2) level and the brake system for any abnormality.
Page 298: Check Right And Left Brake Interlocking Performance
MAINTENANCE Check Right and Left Brake Interlocking Performance --- every 10 hours WARNING:  Put up a no admission notice for the range of 100 m (109.4 yd) ahead in the forward machine travel direction. Arrange a safety monitor person. ...
Page 299: Check Parking Brake Force
MAINTENANCE Check Parking Brake Force --- every 10 hours WARNING: Check the machine in a place where no one is present or ahead in the traveling direction. Keep bystanders away from the machine. Park the machine with no load applied on a 20% (11.3°) inclining dry surface slope.
Page 300: Check Brake Disks (Service And Parking)
MAINTENANCE Check Brake Disks (Service and Parking) --- every 2000 hours Service brake (1) is a closed wet type brake. Parking brake (2) is a wet type disk brake. Parking brake (2) is mounted on the transmission side. Consult your nearest authorized dealer for checking. M4FC-07-023 M4FJ-06-001 Change Brake Oil...
Page 301: Tire
MAINTENANCE J. Tire Check and Replace Tire (Tire Pressure) Check appearance --- every 10 hours Replace --- as necessary WARNING:  Secure the front and rear frames with the articulation lock bar and pins.  When inflating tires, stand behind the tread and use the self-attaching chuck.
Page 302: Check Wheel Bolt Torque
MAINTENANCE Check Wheel Bolt Torque --- every 500 hours (50 hours at first time only) (Right) (Wrong) Be sure to check the wheel bolt torque by turning the bolt in the tightening direction. Tightening torque: 890 N·m (89 kgf·m, 660 lbf·ft) Replace Tire WARNING: Secure the front and rear frames with the articulation lock bar and pins.
Page 303 MAINTENANCE Applicable Tire Size NOTE: Consult your nearest authorized dealer for tread pattern of optional tires. The machine may vibrate while driving depending on the tread pattern of tires. This is a sympathetic vibration due to tread pattern, not a malfunction. Applicable Tire Size Standard Tire Size Bias...
Page 304 MAINTENANCE Tire Rotation Rotate tires when uneven or abnormal wear is recognized on either front or rear, or right and left tire. Tire rotation is recommended to achieve uniformity of wear on tires or equalization of tire service life. Rotation Procedure WARNING: Install a tire with no external damage such as score and abnormal wear.
Page 305: Removal And Installation Of Tire
MAINTENANCE Removal and Installation of Tire WARNING: Wheel with tire is a very heavy part so that removal and installation of a tire is hazardous and difficult work. In addition, a crane to lift a tire is required when removing or installing the tire to the wheel.
Page 306: Air Conditioner
MAINTENANCE K. Air Conditioner Clean/Replace Air Conditioner Circulation/Fresh Air Filters Clean filters --- every 100 hours (or once a week whichever comes first) Replace filter --- after cleaning filters 10 times (or when the filters are severely clogged) NOTE: In case the machine is operated at a dusty job site, clean or replace the filter element earlier than the normal interval.
Page 307 MAINTENANCE IMPORTANT: Inappropriate installation of the filter may cause dust to enter into the air conditioner, causing malfunction or breakdown of the air conditioner. Before installing the filter element, clean off dust around the mounting area; install the filter element with extra care.
Page 308 MAINTENANCE Clean and Replace Double Filter (Optional) --- When cleaning fresh air filter 1. Remove the double filter: The double filter is installed behind cover (1) on the left rear side of the cab exterior. Open cover (1) with the starter key.
Page 309 MAINTENANCE Clean Circulation Air Filter 1. Remove the filter: Remove screw (6) under cup holder (5) and tilt the cup holder forward. Hold handle (7) and pull handle (7) toward you to remove circulation air filter (8). IMPORTANT: Do not use compressed air or water to clean filter (8) as damage to the filter fins may result.
Page 310: Check Air Conditioner
MAINTENANCE Check Air Conditioner --- every 250 hours or 3 months Check the air conditioner switch panel, air conditioner unit, and condenser mounting areas for any abnormality, and check hoses for any damage. NOTE: When the season to use the air conditioner comes close, check the air conditioner to get it ready to use at all times.
Page 311: Check Air Conditioner Condenser
