Page 1 PART NO. ENMNHK-NA1-1 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 (T) 2018, 03...
Page 2 INTRODUCTION 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 LABELS COMPONENTS NAME OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE MOVING THE MACHINE OPERATING THE MACHINE TRANSPORTING MAINTENANCE MAI N TENANCE UNDER SPECI A L ENVI R ONMENTAL CONDI T I O NS STORAGE TROUBLESHOOTING SPECIFICATIONS INDEX ENMNHK-NA1-1...
Page 5: Table Of Contents
CONTENTS MACHINE NUMBERS ............1 Evacuating in Case of Fire ............S-30 Beware of Exhaust Fumes............S-31 SAFETY ................S-1 Precautions for Welding and Grinding ......... S-31 Recognize Safety Information ............S-1 Avoid Heating Near Pressurized Fluid Lines ....... S-31 Understand Signal Words .............S-1 Avoid Applying Heat to Lines Containing Flammable Follow Safety Instructions ............S-2 Fluids ...................
Page 6 CONTENTS Multi Function Monitor .............. 1-19 Key Switch ..................1-89 Feature ..................1-19 Accelerator Pedal ................1-90 Screen Configuration............. 1-19 Brake Pedal ..................1-90 Default Setting ................1-20 Service Brake ................1-90 Basic Screen ..................1-21 Declutch Brake ................. 1-90 How to Use Screens ..............
Page 7 CONTENTS Circulation/Fresh Air Switch ..........1-118 Warm Up ..................3-12 Defroster Switch ..............1-118 Cold Weather Warm Up .............. 3-13 Cab Heater Operation ............1-119 Stopping Engine ................3-15 Cooling Operation ..............1-120 MOVING THE MACHINE ..........4-1 Defroster Operation .............1-121 Driving the Machine ...............4-1 Cool Head/Warm Feet Operation ........1-121 Precautions for Starting to Move .........4-1 Tips for Optimal Air Conditioner Usage ......1-122...
Page 8 CONTENTS Dumping into Truck or Hopper .......... 5-23 Change Planetary Gear Oil ..........7-38 Dozing ....................5-24 Replace Axle Oil Cooler Line Filter (Option) ....7-39 Stock Piling ..................5-24 Clean Axle Oil Cooler Fins (Option) ........7-40 Removing Snow ................5-25 D.
Page 9 CONTENTS Specified DEF/AdBlue® ............7-105 H. Electrical System ..............7-80 Check DEF Level ..............7-106 Batteries ..................7-80 Refill DEF ................7-106 Electrolyte Level Check ........... 7-82 Clean DEF Strainer ............7-107 Check Electrolyte Specific Gravity ....... 7-83 DEF Exchange Procedure..........7-108 Replace Batteries ............... 7-84 Replace DEF Supply Module Main Filter .......7-109 Check Monitor Functions and All Other Instrument Check Dosing Module ............7-110...
Page 10 CONTENTS SPECIFICATIONS ............12-1 Specifications ................. 12-1 Intended Use ................12-1 INDEX ................14-1...
Page 11: 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 12 MACHINE NUMBERS Aftertreatment Device TYPE MFG. NO. 95Z7B-SCR4 TYPE MFG. NO. 95Z7B-SCR4...
Page 13: 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 14: Follow Safety Instructions
 Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Carefully read and follow all instructions for use and safety in the operator's manual for the attachment. Failure to do so may deteriorate the safety, function, and/or service life of the machine.
Page 15: 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 16: 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 17: General Precautions For Cab
SAFETY General Precautions for Cab  Before entering the cab, thoroughly remove all dirt and / or oil 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 18: 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 handholds. ...
Page 19: 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 20: Move And Operate Machine Safely
SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Be advised that there may be blind spots with rear view camera. Confirm the location of bystanders before moving, swinging, or operating the machine by sight and mirrors as well as the rear view monitor.
Page 21: 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 22: 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 23: 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 24: 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 25: Drive Machine Safely (Work Site
SAFETY Drive Machine Safely (Work Site)  Before driving the machine, always confirm that the steering wheel and/or joystick steering and forward/reverse lever (switch) direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions. ...
Page 26: Drive Safely With Bucket Loaded
SAFETY Drive Safely with Bucket Loaded  If the machine is operated incorrectly while driving with the bucket loaded, the machine may turn over. Be sure to follow all of 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 27: 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) 545 mm (21.5 in) above the road surface as illustrated.
Page 28: 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 29: 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 material from the bucket or contact with bucket or attachment may cause serious personal accidents and / or damage to the machine.
Page 30: 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 31: 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 32: 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 33: 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 34: Transport Safely
SAFETY Transport Safely  Be careful because the machine may turn over when loading or unloading the machine on or off of a truck or trailer.  Observe the related regulations and rules for safe transportation. Less than 15 ° ...
Page 35: 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 36: 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 37: 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 38: 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 39: 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 40: 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 41: 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 42: Evacuating In Case Of Fire
SAFETY Check Key Switch:  If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1. Start the engine and run it at low idle. 2.
Page 43: Beware Of Exhaust Fumes
SAFETY Beware of Exhaust Fumes  Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.  If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
Page 44: Avoid Applying Heat To Lines Containing Flammable Fluids
SAFETY Avoid Applying Heat to Lines Containing Flammable Fluids  Do not weld or flame cut pipes or tubes that contain flammable fluids.  Clean them thoroughly with nonflammable solvent before welding or flame cutting them. Precautions for Handling Accumulator and Gas Damper High-pressure nitrogen gas is sealed in the accumulator and the gas damper.
Page 45: Remove Paint Before Welding Or Heating
 Keep bystanders out of the work site during operation.  Asbestos might be present in non-genuine parts. Use only genuine Hitachi Parts. S-33...
Page 46: 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 47: 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, DEF/AdBlue®, 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 48: 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 49: Precaution For Communication Terminal Equipment
SAFETY Precaution 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 to the electrical waves emitted from the communication terminal equipment.
Page 50: Articulation Stopper (Lock Bar
SAFETY Articulation Stopper (Lock Bar) WARNING: With articulation stopper in LOCKED position, machine will not steer; which, while operating, could cause an accident, injury or death. Do not lock Articulation Stopper during normal operation. Articulation stopper locks the front and rear chassis to prevent them from sudden articulation during inspection or transportation.
Page 51: Joystick Steering System On/Off
SAFETY Joystick Steering System ON/OFF "Raised" position WARNING: Accidental movement of the stick while getting on or off the machine may cause unexpected movement of the machine resulting in an accident, injury, or death. Always stop, and properly park the machine and turn off the joystick steering system while getting on or off the machine.
Page 52: Rops (Roll Over Protective Structure
SAFETY ROPS (Roll Over Protective Structure) The Roll Over Protective Structure (ROPS) is attached to protect the cab in case of a machine rollover. WARNING: Operating with damaged or improperly ROPS mounted ROPS could serious injury or death. Be sure to observe the following: - Whenever seated, fasten the seat belt.
Page 53: Safety Labels
SAFETY LABELS All safety signs and their locations on the machine are illustrated in this group. Become familiar with the contents of the safety labels by reviewing them on the machine and understanding them, to ensure safe machine operation. Always keep the safety labels clean. In case a safety sign is lost or no longer readable, immediately-obtain a new replacement and affix it again in position on the machine.
Page 54 SAFETY LABELS 115Z7B-S-42US S-42...
Page 55 SAFETY LABELS 1. Bucket and Hood CAUTION: Sign indicates a fall hazard.  Do not step on or stand in this area. label 44787-24370 115Z7B-S-49 2. Accumulator residual pressure WARNING: Oil injection hazard.  Nitrogen accumulator contains compressed gas and fluid which could result in death or serious injury.
Page 56 SAFETY LABELS 3. Both Sides of Oil Cooler and Engine Housing On the Rear Fenders (Both Sides) 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. 115Z7B-S-45 label 44787-24990 4.
Page 57 SAFETY LABELS 5. Top of Hydraulic Oil Tank label 44787-25030 WARNING: Burn Hazard  Sign indicates a burn hazard from the pressurized tank spurting hot oil if the oil inlet is uncapped during or right 115Z7-S-43K after operation. Read manual for safe and proper handing. 6.
Page 58 SAFETY LABELS 7. Side of Engine Starter label 44787-24930 DANGER: Runover Hazard  If the engine is not started correctly the machine may suddenly start to move. Start the engine from the operator's 115Z7B-S-46 seat only. 8. Both Sides of Front Chassis DANGER: Crush Hazard ...
Page 59 SAFETY LABELS 10. Both Sides of Counterweight WARNING: Runover Hazard  Avoid injury or fatality from being run over with the machine. Keep everyone away from the machine when operating. 115Z7B-S-47 label 44787-24400 11. Bottoms at Both Right and Left Side Covers of Rear Chassis WARNING: Entanglement Hazard ...
Page 60 SAFETY LABELS 13. Inside Battery Box CAUTION: Shock Hazard  Sign indicates a possible shock hazard from handling battery terminals. Read manual for safe and proper handling. 115Z7B-S-44 label 44787-24350 14. Inside Battery Box WARNING: Explosion Hazard  Sign indicates an explosion hazard. Keep fire and open flames away from this area.
Page 61 SAFETY LABELS 16. Top of Battery Recycle Batteries  Batteries contain lead and acid. Obey all local and federal laws and regulation on disposal of batteries and electrolyte solution. label 44774-23030 115Z7-S-47G1 17. Both Sides of Lift Arm DANGER: Crush Hazard ...
Page 62 SAFETY LABELS 18. Cab Inside Right Front Column (First safety sign from the top) WARNING  Prior to operation, maintenance, disassembling, and transportation of the machine, be sure to read and understand the Operator's Manual. 115Z7B-S-50 label 44787-24940 19. Cab Inside Right Front Column (2nd safety sign from the top) DANGER: Electrocution Hazard...
Page 63 SAFETY LABELS 21. Cab Inside Right Front Column (4th safety sign from the top) WARNING: Rollover Hazard  To minimize the injury due to an overturning accident, be sure to fasten the seat belt prior to operating the machine. label 44787-24970 115Z7B-S-50 22.
Page 64 SAFETY LABELS 24. Both Right and Left Side of Engine Housing Frame WARNING: Entanglement Hazard  Sign indicates a hazard of rotating parts, such as fan. Turn off before inspection and maintenance. label 44787-24380 115Z7B-S-47 25. EGR Cooler label 44787-25880 WARNING: Burn Hazard ...
Page 65: Components Name
COMPONENTS NAME Components Name 1- Bucket Teeth 2- Bucket 3- Bell Crank (Lever) 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 (Over the Cab) 9- Rear Fender 10- Front Fender 115Z7B-1-1-1 11- Lift Arm Cylinder...