MAINTENANCE Check Air Conditioner Condenser --- every 250 hours or 3 months If condenser (1) is covered with dirt and/or insects, air conditioner cooling performance will be reduced. Remove dirt or stain from fins of condenser (1) using tap water. In case the condenser has been severely contaminated, use a soft brush.
Page 312: Check Refrigerant
MAINTENANCE Check Refrigerant --- every 250 hours or 3 months After running the engine at 1500 min (rpm) for a few minutes, check the refrigerant quantity through sight glass (inspection port) (1). This machine uses new Freon R134a as the refrigerant. Before charging the refrigerant, first collect the entire refrigerant from the cooling system.
Page 313: Miscellaneous
MAINTENANCE L. Miscellaneous Check Cutting Edge --- every 10 hours Check for wear and looseness. Replace WARNING: Guard against injury from flying pieces of metal. Wear goggles or safety glasses, hard hat and face shield. 1. Raise the bucket to an appropriate height with the bucket bottom parallel to the ground.
Page 314: Check And Replace Seat And Seat Belt
MAINTENANCE Check and Replace Seat and Seat Belt Check appearance --- every 10 hours Replace --- every 3 years Examine buckle (1), attaching hardware (2) and seat belt web. Replace the seat belt web, buckle, or attaching hardware if they are damaged, or worn. Also check the wind-up condition of the seat belt.
Page 315: Check Play Amount In Steering Wheel Stroke
MAINTENANCE Check Play Amount in Steering Wheel Stroke --- every 10 hours WARNING: When the steering wheel is turned, the clearance between the front and rear frames becomes narrower, possibly creating a hazardous situation such as entanglement of limbs. Keep any personnel away from the frame articulation point during inspection.
Page 316: Check Accelerator Pedal Operation, And Exhaust Gas Color And Noise
MAINTENANCE Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise --- every 10 hours WARNING: Move the forward/reverse lever to neutral. Apply the parking brake. After horizontally resting the bucket on the ground, set the wheel stoppers. While slowly stepping on accelerator pedal (1), check that the engine speed smoothly increases.
Page 317: Check Rearview Mirror And Inside Rearview Mirror
MAINTENANCE Check Rearview Mirror and Inside Rearview Mirror --- every 10 hours Check that the inside of rearview mirror (1) and rearview mirror (2) are facing a correct direction. Check inside rearview mirror (1) and rearview mirror (2) for contamination or damage.
Page 318: Clean Engine Compartment And Hood
MAINTENANCE Clean Engine Compartment and Hood --- every 10 hours CAUTION: Dust or chips accumulated in the engine compartment or around the hood may come in contact with high temperature sections near the engine or hood, possibly causing fires. Remove the accumulated dust and chips from the hood. Open the side access cover and check if dust and /or chips are accumulated in the engine compartment and/or the areas above the engine.
Page 319: Check Engine Cylinder Head Bolts
MAINTENANCE Check Engine Cylinder Head Bolts --- every 1000 hours (or once a year whichever comes first) Consult your nearest authorized dealer for check and repair. Check Engine Compression Pressure --- every 1000 hours (or once a year whichever comes first) Consult your nearest authorized dealer for check and repair.
Page 320: Check And Replace Egr Device
MAINTENANCE Check and Replace EGR Device --- every 4500 hours Consult your nearest authorized dealer for check and repair. Clean EGR Cooler --- every 4500 hours Consult your nearest authorized dealer for check and repair. Check Turbocharger --- every 4500 hours Consult your nearest authorized dealer for check and repair.
Page 321: Tightening And Retightening Torque Of Nuts And Bolts
MAINTENANCE Tightening and Retightening Torque of Nuts and Bolts --- every 250 hours (50 hours at first time only) Tighten or retighten nuts and bolts used on this machine in accordance with the torque values shown in the following table. Check nuts and bolts for looseness and missing daily before and after operation.
Page 322 MAINTENANCE Tightening Torque Chart Hexagon Wrench Socket Bolt Bolt Wrench Wrench Dia. Socket Bolt size size N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft) 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.1) (3.0) (22) (2.0) (1.0) (7.4) (2.0)
Page 323: Front Axle Mounting Bolt
MAINTENANCE 1. Front axle mounting bolt Bolt dia. mm (in) 20 (0.8) Quantity M4FJ-07-017 2. Rear axle support mounting bolt Front Rear Bolt dia. mm (in) 20 (0.8) 20 (0.8) Quantity Front Rear M4FC-07-065 3. Wheel rim mounting bolt Bolt dia. mm (in) 24 (0.9) Quantity M4GB-07-127...
Page 324: Propeller Shaft Mounting Bolt
MAINTENANCE 4. Propeller shaft mounting bolt Bolt dia. mm (in) 10 (0.4) Quantity M4FC-07-066 5. Propeller shaft support bearing mounting bolt Bolt dia. mm (in) 16 (0.6) Quantity M4FJ-07-026 6. Transmission mounting bolt: Frame side Bolt dia. mm (in) 16 (0.6) Quantity M4FJ-07-018 7-106...
Page 325: Transmission Mounting Bolt: Transmission Side 16
MAINTENANCE 7. Transmission mounting bolt: Transmission side Bolt dia. mm (in) 16 (0.6) Quantity M4FJ-07-018 8. HST motor mounting bolt Bolt dia. mm (in) 16 (0.6) Quantity M4FJ-07-019 9. HST pump mounting bolt Bolt dia. mm (in) 16 (0.6) 12 (0.5) Quantity M4FJ-07-050 7-107...
Page 326: 10. Engine Mounting Bolt: Bracket
MAINTENANCE 10. Engine mounting bolt: Bracket Front Rear Bolt dia. mm (in) 12 (0.5) 12 (0.5) 16 (0.6) Quantity MNSC-07-033 11. Engine mounting bolt: Cushion rubber Bolt dia. mm (in) 16 (0.6) Quantity 12. Aftertreatment device mounting bolt: Bracket MNSC-07-033 Bolt dia.
Page 327: 13. Counterweight Mounting Bolt
MAINTENANCE 13. Counterweight mounting bolt Bolt dia. mm (in) 24 (0.9) Quantity MNSC-01-032 14. Top center pin lock Bolt dia. mm (in) 12 (0.5) Quantity MNSC-07-036 15. Bottom center pin flange lock bolt Bolt dia. mm (in) 24 (0.9) Quantity MNSC-07-037 7-109...
Page 328: 16. Loader Front Pin Lock
MAINTENANCE 16. Loader front pin lock Bolt dia. mm (in) 12 (0.5) 16 (0.6) Quantity MNSC-07-001 17. Steering cylinder pin lock Bolt dia. mm (in) 12 (0.5) Quantity MNSC-07-038 18. Radiator frame mounting bolt Bolt dia. mm (in) 12 (0.5) 16 (0.6) Quantity MNSC-07-039...
Page 329: 19. Radiator Mounting Bolt
MAINTENANCE 19. Radiator mounting bolt Bolt dia. mm (in) 8 (0.3) Quantity MNSC-07-040 20. Intercooler mounting bolt Bolt dia. mm (in) 8 (0.3) Quantity MNSC-07-040 21. Oil cooler mounting bolt Bolt dia. mm (in) 10 (0.4) Quantity MNSC-07-040 7-111...
Page 330: 22. Air Conditioner Condenser Mounting Bolt
MAINTENANCE 22. Air conditioner condenser mounting bolt Bolt dia. mm (in) 10 (0.4) Quantity MNSC-07-052 23. Air conditioner compressor mounting bolt Bolt dia. mm (in) 8 (0.3) Quantity MNSC-07-041 24. Cab cushion rubber mounting bolt Bolt dia. mm (in) 16 (0.6) Quantity MNSC-07-042 7-112...
Page 331: 25. Cutting Edge Mounting Bolt
MAINTENANCE 25. Cutting edge mounting bolt Bolt dia. in 1" Quantity M4GB-07-116 7-113...
Page 332: Aftertreatment Device
MAINTENANCE M. Aftertreatment Device Check and Clean Aftertreatment Device --- as required IMPORTANT: Check and clean flammable materials on the area around the Aftertreatment device. Do not disassemble the base machine support parts and sensors. When the machine is operated in dusty areas, refer to the page 9-1 "Maintenance Under Special Environmental Conditions".
Page 333: Urea Scr System
MAINTENANCE N. Urea SCR System WARNING: Fill specified DEF/AdBlue® into the DEF/ AdBlue® tank. If improper DEF/AdBlue® is refilled, fire or system failure may result. If improper liquid is refilled in the DEF/AdBlue® tank, consult your nearest authorized dealer for check or repair. Specified DEF/AdBlue®...
Page 334 MAINTENANCE IMPORTANT:  Use dedicated container recommended by the business entity who is handling DEF/AdBlue® to store DEF/AdBlue®. Do not use general container, a container used for other purpose and contaminated container because the quality of DEF/AdBlue® deteriorates.  The DEF/AdBlue® is non-combustible, however, move DEF/AdBlue®...
Page 335: Check Def/Adblue® Level
MAINTENANCE Check DEF/AdBlue® Level --- every 10 hours (daily) Park the machine on a level surface. Lower the bucket to the ground. Check the DEF/AdBlue® level with DEF/AdBlue® gauge (1). If necessary, stop the engine and add DEF/AdBlue®. Refill DEF/AdBlue® CAUTION: ...
Page 336 MAINTENANCE 5. Install cap (3) after refilling DEF/AdBlue®. Close the DEF/ AdBlue® tank cover. IMPORTANT:  Do not get on top of DEF/AdBlue® tank (2) or sensors and piping on the tank. Failure to do so may damage the machine.  White deposits may be observed when DEF/AdBlue®...
Page 337 MAINTENANCE Clean Filler Port Strainer Strainer (1) is provided on the filler port of the DEF/AdBlue® tank. Clean strainer (1) if dirt or dust is observed. CAUTION: Wear safety equipment such as safety glasses or goggles, rubber gloves appropriate to the job.