Page 66 COMPONENTS NAME 115Z7B-1-2-1 1- Bucket Teeth 17- Transmission 2- Bucket 18- Second (Front and Center) Propeller Shaft 3- Bucket Cylinder Rod Pin 19- Steering Cylinder 4- Bucket Cylinder 20- Front Axle 5- Front Combination Lamp 21- Lift Arm Cylinder 6- Hydraulic Oil Tank 22- Lift Arm Cylinder Rod Pin 7- Air Cleaner 23- Bell Crank (Lever) Pin...
Page 67: Operator's Station
OPERATOR'S STATION Aftertreatment Device The machine is equipped with the aftertreatment system combining Diesel Oxidation Catalyst (DOC) block (1) with Selective Catalytic Reduction (SCR) block (2) to remove nitrogen oxide (NOx) from the exhaust gas in order to meet governmental emissions regulations. The DOC reduces harmful substances in exhaust gas by chemical reaction, then DEF is injected in dosing module (injection chamber) (3) and mixed into the exhaust stream.
Page 68 OPERATOR'S STATION  Refill DEF which meets JIS or ISO (International Organization for Standardization). If improper liquid (diesel oil, kerosene or gasoline) is refilled in the DEF tank, fire or system failure may result.  Use only recommended engine oil. Using engine oil other than the recommended may result in malfunction of the aftertreatment device.
Page 69: Automatic Regeneration
OPERATOR'S STATION Automatic Regeneration White deposition may accumulate inside the aftertreatment device. An automatic regeneration (Auto-regeneration) mode is designed to automatically clean the aftertreatment device at regular intervals. The auto-regeneration may start during operation of the machine; you can continue to operate the machine.
Page 70 OPERATOR'S STATION Repeated Inhibiting of Aftertreatment Device Cleaning IMPORTANT: When the machine is operated without performing manual regeneration, the aftertreatment device may be damaged. Immediately move the machine to a safe area and perform manual regeneration.  If auto-regeneration is inhibited or interrupted, the following auto-regeneration will be accompanied by the aftertreatment device manual regeneration request.
Page 71: 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 115Z7-1-7-1 10- Floor Mat...
Page 72: Front Console
OPERATOR'S STATION Front Console 1- Air Conditioner Front Vent 2- Hazard Switch 3- Work Light Switch 4- Parking Brake Switch 5- Monitor Panel 6- Accelerator Pedal 7- Brake Pedal 8- Front Window Wiper Switch 115Z7-1-8-1 9- Rear Window Wiper Switch 10- Light Switch 11- Key Switch 12- Multi Function Monitor/Air Conditioner Switch Panel...
Page 73: Joystick Steering
OPERATOR'S STATION Joystick Steering 21- Forward/Reverse Switch 22- Joystick 23- Shift Up Switch 24- Shift Down Switch 25- Hold Switch (Under the Joystick) 26- Horn Switch (Under the Joystick) 27- Joystick Steering System Switch 28- Armrest Lock Release Button 29- Armrest Adjust Handle 30- Support Bar 31- Armrest 115Z7B-1-10-3...
Page 74: Right Console
OPERATOR'S STATION Right Console Fingertip Control Type 1- Auxiliary Control Lever (Option) 2- Bucket Control Lever 3- Lift Arm Control Lever 4- Turn Signal Switch 5- Control Lever Lock Switch 6- Declutch Position Switch 7- Travel Mode Selector 8- Power Mode Selector 9- Auxiliary 115Z7B-1-9-4 10- Fan Reverse Rotation Switch...
Page 75: Multi-Function Joystick Type
OPERATOR'S STATION Right Console Multi-Function Joystick Type 1- Turn Signal Switch 2- Multi-Function Joystick Lever 3- Quick Power Switch 4- DSS (Down Shift Switch) 5- Auxiliary Control Lever (Option) 6- Control Lever Lock Switch 7- Declutch Position Switch 8- Travel Mode Selector Switch MNEC-01-043 9- Power Mode Selector Switch 10- Auxiliary...
Page 76: Monitor Panel
OPERATOR'S STATION Monitor Panel MNEC-01-001 1- Left Turn Signal Indicator 12- Discharge Warning Indicator 2- High Beam Indicator 13- Fuel Gauge 3- Work Light Indicator 14- Multi Function Monitor 4- Right Turn Signal Indicator 15- Communication System Error Indicator 5- Parking Brake Indicator 16- Coolant Temperature Gauge 6- Brake Oil Low Pressure Indicator 17- Overheat Indicator...
Page 77: 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 switch (or 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 78: Low Steering Oil Pressure Indicator (Option) (Red)
OPERATOR'S STATION Low Steering Oil Pressure Indicator (Option) (Red) IMPORTANT: The secondary steering system shall only be used temporarily when the steering oil pressure has dropped. If continuously used, it may damage the system. If the steering oil pressure decreases, the low steering oil pressure indicator and the service indicator will light, and the alarm buzzer will sound.
Page 79: Engine Warning Indicator (Red)
OPERATOR'S STATION Engine Warning Indicator (Red) If any serious abnormality occurs in the engine and/or engine related parts, the red indicator will light. If the engine 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 80: Air Filter Restriction Indicator (Red)
OPERATOR'S STATION Air Filter Restriction Indicator (Red) If the air cleaner element becomes clogged,, the air filter restriction indicator and the service indicator light. Immediately stop the engine and inspect the air cleaner element. Replace the element, if necessary. NOTE: This indicator may unexpectedly light when the coolant temperature gauge indicates the center or lower position.
Page 81: Coolant Temperature Gauge
OPERATOR'S STATION Coolant Temperature Gauge The engine coolant temperature is indicated with a needle. When the needle stays in the 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. Stop machine operation and run the engine at low idle to lower the coolant temperature.
Page 82: 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 83: Multi Function Monitor
OPERATOR'S STATION Multi Function Monitor Feature The multi function monitor displays various meters, indicators, operation mode selection and maintenance screen. Screen Configuration The multi function monitor consists of the following screens. There are 7 menus, and a further 13 sub menus. Basic Screen Main Menu Alarm List...
Page 84: Default Setting
OPERATOR'S STATION Default Setting Function Item Default Auto Shut-Down ON/OFF of auto idling-stop function Time period for auto idling-stop activation 5 min Rear View Camera Monitor ON (Constant display) OFF (No display) AUTO AUTO (Display at reverse operation only) Aftertreatment Device Regeneration Inhibit regeneration Inhibited Shift Change Delay Mode...
Page 85: Basic Screen
OPERATOR'S STATION Basic Screen 1- Engine Tachometer 2- Economy (ECO) Indicator 3- Speedometer 4- Transmission Oil Temperature Gauge 5- DEF Level Gauge 6- Air Conditioner Display MNHG-01-100EN 7- Ride Control Indicator (Option) 8- Seat Belt Indicator 9- Forward/Reverse Selector Switch Indicator 10- Declutch Indicator 11- Aftertreatment Device Indicator 12- Power Mode Indicator...
Page 86: How To Use Screens
OPERATOR'S STATION How to Use Screens Displaying Basic Screen IMPORTANT: Start the engine after the basic screen is displayed. When the key switch is turned to the ON position, the starting screen displays for about two seconds and the basic screen displays.
Page 87 OPERATOR'S STATION  Engine Tachometer (1) Engine tachometer (1) indicates the speed of currently running engine in a gauge form. (200 min step or "RPM") If the engine overspeeds, the color of the gauge changes.  ECO Indicator (2) ECO indicator (2) lights when the engine runs in energy efficient condition.
Page 88 OPERATOR'S STATION  Forward/Reverse Selector Switch Indicator (9) The forward/reverse indicator lights when the forward/ reverse switch on the joystick steering is usable by turning on the joystick steering system switch. (Refer to OPERATING THE ENGINE.)  Declutch Indicator (10) The declutch indicator lights when the declutch position switch on the right console is in ON position.
Page 89 OPERATOR'S STATION  Fan Reverse Rotation Indicator (16) Displays rotating direction of the fan. Normal Rotation  The icon is not displayed. Changing Rotational  The icon blinks. Direction Reverse Rotation  The icon lights ON.  HOLD Display (17) Hold display (17) is displayed when the hold switch on the side console is in ON position.
Page 90: Monitor Operation
OPERATOR'S STATION Monitor Operation  Select/Confirm Knob (1) Push Push this switch while the basic screen is displayed, the Main Menu Screen opens. Push this switch after the menu screen, the action is confirmed. Rotate : Cursor moves. MNEC-01-006 Multi Function Monitor/Air Conditioner Switch Panel MNEC-01-078 ...
Page 91: Alarm Occurrence Screen
OPERATOR'S STATION Alarm Occurrence Screen In case any abnormality occurs, alarm symbols (1) and service indicator (3) are displayed on the basic screen. MNHG-01-290EN Basic Screen If 8 or more alarms are generated, the alarm symbols (1) can be scrolled by rotating selector knob (2). When the rear view monitor is operating, service indicator (3) is displayed.
Page 92 OPERATOR'S STATION Follow the procedure below to display detailed information for an alarm. Push selector knob (1) on the basic screen to display the main menu. MNHG-01-290EN Rotate selector knob (1) to select the alarm list, and push selector knob (1). MNEC-01-006 NOTE: The main menu displays the alarm list (faults) only when an alarm occurs.
Page 93: Remedy
OPERATOR'S STATION Remedy Display Contents of Alarms Remedy System Failure Alarm Communication system is abnormal. Consult your nearest authorized dealer. Brake Oil Pressure Alarm Brake oil pressure has decreased. Immediately stop the machine and check the brake system. Low Steering Oil Pressure Steering oil pressure has decreased.
Page 94 OPERATOR'S STATION Display Contents of Alarms Remedy Hydraulic Oil Overheat Alarm Hydraulic oil temperature is above normal. Stop operation. Run the engine at slow idle speed to lower the oil temperature. Axle Oil Temperature Alarm Axle oil temperature is above normal. Check if the service brake drags. Transmission Oil Temperature Transmission oil temperature is above normal.
Page 95 OPERATOR'S STATION Display Contents of Alarms Remedy Exhaust Temperature Rise Exhaust temperature is abnormally high. Alarm Stop machine operation, apply parking brake, and check the exhaust lines. Intake Air Temperature Rise Intake air temperature is abnormally high. Stop machine operation Alarm and apply parking brake.
Page 96: Def/Scr System Alarm
OPERATOR'S STATION DEF/SCR System Alarm When the DEF 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. Move and park the machine in a safe place and follow the displayed message, or troubleshooting guide for the accompanied alarms.