Page 338 MAINTENANCE Change DEF/AdBlue® ---As required CAUTION: Wear safety equipment such as safety glasses or goggles, rubber gloves appropriate to the job. Wash DEF/AdBlue® with clean water when it contacts with the skin. If DEF/AdBlue® is accidentally splashed into eyes, flush with water for 15 minutes or longer and get emergency medical attention.
Page 339: Replace Def/Adblue® Tank Water Supply Inlet Filter
The inlet of the DEF/AdBlue® tank water supply is equipped with a filter (2), which must be replaced periodically. When it is time to replace it, consult the nearest Hitachi dealer. 95Z7B-7-126-2 7-121...
Page 340: Replace Def/Adblue® Supply Module Main Filter
MAINTENANCE Replace DEF/AdBlue® Supply Module Main Filter --- every 4500 hours DEF/AdBlue® Supply Module A filter (2) is mounted in the DEF/AdBlue® supply module. Periodically replace filter (2). CAUTION: Wear safety equipment such as safety glasses or goggles, rubber gloves appropriate to the job.
Page 341: Maintenance Under Special Environmental Conditions
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Maintenance Under Special Environmental Conditions WARNING:  Before operating the machine in a river, check the riverbed conditions in advance.  Avoid driving the machine into a river where the riverbed is steep and deep or the current is strong. Operating Conditions Precautions for Maintenance Muddy Soil, Rainy or...
Page 342: Maintenance Under Special Environmental Conditions
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Precautions for Maintenance During Cold Weather Season Before the atmospheric temperature becomes down below -0 °C (32 °F), practice the following points.  Water and oil in the machine will freeze.  Road surfaces will freeze so that tires may slip. Keeping the above points in mind, follow the advices below: 1.
Page 343 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS DANGER: Sufficiently ventilate when carrying out warming up operation indoors. Failure to do so may cause intoxication by exhaust gas, possibly resulting in personal death accident. 7. After preheating the engine, start the engine. Sufficiently perform warm-up operation.
Page 344 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 345: Storage
STORAGE Storing the Machine WARNING: In case lubrication operation is unavoidably performed indoors, open windows and doors to maintain good air ventilation to prevent asphyxiation. Lubricant property will deteriorate even if the machine is kept stored. Check all lubricants before operating the machine after being stored. Apply the parking brake while storing.
Page 346 STORAGE Removing the Machine from Storage WARNING: In case lubrication operation is unavoidably performed indoors, open windows and doors to maintain good air ventilation to prevent asphyxiation. Lubricant property will deteriorate even if the machine is kept stored. Check all lubricants before operating the machine after being stored.
Page 347 STORAGE 1. Remove the covers. 2. Remove grease from the cylinder rods if coated. 3. Fill the fuel tank. Bleed air from the fuel system. Check all fluid levels. 4. Adjust the alternator and fan belt tension. 5. Check the oil level. Add oil as needed. 6.
Page 348 STORAGE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................10-4...
Page 349: Troubleshooting
TROUBLESHOOTING Troubleshooting If any abnormality is found on the machine, immediately take action to solve it. Find out the cause of the abnormality to prevent the recurrence of malfunction. If the cause of malfunction is unknown or for inquiry on solution item with mark "*" on the list below, consult your nearest authorized dealer.
Page 350 TROUBLESHOOTING Engine does not Start. Symptom Cause Solution The starter does not turn. Reduced battery voltage Charge the batteries. Replace. High resistance in the starter circuit * Clean and/or retighten the battery terminals and starter terminals. Faulty key switch * Replace Damaged wire harness * Repair, Replace Faulty battery relay...
Page 351 TROUBLESHOOTING Hydraulic System After the machine has been kept stored for a long time, air in the oil may be separated and accumulate in the upper section in the cylinder, causing slow response time in operation or reducing cylinder power. In case these symptoms appear, repeatedly operate all actuators several times.
Page 352 TROUBLESHOOTING Drive Function Steering System Symptom Cause Solution Steering wheel is heavy to operate. Faulty hydraulic pump * Repair, Replace Faulty steering device * Repair, Replace Relief valve set pressure reduction *Adjust Faulty steering column * Repair, Replace Steering wheel turns in unexpected Faulty steering device * Repair, Replace direction.