Page 97: Urea Scr System Malfunction
OPERATOR'S STATION Urea SCR System Malfunction Alarm Indicator Status/Inducement Urea SCR system is broken. (Red, light) Urea SCR system is broken. Engine output is restricted. (Red, slow blink) Urea SCR system is broken. Engine output and speed are restricted. (Red, fast blink) Contact your authorized dealer for service.
Page 98: Aftertreatment Device Regeneration
OPERATOR'S STATION Aftertreatment Device Regeneration To keep the system working correctly, periodically, the collected deposit is removed by purging it at a high temperature. This process is known as "regeneration". The regeneration is done in three ways; automatic regeneration (abbreviated as auto-regeneration), manual regeneration, and service regeneration.
Page 99: Automatic Regeneration (Auto-Regeneration)
OPERATOR'S STATION Automatic regeneration (Auto-regeneration) The machine automatically increases the exhaust temperature during normal operation to purge the deposit. There are no actions on the part of the operator when auto-regeneration is performed.  Auto-regeneration may start while operating the machine, and there is no need to stop the machine when this happens.
Page 100: Manual Regeneration
OPERATOR'S STATION Manual Regeneration When the deposit level increases to a level that is more than an auto-regeneration can remove, a manual regeneration is required. The yellow regeneration symbol (shown below)(1) and service indicator (2) appear to make the operator aware that this is required.
Page 101: Main Menu
OPERATOR'S STATION Main Menu IMPORTANT: If the forward/reverse lever is in the forward or reverse position, the basic screen is displayed. (You can not change to the other screen.) When the forward/reverse lever is changed to forward or reverse position while displaying the main menu screen, the screen changes back to the basic screen.
Page 102: Ride Control Drive Speed Setting (Option)
OPERATOR'S STATION Ride Control Drive Speed Setting (Option) 1. Press selector knob (2) while displaying basic screen (1) to display Main Menu screen (3). MNHG-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Ride Control (4). 3. Press selector knob (2) to display Ride Control Drive Speed Setting screen (5).
Page 103: Dual Lift Arm Auto-Leveler
OPERATOR'S STATION Dual Lift Arm Auto-Leveler 1. Press selector knob (2) while displaying basic screen (1) to display Main Menu screen (3). MNHG-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Dual Lift Arm Auto- Leveler (4). MNHG-01-110EN 3. Press selector knob (2) to display Dual Lift Arm Auto- Leveler screen (5).
Page 104: Height Kickout On/Off, Stop Height Setting
OPERATOR'S STATION Height Kickout ON/OFF, Stop Height Setting  Rotate selector knob (2) to highlight ON (8).  ON/OFF Selection Press selector knob (2) to turn ON (enabled). (A box next to ON turns green.) This enables the setting of the lift arm height. Press selector knob (2) again to turn OFF (disabled).
Page 105: Lower Kickout On/Off, Stop Height Setting
OPERATOR'S STATION Lower Kickout ON/OFF, Stop Height Setting  Rotate selector knob (2) to highlight ON (8).  ON/OFF Selection Press selector knob (2) to turn ON (enabled). (A box next to ON turns green.) This enables the setting of the lift arm height. Press selector knob (2) again to turn OFF (disabled).
Page 106: Brightness Adjustment
OPERATOR'S STATION Brightness Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNHG-01-103EN 2. Rotate selector knob (2) to highlight Brightness MNEC-01-006 Adjustment (4). MNHG-01-120EN 1-42...
Page 107 OPERATOR'S STATION 3. Press selector knob (2) to display Brightness Adjustment screen (5). MNEC-01-006 4. Rotate selector knob (2) clockwise to make the screen brighter, counterclockwise to make the screen darker. NOTE: When the machine's head light switch is turned ON, the monitor screen changes to night mode and mark (6) is MNHG-01-121EN displayed.
Page 108: Mail (Option)
OPERATOR'S STATION Mail (Option) IMPORTANT: This function is available only to a machine equipped with a communication terminal. When using the mail function, consult your nearest authorized dealer. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNHG-01-103EN MNEC-01-006 2.
Page 109 OPERATOR'S STATION 6. While mail information is sent to the communication terminal, the message "Wait." is displayed on the screen. MNHG-01-132EN 7. When the communication terminal completes receiving mail information, the message "Request Was Accepted." is displayed on the screen. Push back key (6) to return to the Mail screen.
Page 110: Setting Menu
OPERATOR'S STATION Setting Menu Setting menu consists of date and time setting, auto idling stop setting, and rear view camera monitor setting. 1. Press selector knob (2) while displaying basic screen (1) to display Main Menu screen (3). MNHG-01-103EN MNEC-01-006 2.
Page 111: Date And Time
OPERATOR'S STATION Date and Time Time, date and display mode can be set on this screen. Year- month-day format and 24h/12h display mode are selected in the display setting. Time Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
Page 112 OPERATOR'S STATION 5. Press selector knob (2) to display Date and Time screen (7). MNEC-01-006 6. Rotate selector knob (2) to highlight Time Setting (8). 7. Press selector knob (2) to display Time Setting screen (9). 8. Rotate selector knob (2) to highlight Hour or Minute and push selector knob (2).
Page 113: Date Adjustment
OPERATOR'S STATION Date Adjustment 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNHG-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Setting Menu (4). MNHG-01-140EN 3. Press selector knob (2) to display Setting Menu screen (5).
Page 114 OPERATOR'S STATION 5. Press selector knob (2) to display Date and Time screen (7). MNEC-01-006 6. Rotate selector knob (2) to highlight Date Setting (8). 7. Press selector knob (2) to display Date Setting screen (9). 8. Rotate selector knob (2) to highlight Year, Month or Day and push selector knob (2).
Page 115: Display Mode Setting
OPERATOR'S STATION Display Mode Setting 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNHG-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Setting Menu (4). MNHG-01-140EN 3. Press selector knob (2) to display Setting Menu screen (5).
Page 116 OPERATOR'S STATION 5. Press selector knob (2) to display Date and Time screen (7). MNEC-01-006 6. Rotate selector knob (2) to highlight Display Form (8). MNHG-01-148EN 7. Press selector knob (2) to display Display Form screen (9). 8. Rotate selector knob (2) to highlight Date (10) and push selector knob (2).
Page 117: Auto Idling Stop
OPERATOR'S STATION Auto Idling Stop WARNING: This function automatically idles, then stops the engine. Take extra care on the work and environment when using this function. The auto idling stop function can be set in this screen. Set the auto idling stop time and enable the function beforehand (set to ON).
Page 118: Acting Time Setting
OPERATOR'S STATION 5. Press selector knob (2) to display Auto Shut-Down screen (7). MNEC-01-006 6. Rotate selector knob (2) to highlight ON (8). 7. Press selector knob (2) to set the auto idling stop function ON and indicator (11) will be lit. Press selector knob (2) again to set the auto idling stop function OFF and indicator (11) goes off.
Page 119: Rear View Camera Monitor
OPERATOR'S STATION Rear View Camera Monitor IMPORTANT: The image displayed on the rear view monitor is meant only as an aid. Actual position and distance of people and objects in the rear view monitor will be different from the actual view. When operating the machine, pay thorough attention to the surroundings with use of mirrors and windows.
Page 120 OPERATOR'S STATION 5. Press selector knob (2) to display Rear View Camera Monitor screen (7). MNEC-01-006 6. Press selector knob (2) to turn the rear view camera monitor ON/OFF/AUTO. 7. When the rear view camera monitor is ON, rear view image is continuously displayed on the basic screen.
Page 121: Aftertreatment Device Regeneration Inhibited
OPERATOR'S STATION Aftertreatment Device Regeneration Inhibited IMPORTANT: The aftertreatment device regeneration can be inhibited at this screen to prevent auto regeneration while operating the machine in a flammable area or indoors. Setting Procedure MNHG-01-103EN 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
Page 122 OPERATOR'S STATION 4. Rotate selector knob (2) to highlight Aftertreatment Device Regeneration Inhibited (6). MNEC-01-006 5. Press selector knob (2) to display Aftertreatment Device Regeneration Inhibited screen (7). 6. Rotate selector knob (2) to highlight (8), and press MNHG-01-170EN selector knob (2) to display Aftertreatment Device Regeneration Inhibited screen (9).
Page 123: Transmission Setting
OPERATOR'S STATION Transmission Setting Shift Change Delay Mode Setting Refer to page 4-6 for Shift Change Delay Mode. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNHG-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Setting Menu (4). MNHG-01-140EN 3.
Page 124 OPERATOR'S STATION 4. Rotate selector knob (2) to highlight Transmission Setting Menu (6). MNHG-01-180EN 5. Press selector knob (2) to display Transmission Setting screen (7). 6. Rotate selector knob (2) to highlight Shift Change Delay Mode (8). MNHG-01-181EN 7. Press selector knob (2) to display Shift Change Delay Mode screen (9).
Page 125: Lockup Setting
OPERATOR'S STATION Lockup Setting Lock-up clutch is provided for efficient power transmission from the engine, that helps to improve fuel efficiency and have higher ground speed. Use this setting to activate the lockup shifting (refer to page 4-5). NOTE: The lock-up control directly links the transmission to the engine when the Auto Shift Mode 1 or 2 is selected.
Page 126 OPERATOR'S STATION 4. Rotate selector knob (2) to highlight Transmission Setting Menu (6). MNHG-01-180EN 5. Press selector knob (2) to display Transmission Setting screen (7). 6. Rotate selector knob (2) to highlight Lockup (8). MNHG-01-184EN 7. Press selector knob (2) to display Lockup setting screen (9).
Page 127: Traction Control Setting
OPERATOR'S STATION Traction Control Setting If the tire is ready to spin, by keeping the traction control function ON, the engine speed is temporarily slowed down and tire spin is reduced. This increases tire life. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3).
Page 128 OPERATOR'S STATION 4. Rotate selector knob (2) to highlight Transmission Setting Menu (6). MNEK-01-180EN 5. Press selector knob (2) to display Transmission Setting screen (7). 6. Rotate selector knob (2) to highlight Traction Control (8). 95Z7-01-05 7. Press selector knob (2) to display Traction Control screen (9).
Page 129: Parallel/Tandem Switching Height Setting
OPERATOR'S STATION Parallel/Tandem Switching Height Setting With parallel/tandem circuits, the lift arm and bucket can be operated at the same time, under a set height. This setting is adjustable. 1. Press selector knob (2) while displaying basic screen (1) MNHG-01-103EN to display main menu screen (3).
Page 130 OPERATOR'S STATION 4. Rotate selector knob (2) to highlight Parallel/Tandem Switching Height (6). MNEC-01-006 5. Press selector knob (2) to display Parallel/Tandem Switching Height screen (7). 6. When the lift arm height changes by operating the lift MNHG-01-190EN arm control lever, the height is displayed on segment (8). 7.
Page 131: Warm Up Operation
OPERATOR'S STATION Warm Up Operation Refer to "Cold Weather Warm Up" (page 3-13) for the operation when using this setting. 1. Press selector knob (2) while displaying basic screen (1) to display main menu screen (3). MNHG-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Setting Menu (4). MNHG-01-140EN 3.
Page 132 OPERATOR'S STATION 4. Rotate selector knob (2) to highlight Warm Up (6). MNEC-01-006 5. Press selector knob (2) to display Warm Up Setting screen (7). 6. Press selector knob (2) to turn ON (enabled). MNHG-01-200EN Press selector knob (2) again to turn OFF (disabled). NOTE: When the function is ON, the mark ""...
Page 133: Display Item Selection
OPERATOR'S STATION Display Item Selection Unit system displayed on the monitor can be selected in this screen. 1. Press selector knob (2) while displaying basic screen (1) MNHG-01-103EN to display main menu screen (3). MNEC-01-006 2. Rotate selector knob (2) to highlight Setting Menu (4). MNHG-01-140EN 3.
Page 134 OPERATOR'S STATION 5. Press selector knob (2) to display Display Item Selection screen (7). MNEC-01-006 6. Rotate selector knob (2) to highlight Unit. Press selector knob (2) to set the unit (Metric or US system). 7. Rotate selector knob (2) to highlight Accumulated Operation Display.
Page 135: Main Menu Display Order Change
OPERATOR'S STATION Main Menu Display Order Change Menu sequence of "Ride Control" (option), "Dual Lift Arm Auto Leveler", "Brightness Adjustment" and "Mail" can be changed in this screen. Frequently used menu can be located on top of the screen. 1. Press selector knob (2) while displaying Basic Screen (1) MNHG-01-103EN to display Main Menu screen (3).
Page 136 OPERATOR'S STATION 3. Press selector knob (2) to display Setting Menu screen (5). 4. Rotate selector knob (2) to highlight Main Menu Sequence Change (6). MNHG-01-230EN-KC 5. Press selector knob (2) to display Main Menu Sequence MNEC-01-006 Change screen (7). 6.
Page 137: Information Menu
OPERATOR'S STATION Information Menu The information menu includes Operation, Maintenance, Troubleshooting and Monitoring. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNHG-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Information Menu (4).
Page 138: Operation Condition
OPERATOR'S STATION Operation Condition The Operation screen displays fuel consumption, operating hours, and fuel consumption rate from resetting of the monitoring unit. Fuel Consumption MNHG-01-103EN 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNEC-01-006 2.
Page 139 OPERATOR'S STATION 5. Press selector knob (2) to display Operation screen (7). 6. Rotate selector knob (2) to highlight Fuel Consumption MNEC-01-006 (8) or Machine Information (9). 7. Press selector knob (2) while selecting Fuel Consumption MNHG-01-242EN (8) to display Fuel Consumption screen (10). The Machine Operation Hours, Fuel Consumption, and Average Fuel Consumption Rate can be checked on Fuel Consumption screen (10).
Page 140: Maintenance
OPERATOR'S STATION Maintenance The maintenance screen includes maintenance notice, remaining hours until the next maintenance, and maintenance intervals. Maintenance Items  Engine Oil  Engine Oil Filter MNHG-01-103EN  Hydraulic Oil  Hydraulic Oil Pilot Filter  Hydraulic Oil Return Filter ...
Page 141 OPERATOR'S STATION 5. Press selector knob (2) to display Maintenance screen (7). 6. Rotate selector knob (2) to highlight Maintenance Notice MNEC-01-006 (8). 7. Press selector knob (2) to turn the Maintenance Notice ON. Press selector knob (2) again to turn the Maintenance Notice OFF.
Page 142: Time Remains And Maintenance Interval
OPERATOR'S STATION Time Remains and Maintenance Interval 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNHG-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Information Menu (4). MNHG-01-240EN 3. Press selector knob (2) to display Information Menu screen (5).
Page 143 OPERATOR'S STATION 5. Press selector knob (2) to display Maintenance screen (7). 6. Rotate selector knob (2) to highlight a maintenance item to be checked (8). (In the right example, Engine Oil is MNEC-01-006 selected.) 7. Press selector knob (2) to display the time remaining for the selected maintenance item.
Page 144: Troubleshooting
OPERATOR'S STATION Troubleshooting An active fault code generated by the controller connected to the controller area network is displayed on this screen. 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNHG-01-103EN MNEC-01-006 2.
Page 145 OPERATOR'S STATION 4. Rotate selector knob (2) to highlight Troubleshooting (6). MNHG-01-260EN-KC 95MNEC-01-261EN 5. Press selector knob (2) to start troubleshooting. After displaying "Wait." message, the screen displays controller troubleshooting (7). 6. Active fault codes are displayed at the right side of each 95MNEC-01-262EN item.
Page 146: Monitoring
OPERATOR'S STATION Monitoring 1. Press selector knob (2) while displaying Basic Screen (1) to display Main Menu screen (3). MNHG-01-103EN MNEC-01-006 2. Rotate selector knob (2) to highlight Information Menu (4). MNHG-01-240EN 3. Press selector knob (2) to display Information Menu screen (5).
Page 147 OPERATOR'S STATION 5. Press selector knob (2) to display Monitoring screen (7). NOTE:  When the "PM Accumulation" bar reaches the right end, auto-regeneration takes place. However, auto- regeneration may not be performed depending on the machine condition.  The PM Accumulation is not displayed during regeneration. MNHG-01-271EN 1-83...
Page 148 OPERATOR'S STATION MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1-84...
Page 149: Front Console Switches, Pedals, And Joystick Steering
OPERATOR'S STATION Front Console Switches, Pedals, and Joystick Steering 1- Hazard Switch 2- Work Light Switch 3- Parking Brake Switch 4- Key Switch 5- Accelerator Pedal 6- Brake Pedal 7- Front Window Wiper Switch 8- Rear Window Wiper Switch 9- Light Switch 115Z7B-1-81-1 10- Brake/Declutch Pedal 11- Forward/Reverse Switch...
Page 150: Hazard Switch
OPERATOR'S STATION Hazard Switch IMPORTANT: Do not leave the hazard switch (1) in the " " or "ON" 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 151: Work Light Switch
OPERATOR'S STATION Work Light Switch Press the mark on switch (1) while the light switch is in tail, low, or high position to turn front work lights (2) ON. Rear work lights (3) stay OFF. NOTE: Refer to page 1-91 for the light switch position. 115Z7B-1-81-1 When the side with mark on switch (1) is pressed,...
Page 152: Parking Brake Switch
OPERATOR'S STATION Parking Brake Switch WARNING:  To prevent accidents due to rolling 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 the machine is moving except in an emergency.
Page 153: Key Switch
OPERATOR'S STATION Key Switch WARNING: Before starting the engine, return the forward/reverse switch (or lever) to neutral (N), apply the parking brake, lock the neutral lever lock, and lock the control lever. Refer to the descriptions in the OPERATING ENGINE section for the detail information.
Page 154: Accelerator Pedal
OPERATOR'S STATION Accelerator Pedal When accelerator pedal (3) is applied, 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 Pedal 115Z7B-1-81-1 WARNING: ...
Page 155: Joystick Steering
OPERATOR'S STATION Joystick Steering Joystick steering system allows quick easy steering on one joystick type lever. The transmission forward and reverse changeover switch and the shift up/down buttons are built into the joystick steering. This allows the operator to change the direction and speed of the machine without releasing the joystick steering.
Page 156: Shift Switch
OPERATOR'S STATION Shift Switch Press shift switch (3) to shift up the gear. Press shift switch (4) to shift down the gear. Select a proper shift for the work. IMPORTANT: The joystick steering lever and switches are designed to operate with low effort. Do not press and twist the lever and switches firmly.
Page 157: Light Switch
OPERATOR'S STATION Light Switch Light switch (1) has four positions; OFF, tail, high and low. As shown below, each light comes ON ( ) or OFF ( according to the selected position of the light switch. 2- Headlight 3- Clearance Light 4- Tail Light Light Headlight...
Page 158: Wiper Switch
OPERATOR'S STATION NOTE: When the light switch position (high) is selected, high beam indicator (6) comes ON. MNEC-01-073 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 blade and the windshield.
Page 159: Front/Rear Wiper Switch
OPERATOR'S STATION Front/Rear Wiper Switch Operate wiper switches (1)(2) 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 washer motor pump switch is operated with no fluid in the washer tank.
Page 160: Right Console/Switches
OPERATOR'S STATION Right Console/Switches Fingertip Control Type 1- Auxiliary Control Lever (Option) 2- Bucket Control Lever 3- Lift Arm Control Lever 4- Turn Signal Switch 5- Control Lever Lock Switch 6- Declutch Position Switch 7- Travel Mode Selector 8- Power Mode Selector 9- Auxiliary 115Z7B-1-9-4 10- Fan Reverse Rotation Switch...
Page 161: Loading Control Levers
OPERATOR'S STATION Loading Control Levers The lift arm control lever and the bucket control lever are used to operate the lift arm and/or bucket. Lift Arm Control Lever (1) Lever Lift Arm Operation Position Float (Detent): The lift arm free falls and can be moved as loads are applied.
Page 162 OPERATOR'S STATION  When pushing down the lift arm control lever to the "Float" position (C), the lift arm moves to the position preset at lower kickout and is held in that position. When the lift arm moves to the preset position, the lift arm control lever automatically moves to "Neutral"...
Page 163: Right Console/Switches
OPERATOR'S STATION Right Console/Switches Multi-Function Joystick Type 1- Turn Signal Switch 2- Multi-Function Joystick Lever 3- Quick Power Switch 4- DSS (Down Shift Switch) 5- Auxiliary Control Lever (Option) 6- Control Lever Lock Switch 7- Declutch Position Switch 8- Travel Mode Selector Switch MNEC-01-043 9- Power Mode Selector Switch 10- Auxiliary...
Page 164: Loading Multi-Function Joystick Lever (Option)
OPERATOR'S STATION Loading Multi-Function Joystick Lever (Option) The multi-function joystick lever is used to operate the lift arm and/or bucket. Lever Bucket Operation Position Float (Detent): The lift arm free falls and can be moved as loads are applied. The lever is held in this position.
Page 165: Auxiliary Control Lever (Option)
OPERATOR'S STATION Auxiliary Control Lever (Option) An optional control lever (1) can be installed to control the attachment. Refer to the operator's manual for the attachment how to use this lever. 115Z7-1-9-4a MNEC-01-043 Fingertip Control Type Multi-Function Joystick Type Turn Signal Switch Indicates the drive change direction to persons and/or NOTE: This switch (4) does not return automatically other vehicles by operating turn signal switch (4).