Page 353 TROUBLESHOOTING Service Brake Symptom Cause Solution Service brake does not work properly. Malfunction of brake valve * Repair, Replace Oil leak from brake line, Air mixing * Repair, Bleed air Brake is dragged. Malfunction of brake valve * Repair, Replace Faulty brake pedal * Repair, Replace Lack of brake fluid (hydraulic oil)
Page 354 TROUBLESHOOTING MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................11-6...
Page 355: Specifications
SPECIFICATIONS Specifications 45 ° 50° 40 ° 30° MNSC-12-001 Bucket Capacity: heaped 1.5 m (1.96 yd Operating Weight 8430 kg (18600 lb) Tipping Load (Straight) 2400 kg (5300 lb) Engine DEUTZ TCD 3.6L4F A: Overall Length 6545 mm (21 ft 6 in) B: Overall Width (Bucket) 2450 mm (8 ft 1 in) C: Overall Height...
Page 356 SPECIFICATIONS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................12-2...
Page 357: Optional Attachments
OPTIONAL ATTACHMENTS HYDRAULIC TYPE QUICK COUPLER OPERATION Hydraulic Type Quick Coupler Operation A quick coupler is a system by which a front attachment work tool such as a bucket can be easily replaced with other type of a work tool. WARNING: During replacement work, keep personnel away from the machine.
Page 358 OPTIONAL ATTACHMENTS HYDRAULIC TYPE QUICK COUPLER OPERATION Installation WARNING: Complete installation work only after checking that both right and left coupler pins (1) have been correctly installed. WARNING: Before leaving the machine apply the parking brake. 1. After checking that coupler pin (1) is removed, slowly bring the machine close to bucket (attachment) hook (3) and install the quick coupler to the hook.
Page 359 OPTIONAL ATTACHMENTS HYDRAULIC TYPE QUICK COUPLER OPERATION Disconnecting/connecting hydraulic hose When activating an attachment with a hydraulic cylinder other than the lift arm cylinder or bucket cylinder using the machine hydraulic pressure oil, hydraulic hoses must be connected or disconnected. At this time, connect or disconnect the hydraulic hoses following the procedures below.
Page 360 OPTIONAL ATTACHMENTS HYDRAULIC TYPE QUICK COUPLER OPERATION MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 361: Index
INDEX Change Transmission Oil ............7-32 Changing Forward/Reverse Drive Direction ......4-5 About Aftertreatment Device .............1-3 Check Accelerator Pedal Operation, and Exhaust Gas Accelerator Pedal ................1-52 Color and Noise ............... 7-98 Adjust Operator’s Seat ..............S-6 Check After Starting ...............3-8 Adjusting Operator’s Seat (Air Suspension Type Seat) Check Air Conditioner ..............
Page 362 INDEX Check Wheel Bolt Torque ............7-84 Engine Oil Low Pressure Indicator (Red) ......1-13 Check Windshield Washer Fluid Level ........7-96 Engine Trouble Indicator (Red) ..........1-12 Cigar Lighter ................... 1-66 Ensure Safety Before Rising from or Leaving Operator’s Clean and Replace Air Cleaner Element .......
Page 363 INDEX Opening the rear grille ............... 1-94 Operate Only from Operator’s Seat ..........S-9 Inspect Machine ................S-4 Operational Procedure ............... 1-65 Inspect Machine Daily Before Starting ........3-1 Outside Rear View Mirror ............1-86 Inspect the Air Cleaner Element for Clogging ....7-64 Overheat Indicator (Red) ............
Page 364 INDEX Replace Fuel Pre-Filter Element ..........7-62 Tips for Optimal Air Conditioner Usage ....... 1-75 Replace HST Charge Filter ............7-46 Tire ..................... 7-83 Replace Hydraulic Tank Oil Filter ..........7-44 Towing Method ................6-9 Replace Pilot Circuit Accumulator .......... 7-50 Towing Pin ..................

Hitachi ZW 120-6 Operator's Manual

Table of Contents

Machine Numbers

Safety

Safety Signs

Components Name

Getting On/Off the Machine

Operator's Station

Break-In

Operating Engine

Operating Engine

WARNING: after Starting the Engine, Start the

Machine Operation Only after Confirming that the Engine Speed Changes by Operating Accelerator Pedal

Otherwise, the Machine or the Front Attachment May

Unexpectedly Start Moving, Possibly Causing Accidents

Driving Machine

Operating Machine

Transporting

Maintenance

Quick Links

Chapters

Related Manuals for Hitachi ZW 120-6

Summary of Contents for Hitachi ZW 120-6