Page 166: Loading Control Lever Lock Switch
OPERATOR'S STATION Loading Control Lever Lock Switch WARNING:  Before leaving the operator's seat, be sure to stop the engine. Place the boom and bucket in a level, safe position. Then, set control lever lock switch (1) to the lock ( ) position. ...
Page 167: Declutch Position Switch
OPERATOR'S STATION Declutch Position Switch Declutch position switch (2) changes the function of left brake pedal. Operating declutch position switch (2) turns the declutch function ON and OFF.  Declutch ON By depressing left brake pedal, the clutch is disengaged and brake is applied without transmitting the drive power to the tires.
Page 168: Travel Mode Selector Switch
OPERATOR'S STATION Travel Mode Selector Switch Travel mode selector switch (1) selects the travel mode. Selecting the manual mode " " by using travel mode selector switch (1) switch 1 sets the transmission to manual mode, which allows manual shift change by using shift switch (2).
Page 169: Power Mode Selector Switch
OPERATOR'S STATION Power Mode Selector Switch Two operation modes are available and can be selected by power mode selector switch (1) depending on the applications. Each time the switch is pressed, the power mode is activated (ON) and deactivated (OFF) alternately. Power : The power mode is suitable for mode...
Page 170: Fan Reverse Rotation Switch
OPERATOR'S STATION Fan Reverse Rotation Switch Fan reverse rotation switch (1) reverses the hydraulic driven fan. In case the radiator is clogged, rotate the hydraulic driven fan in reverse direction to blow out the clogged dust. It is recommended to carry out the fan reverse rotation regularly to prevent the cooling system from clogging.
Page 171: Manual Operation
OPERATOR'S STATION Manual Operation IMPORTANT:  Fan rotating direction can be manually changed when the engine is running. Each time the ON side of fan reverse rotation switch (1) is pressed, the fan's rotating direction switches alternatively. While switching the fan rotating direction, fan OFF (Neutral) reverse rotation indicator (2) flashes.
Page 172: Secondary Steering Operation Check Switch (Option)
OPERATOR'S STATION Secondary Steering Operation Check Switch (Option) Use this switch to check if the secondary steering pump is operable. While the ON side of switch (1) is being pressed, secondary steering pump operates. Secondary steering indicator (2) lights ON while the pump is operating.
Page 173: Ride Control Switch (Option)
OPERATOR'S STATION Ride Control Switch (Option) 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 174: Hold Switch
OPERATOR'S STATION Hold Switch Press hold switch (1) while letting the machine travel in the auto shift mode, and the machine holds the speed gear range that is currently displayed on the monitor. Operate one of the following to release the hold function: Press the hold switch again, Change the gear range, Change the travel mode, or Press DSS (down shift switch).
Page 175: Quick Power Switch
OPERATOR'S STATION Quick Power Switch By pressing quick power switch (1) when the power mode is OFF, the power mode is temporarily activated. (The power mode indicator on the monitor shows symbol ( NOTE: The quick power switch is operable only in the following cases.
Page 176: Dss (Down Shift Switch)
OPERATOR'S STATION DSS (Down Shift Switch) Press DSS (1) to down shift the gear. Set the shift gear to 2nd speed for normal operation. By pressing DSS (1) while digging with the machine in forward, the gear automatically shifts to 1st speed, which increases drive force and digging force.
Page 177: Horn Switch
OPERATOR'S STATION Horn Switch Press horn switch (1) to sound the horn. The horn switches are provided on the control lever and the joystick steering to improve operator comfort.  Loading Control Lever Fingertip Control Type Multi-Function Joystick Type MNEC-01-044 115Z7-1-92-1 ...
Page 178: Cigar Lighter (24 V Dc Electrical Outlet)
OPERATOR'S STATION Cigar Lighter (24 V DC Electrical Outlet) Using Cigar Lighter WARNING: Never touch other than insulated the knob part. Otherwise, it may result in severe burns. IMPORTANT: In case the cigar lighter does not pop out automatically after 30 seconds after pushing the cigar lighter in, pull out the cigar lighter manually.
Page 179: 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 rotating the temperature control switch clockwise (32°C) (90°F) or counterclockwise (18°C) (64°F) respectively.
Page 180: Components Name
OPERATOR'S STATION Components Name 1- Monitor 2- Control Panel 3- Temperature Control Switch (Rotate)/Mode Switch (Press) 4- Defroster Switch MNHG-01-103EN 5- Circulation/Fresh Air Switch 6- Air Conditioner ON/OFF Switch 7- Fan (Rotate)/Auto Switch (Press) MNEC-01-006 8- Defroster Vent 9- Rear Vent 10- Foot Vent 11- Air flows out of front vent and the defroster vents.
Page 181: Controller Part Name And Function
OPERATOR'S STATION Controller Part Name and Function Mode/Temperature Control Switch  Mode Switch (3) Selects the air vent. The selected air vent is indicated on monitor (1). Front Vent Mode Front/Rear Vent Mode Front/Rear/Foot Vent Mode MNEC-01-006 Foot Vent Mode Foot/Defroster Vent Mode Defroster Vent Mode Each time mode switch (3) is pressed, the vent location can...
Page 182: Fan/Auto Switch
OPERATOR'S STATION Fan/AUTO Switch  Blower Switch (7)  When the AUTO indicator (8) is ON, the blower speed is automatically controlled.  When AUTO indicator (8) is OFF, the blower speed is controlled in 6 steps. Rotate blower switch (7) clockwise to increase blower speed.
Page 183: Cab Heater Operation
OPERATOR'S STATION Cab Heater Operation 1. AUTO switch (7): According to signals sent from various sensors, the air conditioner amplifier automatically selects the air flow inlet ports, and air temperature, and controls the blower speed. 2. Temperature Control Switch (3): Adjust the temperature in the cab by using temperature control switch (3).
Page 184: Cooling Operation
OPERATOR'S STATION Cooling Operation 1. AUTO switch (7): Press AUTO switch (7) to set the air conditioner AUTO mode. According to signals sent from various sensors, the air conditioner amplifier automatically selects the air flow-in vents, air suction ports, and air flow- in temperature at the vent, and controls the blower speed.
Page 185: Defroster Operation
OPERATOR'S STATION Defroster Operation 1. Press defroster switch (4) to change defroster vent mode; the fresh air mode and air conditioner will turn ON. 2. Temperature in the cab can be adjusted by operating temperature control switch (3). 3. Operate fan switch (7) to adjust flow. 4.
Page 186: 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. In this case, ventilate air in the cab first by opening the windows for rapid cooling.
Page 187: Adjusting Operator's Seat (Air Suspension Type Seat)
OPERATOR'S STATION Adjusting Operator's Seat (Air Suspension Type Seat) 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- Lumbar Support Adjustment 2- Reclining Angle Adjustment 3- Damper Adjustment 4- Fore-Aft Position Adjustment...
Page 188: Rear Tray
OPERATOR'S STATION Rear Tray 1- Document Holder 2- Hot/Cool Box 3- Electric Power Output (12 VDC, 15 A) (Option) 4- Glove Compartments, Tray 5- Fuse Box 115MNEC-01-46 Electric Power Output (Option) Use the electric power output (Max. 60W) such as electric power to an instrument used for inspection/ maintenance work such as an illumination light.
Page 189: Fuse Box
OPERATOR'S STATION Fuse Box IMPORTANT: If a fuse blows, turn the key switch OFF. Fuse box B Fuse box A 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 through, and to protect the electrical system.
Page 190: Fuse Box A
OPERATOR'S STATION Fuse Box A 10- Parking solenoid 20- Option 4 (Joystick steering) (5 A) 9- Air conditioner 1 19- Option 3 (Fuel pump) 10 A 15 A 8- Stop lamp, Turn signal 18- SCR DCU 20 A 7- Back lamp, Back buzzer 17- ECM DCU (POWER ON) 10 A 6- Head lamp (left)
Page 191: Hot/Cool Box
OPERATOR'S STATION Hot/Cool Box Cool or warm air from the air conditioner or heater 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. ...
Page 192: Cab
OPERATOR'S STATION The ROPS (Roll Over Protective Structure) is attached to ROPS Cab (1) as standard equipment. 1- Cab 115Z7B-1-128-1 2- Speakers 3- Front Interior Light 115Z7B-1-128-2 4- Sun Visor 115Z7B-1-128-3 1-128...
Page 193 OPERATOR'S STATION 5- Radio 6- Cab Switch Panel (Option) 7- Inside Rear View Mirror 115Z7B-1-129-1 8- Rear Interior Light 9- Emergency Exit Hammer 115Z7B-1-129-2 10- Coat/Hat Hook 115Z7B-1-129-3 1-129...
Page 194: Front Interior Light
OPERATOR'S STATION Front Interior Light Slide to ON side of switch (1) to turn the interior light ON. The front interior light switch has three operation positions.  ON: The light (2) turns and stays ON.  Neutral: When the cab door is opened, the light (2) turns ON.
Page 195: 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 place. 115Z7B-1-128-3 Emergency Exit Hammer In case the cab door becomes difficult or impossible to open if an emergency situation occurs, exit machine by breaking the windowpane using the provided hammer.
Page 196: Upper Switch Panel (Option)
OPERATOR'S STATION Upper Switch Panel (Option) 1- Rotary Light Switch 2- Auxiliary 3- Auxiliary 4- Auxiliary 5- Auxiliary 115Z7B-1-129-1 Rotary Light Switch (Option) Press either upper part or lower part of the switch to turn the rotary light ON. Press middle part of the switch to turn OFF.
Page 197: Outside Rear View Mirror
OPERATOR'S STATION Outside Rear View Mirror WARNING: Do not move 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 a visual aid during travel. Be sure to confirm safety by looking to the rear when moving the machine in reverse.
Page 198: Door Open/Close Lever
OPERATOR'S STATION Door Open/Close Lever When opening the door, while lifting door lock knob (5), pull lever (6) to disengage the door lock. 115Z7B-1-134-1 Window Open/Close Levers When window open/close levers (7) on both sides are simultaneously pressed, the window is unlocked, allowing the windowpanes to move.
Page 199: Battery Disconnect Switch
OPERATOR'S STATION Battery Disconnect Switch IMPORTANT: Never attempt to turn the battery disconnect switch OFF while engine running. Failure to do so may damage the electrical system. WARNING: After stopping the engine, the DEF pump keeps operating to return the DEF in piping to the DEF tank.
Page 200: Switch Operation
OPERATOR'S STATION Switch Operation 1. Open battery box cover (1). 115Z7-BatterySW1 2. When lever (2) is parallel to the ground, battery disconnect switch (3) turns ON. The lever can not be removed when lever (2) points right. When operating the machine with battery disconnect switch (3) ON, close cover (1).
Page 201: Articulation Stopper (Lock Bar)
OPERATOR'S STATION Articulation Stopper (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 chassis and fasten the lock bar to the rear chassis with lock bolt (2).
Page 202: Towing Pin
OPERATOR'S STATION Towing Pin WARNING: Since towing is a potentially dangerous operation, perform only when there is an emergency or crisis situation. IMPORTANT: To prevent excessive wear of tires and for safety, avoid towing requiring more than the available towing force, and keep the specified speed during towing.
Page 203: Inspection/Maintenance Access Covers
OPERATOR'S STATION Inspection/Maintenance Access Covers CAUTION:  Always close side covers (1) and top cover (3) when moving and/or operating machine.  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 move or close.
Page 204: Rear Grille
OPERATOR'S STATION Rear Grille WARNING: Open or close rear grille (4) only after stopping the engine. It is very dangerous if you are entangled in the cooling fan. Before operating the machine, always check that the rear grille is well latched.
Page 205: Steps
OPERATOR'S STATION Steps WARNING: When getting on and off the machine, use steps and handrails to support your body with at least three points of contact. Getting on and off the machine with less than three support points may cause you to slip, possibly resulting in a falling accident.
Page 206: Vandal-Resistant Devices
OPERATOR'S STATION Vandal-Resistant Devices Locks can be installed to transmission oil inlet cap cover (1), battery box cover (2), and relay and fuse box cover (3). 115Z7-Vandal-1 115Z7-Vandal-4 1-142...
Page 207 OPERATOR'S STATION Vandal-Resistant Devices (continue from previous page) Fuel tank cap (4), side covers (5), and air conditioner fresh air filter (6) can be locked with the starter key. 115Z7B-1-146-1 115Z7B-1-146-2 MNEC-01-055 1-143...
Page 208 OPERATOR'S STATION MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1-144...
Page 209: Break-In
BREAK-IN Break-in Period for New Machine Machine life and performance will be greatly affected by the treatment during operation and maintenance of the machine, but especially so during the initial operation. IMPORTANT: Always correctly warm the machine up to operating temperatures before running the machine ! This is always a requirement for good machine life.
Page 210 BREAK-IN MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 211: Operating The Engine
OPERATING THE ENGINE Inspect Machine Daily Before Starting Perform the required daily check before starting the engine.  Refer to "Maintenance" section for detailed information. Check Points Check Contents Brake System The brake pedal stroke is appropriate, brake performance is sufficient, and the brakes apply evenly.
Page 212 OPERATING THE ENGINE Check Points Check Contents Chassis Oil leaks of the transmission and the axle Level, leaks and contamination of the fuel tank. Drain water from fuel tank. Level and leaks of the hydraulic oil tank Operation, play and operating force of control levers and steering wheel Operation of hydraulic equipment.
Page 213: Check Before Starting
OPERATING THE ENGINE Check Before Starting 1. If your machine is equipped with the battery disconnect switch, check that the switch is in the ON position. 115Z7-3-3-1 2. Lower armrest (1) fully to the operating position until it is locked. Hold support bar (2) when moving armrest. 3.
Page 214 OPERATING THE ENGINE 5. Check that parking brake switch (5) is in the ON position. After the engine starts and checking indicator bulbs and display (refer to page 3-6), check that parking brake indicator is ON. 115Z7B-1-81-1 6. Check that bucket control lever (6) and lift arm control lever (7) are in the neutral (N) position.
Page 215 OPERATING THE ENGINE 6. Adjust the position of outside rear view mirror (9) and inside rear view mirror (10) so that the best rear visibility can be obtained. 7. While seated on the operator's seat with your back in 115Z7-01-126 contact with the backrest, adjust each function of the seat so that the brake pedal can be fully applied.
Page 216: Starting Engine
OPERATING THE ENGINE Starting Engine Follow the following steps to start the engine. 1. Check that parking brake switch (1) is ON, with parking brake set. Make sure the armrest is fully lowered and locked in position. 2. Turn key switch (2) ON. 3.
Page 217 OPERATING THE ENGINE 6. Turn joystick steering system switch (8) ON. The F/R selector switch indicator (9) turns ON. NOTE: Turn ON joystick steering system switch (8) after turning key switch to ON position. Otherwise, the machine cannot move forward/reverse. IMPORTANT: Never operate the starter for more than 15 seconds at a time.
Page 218: Starting In Cold Weather
OPERATING THE 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) should turn ON. As long as the preheat indicator stays ON, the engine is being heated. M4GB-01-089 NOTE:  Preheating time varies depending on the coolant...
Page 219: Check After Starting
OPERATING THE 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 Monitor Operation 1. Check that service indicator (1) is OFF. 2. Check that discharge warning indicator (2) is OFF. In case the discharge warning indicator stays ON, immediately stop the engine.
Page 220: Using Booster Batteries
OPERATING THE 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 221 OPERATING THE 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 222: Warm Up
OPERATING THE ENGINE Warm Up IMPORTANT: At starting the engine, the engine RPM (min ) is kept at low idle for maximum 35 seconds to warm up the coolant or hydraulic oil. After this period, the engine RPM will increase by applying the accelerator pedal (3).
Page 223: Cold Weather Warm Up
OPERATING THE ENGINE Cold Weather Warm Up IMPORTANT: At starting the engine, the engine RPM (min ) is kept at low idle for maximum 35 seconds to warm up the coolant or hydraulic oil. After this period, the engine RPM will increase by applying the accelerator pedal (3).
Page 224 OPERATING THE ENGINE 2. Fully extend the bucket cylinder. NOTE: Do not continuously operate the bucket control lever for more than 10 seconds at a time. Do not bang linkage when cold. 3. Slowly and fully retract the bucket cylinder. NOTE: Do not continuously operate the bucket control lever for more than 10 seconds at a time.
Page 225: Stopping Engine
OPERATING THE ENGINE Stopping Engine Stop the engine in the following manner. IMPORTANT: Never stop the engine while moving the machine. If the engine stops, the steering system may become inoperable, or it may cause other malfunctions or seizure of parking brake. 1.
Page 226 OPERATING THE ENGINE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 227: Moving The Machine
MOVING THE 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. IMPORTANT: The engine must be started and ready for driving correctly by referring to the previous section “OPERATING THE ENGINE”.
Page 228: Starting To Move
MOVING THE 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 (4) (option) to ON position when traveling the machine or raising the bucket.
Page 229 MOVING THE MACHINE 3. Step on brake pedal (6) or (7) and press parking brake switch (8) to the OFF position to release the parking brake. 115Z7B-1-81-1 Check that at this time parking brake indicator (1) goes OFF. MNEK-01-500 NOTE: When starting to ascend a slope, turn declutch switch (9) ( ) OFF (clutch engaged), and depress the brake pedal (6).
Page 230 MOVING THE MACHINE 4. Manual Shift (M) After setting forward/reverse switch (11) to either forward (F) or reverse (R) position, press the shift switch (12) to the desired position. The transmission gear position can be shifted in 4 ranges in the forward and 3 ranges in the reverse mode.
Page 231: Shift Range Of Auto Transmission
MOVING THE MACHINE Shift Range of Auto Transmission Mode Shift Position Shift Range AUTO 1: 1st range 1st range only  2nd L-UP  3rd  3rd L-UP  4th (Forward)   range range range range L-UP  2nd L-UP  3rd (Reverse) ...
Page 232: Power Mode Selector
MOVING THE MACHINE Power Mode Selector Pressing power mode selector switch (14) alternately activates (ON) and deactivates (OFF) the power mode. When the power mode is activated (ON), the indicator “ ” appears on the monitor display. The power mode is suited for heavy digging work prioritizing work effectiveness.
Page 233: Parking Brake Switch
MOVING THE 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 switch (1) while moving the machine except in an emergency.
Page 234: Drive Speed Change (Manual Shift)
MOVING THE MACHINE Drive Speed Change (Manual Shift) The transmission gear range of 2nd, 3rd and 4th can be selected with shift switch (1). 1st and 2nd : To be used for excavation and Shift up ranges loading work 3rd and 4th : To be used for traveling over long ranges distances.
Page 235: Steering
MOVING THE MACHINE Steering WARNING:  Avoid sudden steering while moving the machine at high speeds, while moving 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 236: Secondary Steering (Option)
MOVING THE MACHINE Secondary Steering (Option) If the oil pressure in the steering system lowers, the secondary steering system is activated so that steering operation can be achieved. If the secondary steering system is activated, the secondary steering indicator lights and the buzzer sounds.
Page 237: Emergency Stop And Restart Of Operation
MOVING THE MACHINE Emergency Stop and Restart of Operation Follow the tips described below when required to stop or restart operation when an emergency has occurred. 1. Slowly release the accelerator pedal. Depress the service brake pedal to stop the machine. 2.
Page 238: Precautions For Traveling
MOVING THE MACHINE Precautions for Traveling When operating, observe the previously noted operating precautions along with the others shown 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 239: Operating In Water Or On Soft Ground
MOVING THE MACHINE Operating in Water or on Soft Ground IMPORTANT: If the axles, transmission, etc. should become submerged under water to the point that water enters into them, they must be reconditioned immediately, otherwise the inner gears may wear excessively, or the machine may become damaged.
Page 240: Precautions For Driving On Slopes
MOVING THE MACHINE Precautions for Driving on Slopes WARNING:  Never allow the machine to descend a slope with the forward/reverse switch (or lever) in neutral (N). This will not only cause the excessive engine revolutions to malfunction but also cause other engine and machine troubles.
Page 241: Precautions To Be Taken If Machine Failure Occurs
MOVING THE 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 away from flow of traffic. ...
Page 242: Stop
MOVING THE MACHINE Stop 1. Avoid sudden deceleration. Smoothly reduce operating speed. Release accelerator pedal (1) and step on brake pedal (2) to stop the machine. 115Z7B-1-81-1 2. Set forward/reverse switch (3) to neutral (N). 3. Press the ON position of parking brake switch (4). 115Z7B-4-4-1 5, 6 4.
Page 243 MOVING THE MACHINE IMPORTANT: Do not leave the machine with key switch (8) in ACC position. This may discharge the batteries. Be sure to turn key switch to OFF position before leaving the machine. 7. Turn key switch (8) to OFF position to stop the engine.
Page 244: Parking
MOVING THE 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 doors when parking the machine. 1. Stop and park the machine on level surface. Lower Stop and Parking Position the bucket to the ground.
Page 245: Emergency Stopping
MOVING THE MACHINE Emergency Stopping When the Engine has Stalled During Operation: Pressurized oil in the accumulator 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 repeatedly apply the brake pedal.
Page 246: Auto Brake
MOVING THE MACHINE Auto Brake Auto brake applies the service brakes and turns on the warning buzzer when the machine speed exceeds the preset limit. Auto brake indicator (1) appears on the monitor panel (refer to page 1-25). This feature protects the transmission from excessive speed.
Page 247: Operating The Machine
OPERATING THE MACHINE Loading Control Levers Fingertip Control Type The fingertip control lever is used to operate the lift arm and/or bucket. Lift Arm Control Lever (1) Lever Lift Arm Operation Position Float (Detent): The lift arm free falls and can be moved as loads are applied.
Page 248 OPERATING THE MACHINE NOTE: 1. When applying lift arm control lever (1) in the "Raise" position (A), the lever is moved (F) until the lift arm reaches the position preset by the lift arm kickout. When the lift arm moves the preset position, lift arm control lever (1) automatically moves to the Neutral (N) position.
Page 249: Loading Multi-Function Joystick Lever (Option)
OPERATING THE MACHINE Loading Multi-Function Joystick Lever (Option) The multi-function joystick lever is used to operate the lift arm and/or bucket. Lever Lift Arm/Bucket Operation Position Float (Detent): The lift arm free falls and can be moved as loads are applied. The lever will stay in this position.
Page 250: Control Lever Lock
OPERATING THE MACHINE Control Lever Lock WARNING:  Be sure to press lock ( ) side of control lever lock switch (1).  Before leaving the operator's seat, be sure to stop the engine. Then, set control lever lock switch (1) to the lock ( ) position.
Page 251: Declutch Position Switch
OPERATING THE MACHINE Declutch Position Switch To perform digging (scooping) or loading operation, declutch position switch (1) can be set to any position Turn the declutch position switch ON to let the engine speed and power be applied to loading circuits. ...
Page 252: Adjustment Of Bucket Auto Leveler
OPERATING THE MACHINE Adjustment of Bucket Auto Leveler WARNING: CRUSH HAZARD  Be careful to avoid injury and/or death when adjusting the bucket auto leveler.  Stop the engine. Lower the loader arm and bucket to the ground to release oil pressure. ...
Page 253 OPERATING THE MACHINE Adjustment Procedures IMPORTANT: Do not operate the machine with the bucket dumped more than 10°. 1. After moving the bucket to the desired digging angle, stop the engine. 2. Loosen bolt (2). Slide the end edge of rod (3) up to the center of proximity switch (4) (orange color).
Page 254: Adjustment Of Bucket Angle Switch
OPERATING THE MACHINE Adjustment of Bucket Angle Switch WARNING: CRUSH HAZARD  Be careful to avoid injury and/or death when adjusting the bucket angle switch.  Stop the engine. Lower the loader arm and bucket to the ground to release oil pressure. ...
Page 255 OPERATING THE MACHINE Adjustment Procedures IMPORTANT: Do not operate the machine with the bucket dumped more than 10°. 1. After moving the bucket to the desired operating angle, stop the engine. 2. Loosen bolt (2). Slide the end edge of rod (3) up to the center of proximity switch (4) (orange color).
Page 256: Adjustment Of Dual Lift Arm Auto Leveler
OPERATING THE MACHINE Adjustment of Dual Lift Arm Auto Leveler WARNING:  Take extra care to prevent injury and/or death when adjusting the lift arm auto leveler (kickout).  Apply the parking brake to prevent the machine from moving unexpectedly. Chock the wheels with blocks.
Page 257: Auto Idling Stop
OPERATING THE MACHINE Auto Idling Stop WARNING: This function automatically stops the engine. Carefully operate within the work environment when using this function. When the auto idling stop function is ON (enabled), the engine automatically stops after the preset time from the state in which the specified conditions are met (see the operating condition on the next page).
Page 258: Auto Idling Stop Operating Condition
OPERATING THE MACHINE Auto Idling Stop Operating Condition  The engine is running.  The parking brake switch is ON.  The accelerator pedal is not depressed.  The brake pedal is not depressed.  The loading control lever is not operated. ...
Page 259: Aftertreatment Device Manual Regeneration
OPERATING THE MACHINE Aftertreatment Device Manual Regeneration When manual regeneration is needed, symbol (1) and service indicator (2) as shown to the right will be displayed. Perform manual regeneration in the following procedure. IMPORTANT: Park the machine in a safe area where exhaust temperatures will not damage property or other Basic Screen MNHG-01-280EN...
Page 260 OPERATING THE MACHINE 4. When aftertreatment device switch has been pressed, screen (5) appears as shown to the right and manual regeneration starts. The bar graph on the screen (6) indicates regeneration progress. NOTE: The manual regeneration cannot start unless the following items are as indicated.
Page 261 OPERATING THE MACHINE 5. Manual Regeneration Completed (Successful) When manual regeneration is completed, "Regeneration Has Completed." message will be displayed and the regeneration symbol disappears. 6. Manual Regeneration Failed (Unsuccessful) If the message "Regeneration Has Failed." appears on the monitor panel, start the regeneration process over MNHG-01-284EN again.
Page 262: Before Operation
OPERATING THE MACHINE Before Operation WARNING:  Be sure to install only authorized buckets and other work tools.  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 263: Avoid Overloading
OPERATING THE MACHINE Avoid Overloading WARNING:  Do not penetrate the bucket into piles of soil and/or gravel at fast travel speed.  Avoid excavating or scooping loads when the machine is articulated, which could possibly cause the machine to turn over. IMPORTANT: Avoid machine abuse by allowing the bucket or attachment to receive loads at only one side.
Page 264: Excavation
OPERATING THE MACHINE Excavation Loading Accumulated Soil IMPORTANT:  Do not dig or scoop with machine frame articulated.  Avoid operating the machine with the front wheels raised off the ground. Machine traction force is reduced and excessive loads are applied to the M4GB-05-003 undercarriage.
Page 265: Digging And Loading Level Ground
OPERATING THE MACHINE Digging and Loading Level Ground IMPORTANT: While excavating with the bucket or fork, never apply excessive force to the tooth tips with the bucket or fork tilted more than 10°. This may result in cracks or damage to the front attachment. Slightly position the bucket teeth downward (0 to 10 M4GB-05-007 degrees) and dig the ground while moving the machine...
Page 266: Grading
OPERATING THE MACHINE Grading WARNING: When operating a machine equipped with ride control and the lift arm control lever in the float position, when performing 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 M4GB-05-011 attachment may automatically move up and down.
Page 267: Loading
OPERATING THE MACHINE Loading IMPORTANT:  Always maintain a clean surface for machine operation. Cleaning of materials such as soil and stones spilled on the work surface will reduce wear and/or damage on tires.  When carrying loads in the bucket, pay attention to the road surface conditions.
Page 268: Loader And Dump Truck Combination Method
OPERATING THE MACHINE Loader and Dump Truck Combination Method WARNING:  Always maintain a flat and clean 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. ...
Page 269: Dumping Into Truck Or Hopper
OPERATING THE MACHINE Dumping into Truck or Hopper WARNING:  When boom is raised, machine stability is reduced and could cause machine to tip over causing serious injury or death.  Do not make quick turns or abrupt braking when boom is raised.
Page 270: Dozing
OPERATING THE MACHINE Dozing IMPORTANT:  Dozing or pushing with dumped bucket or attachment may cause severe damage to linkages. It may also cause engine over-heating and torque converter over-heating.  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.
Page 271: Removing Snow
OPERATING THE MACHINE Removing Snow WARNING: When operating a machine equipped with ride control and the lift arm control lever in the float position, when performing work as soil scooping, land grading, or snow removal, be sure to turn the ride control switch OFF.
Page 272: Precautions For After Operation
OPERATING THE MACHINE Precautions for After Operation 1. After finishing operation, move the machine to firm, level ground where no possibility of falling stones, ground collapse, or floods are present. (Park the machine referring to the "Parking" in the "MOVING THE MACHINE" chapter.) 2.
Page 273 OPERATING THE MACHINE 4. Maintenance for long term machine storage after engaging in snow removal. (Refer to STORAGE section.) Anti-freeze agents such as salt (sodium chloride or calcium chloride) usually are scattered on snow covered Battery relay roads. When the machine is stored for a long time after engaging in snow removal work, perform the following Red cap maintenance to protect the machine from being...
Page 274 OPERATING THE MACHINE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 275: 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. 2.
Page 276: 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 277: Loading/Unloading On Trailer
TRANSPORTING Loading / Unloading on Trailer WARNING:  Keep machine straight while moving up or down a ramp since turning on a ramp may cause the machine to turn over. Never attempt to steer the machine on a ramp. If the travel direction must be changed on a slope, move the machine back to the flat surface on flatbed.
Page 278: Fastening Machine For Transporting
TRANSPORTING Fastening Machine for Transporting WARNING: Fasten the machine chassis to the trailer 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 279: 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 Driving On Roads 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 280: Precautions For Towing
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 repairs is completed. Avoid towing the machine as much as possible. If the machine must be towed, be careful about the following points.
Page 281: Releasing Parking Brake
TRANSPORTING Releasing Parking Brake WARNING:  Once the parking brake is released, the machine becomes impossible to stop with the parking brake system, possibly resulting in personal injury or death.  Before releasing the parking brake be sure to chock tires with wheel stoppers. CAUTION: ...
Page 282 TRANSPORTING Procedures WARNING:  Once the parking brake is released, the machine becomes impossible to stop with the parking brake system.  Chock 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 283: Towing Method
TRANSPORTING Towing Method Attach wire ropes to the machine when the machine must be towed, in such cases when the machine cannot be moved from soft ground under its own power. CAUTION:  Use wire cable having the strength more than approx.
Page 284: Lifting Machine
TRANSPORTING Lifting Machine WARNING:  The lifting tools are optional. Install specified lifting tools at your nearest authorized dealer.  Use lifting cables and other lifting tools that are free from any damage and/or aging, and properly rated for the load. ...
Page 285: Maintenance
IMPORTANT:  Use only recommended coolant, fuel, DEF, 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 coolant, fuel, DEF, lubricants, and genuine Hitachi parts will result in loss of Hitachi product warranty.
Page 286 MAINTENANCE  Machine Information Controller This machine provides a machine information controller that stores machine operation information for preventive maintenance. When maintaining the machine, our authorized service man may down load the stored information via satellite. Consult with your nearest authorized dealer for detailed function of this device. ...
Page 287: 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 lubrication chart is affixed on the left side of the front chassis. Refer to 7-5 page. This manual recommends grouping the intervals into three categories as follows: Daily Check : To be conducted daily before operation (every 10 hours)
Page 288: Layout
MAINTENANCE Layout 115Z7B-1-2-1 1- Bucket Teeth 17- Transmission 2- Bucket 18- Second (Front and Center) Propeller Shaft 3- Bucket Cylinder Rod Pin 19- Steering Cylinder 4- Bucket Cylinder 20- Front Axle 5- Front Combination Lamp 21- Lift Arm (Boom) Cylinder 6- Hydraulic Oil Tank 22- Lift Arm (Boom) Cylinder Rod Pin 7- Air Cleaner...
Page 289: Lubrication Guide
MAINTENANCE Lubrication Guide The lubrication chart is affixed on the left side of the front chassis. Lubricate and/or service the parts at the intervals as instructed in the chart so that all necessary maintenance can be performed regularly.  Lubrication Chart 115Z7-44794-24380 ...
Page 290: Preparations For Inspection And Maintenance
MAINTENANCE Preparations for Inspection and Maintenance WARNING: If ride control switch (3) (option) is in the AUTO position, the lift arm may unexpectedly rise. To avoid an accident due to unexpected movement of the lift arm and bucket, always turn ride control switch (3) OFF before beginning the inspection and/or maintenance of the machine.
Page 291 MAINTENANCE 5. Apply the parking brake (Turn parking brake (6) ON.) 6. Chock the tires. 7. Run the engine at low idle speed for a few minutes to cool the engine. Turn key switch (7) OFF to stop the engine. Again, turn key switch (7) ON and place control lever lock switch (2) to the unlock ( ) position.
Page 292: Articulation Lock
MAINTENANCE Articulation Lock WARNING: With articulation stopper in LOCKED position, machine will not steer; which, while operating, could cause an accident, injury or death. Do not lock Articulation Stopper during normal operation. Articulation stopper locks the front and rear chassis to prevent them from sudden articulation during inspection or transportation.
Page 293: Inspection/Maintenance Access Covers
MAINTENANCE Inspection/ Maintenance Access Covers CAUTION:  Always close side covers (1) and top cover (3) during operation.  Do not keep side covers (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 294: Rear Grille
MAINTENANCE Rear Grille WARNING: Open or close rear grille (4) only after stopping the engine. It is very dangerous if you are entangled in the cooling fan. Before operating the machine, always check that the rear grille is well latched. NOTE: The starter key cannot be removed from latch (3) while rear grille (4) is being opened.
Page 295: Inspection And Maintenance Table
MAINTENANCE Inspection and Maintenance Table Check and/or carry out the maintenance at intervals of IMPORTANT the specified operating hours below or the calender date, Severe applications require more frequent whichever comes first. maintenance. Severe conditions include heavy dust, extremely abrasive material, caustic chemicals, extremely wet conditions or abnormally hot or cold ambient temperatures.
Page 296 MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 4000 4500 Check Transmission Oil Level 7-30  Replace Transmission Oil Filter Cartridge  7-31  Transmission Replace Transmission Oil and Clean &...
Page 297 MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 4000 4500 Check Hydraulic Oil Level 7-43  Check Bucket Teeth 7-111  Check Hoses and Lines for Leaks 7-53 ...
Page 298 MAINTENANCE : First time replacement or cleaning only Operating hours Section Item for check Page 100 250 500 1000 2000 4000 4500 Clean/Replace Air Conditioner 7-99   Circulation/Fresh Air Filters Check Air Conditioner Compressor Belt 7-102  (and adjust if needed) Check Refrigerant Level 7-103 ...
Page 299: Kind Of Oils
Please be noted that all engine failures caused by using engine oil other than specified are excluded from Hitachi Warranty Policy. Consult your nearest authorized dealer for the unclear points. Kind of Oil...
Page 300: Axle Oil
Kind of Oil Gear Oil Axle & Wet Disc Brake Application Air Temperature -25 to 45 °C (-13 to 113 °F) High Gear Oil Hitachi Recommended Product TKTT15150-4th TO-4 SAE50 Fluid, TO-4M Fluid, Alternative Product with 6% friction modifier NOTE:  When using TO-4 SAE50 or TM-4M Fluid other than the listed recommended products, add...
Page 301: List Of Consumable Parts
MAINTENANCE List of Consumable Parts 1. Filter Elements Part No. Engine Oil Filter 4696643 Fuel Main Filter YA00033486 Fuel Pre-Filter Element 4906070100 Air Cleaner Element (Outer) 3098171070 Air Cleaner Element (Inner) 3098171060 Hydraulic Oil Tank Suction Filter 4033560150 Hydraulic Oil Tank Filter (with O-ring) YA00026486 Pilot Oil Filter (Brake Circuit) 4033060610...
Page 302 MAINTENANCE 3. Combination Light and Other Light Part No. Head Light Assembly 4436232 Head Light 4434679 Bulb (24 V, 70/75 W) Front Combination Light Assembly 2640242432 Front 4661233 Front Combination Light Lens Rear 4661234 Bulb 3848070930 Front Work Light Assembly 4336570 Bulb 3848071100...
Page 303: Greasing
MAINTENANCE A. Greasing CAUTION: Apply the parking brake and the articulation stopper (lock bar) (Refer to page 7-8). NOTE:  Until break-in is performed for more than 50 hours, lubricate the machine every day to get initial lubrication.  In case excavation is made in mud, water or snow, lubricate the machine after operation is complete.
Page 304 MAINTENANCE 7. Two points to right steering cylinder pins (10 and 11). --- every 250 hours Cylinder right front (10) Cylinder right rear (11) 11,13 8. Two points to left steering cylinder rod pins (12 and 13). --- every 250 hours Cylinder left front (12) MNHE-07-010 Cylinder left rear (13)
Page 305 MAINTENANCE 9. One point each to upper and lower center hinge pins (14 and 15). --- every 250 hours Upper (14) Lower (15) MNHE-07-010 10. One point each to front and rear axle support pins (16 and 17). --- every 10 hours 16,17 MNHE-07-012 7-21...
Page 306 MAINTENANCE 11. Two points to main propeller shaft universal (26). --- every 12000 hours NOTE: When the machine is continuously operated under severe conditions for a long time, shorten the greasing intervals. MNHE-07-017 12. One point to front (second) propeller shaft universal (18).
Page 307 MAINTENANCE 13. One point to propeller shaft pillow unit (19). --- every 250 hours 14. One point to center (second) propeller shaft universal front (20). --- every 12000 hours One point to center (second) propeller shaft universal rear (22). MNHE-07-014 --- every 12000 hours 15.
Page 308 MAINTENANCE 17. One point each to front and rear axle seal (24). --- every 1000 hours  Remove breather nipple (25).  Fill grease from grease nipple (24) until it spills out of breather nipple (25) hole.  Wipe the spilled grease and install breather nipple (25).
Page 309: Engine
MAINTENANCE B. Engine Check Engine Oil Level --- every 10 hours (machine parked on a level surface 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 engine oil level is too high, lower the oil level to the proper place before starting the engine.
Page 310: 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 311 MAINTENANCE 6. Allow oil to drain through a clean cloth to check if any foreign matters such as metal pieces are not in the oil. 7. Install a new oil filter. (Refer to the descriptions for 3 Replace Engine Oil Filter.) 8.
Page 312: 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. 1.
Page 313 MAINTENANCE 5. Remove element (3) by turning it counterclockwise with the tool (oil filter wrench). Filter Body 6. Apply a thin coat of clean engine oil to the gasket of a new element. IMPORTANT:  Do not reuse element (1). Gasket  When replacing oil filter elements, make sure to replace both of them at the same time.
Page 314: Power Train
MAINTENANCE C. Power Train Check Transmission Oil Level --- every 10 hours (daily) WARNING:  Move forward/reverse switch (or 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 315: Change Transmission Oil
MAINTENANCE Change Transmission Oil --- every 1000 hours (250 hours at first change only) Clean Suction Strainer Fully raise up. --- when changing transmission oil Change Transmission Oil Filter --- every 1000 hours (250 hours at first change only) NOTE: Be sure to replace the transmission oil filter when changing the transmission oil.
Page 316 MAINTENANCE IMPORTANT: The machine is equipped with a turbocharged engine. Cool down before stopping the engine. Failure to do so may cause the lubricant on the turbocharger bearing and seal surfaces to be dissipated due to the intense heat present inside the turbocharger, possibly damaging the turbocharger.
Page 317 MAINTENANCE 13. Prepare a container of about 4 L (1 gal) capacity under oil filter (11). 14. Remove the drain plug on the bottom of the filter case with a 24 mm (0.94 in) wrench. 15. Using a 46 mm (1.8 in) wrench, remove the filter case. 16.
Page 318: Clean Transmission And Torque Converter Air Breathers
MAINTENANCE Clean Transmission and Torque Converter Air Breathers --- every 1000 hours 1. Open two top covers (decks) (1) behind the cab by removing two each of fixing bolts (2). Lock the covers in the opened position. 2. Clean the vicinity around air breathers (3, 4). Put a cover on the air breather port to prevent foreign matter from entering.
Page 319: Check Axle Oil Level
MAINTENANCE Check Axle Oil Level --- every 250 hours 1. Park the machine and follow the procedures as described on page 7-6 for preparation of inspection/ maintenance work. NOTE: Adjust so that the "TOP" mark on the planetary gear housing comes top. See the illustration on the next page.
Page 320: Check Planetary Gear Oil Level
MAINTENANCE Check Planetary Gear Oil Level NOTE: Check the oil level on all four wheels. 6. Clean the vicinity of oil level plug (4). 7. Check that "TOP" mark (3) on the planetary gear housing comes top as shown. If not, move the machine and adjust the position.
Page 321: Change Axle Oil
MAINTENANCE Change Axle Oil --- every 2000 hours WARNING: Be cautious about the following items.  Starting repair work immediately after operation may cause burns. Wait for oil temperature to lower.  Lock the front and rear chassis with the articulation stopper (lock bar).
Page 322: Change Planetary Gear Oil
MAINTENANCE Change Planetary Gear Oil 9. Check that "TOP" mark (3) on the planetary gear housing comes top as shown. If not, move the machine and adjust the position. 10. Make sure to turn ON the parking brake switch, lower the attachment to the ground, and stop the engine.
Page 323: Replace Axle Oil Cooler Line Filter (Option)
MAINTENANCE Replace Axle Oil Cooler Line Filter (Option) --- every 500 hours WARNING: Be cautious about the following items.  Starting repair work immediately after operation may cause burns. Wait for oil temperature to lower.  Lower the attachment to the ground. ...
Page 324: Clean Axle Oil Cooler Fins (Option)
MAINTENANCE Clean Axle Oil Cooler Fins (Option) --- as required 1. Park the machine following the same procedures as described on page 7-6 for preparation of inspection/ maintenance work. Stop the engine. IMPORTANT: High pressure air or water may damage oil cooler fins.
Page 325: Hydraulic System
MAINTENANCE D. Hydraulic System Inspection and Maintenance of Hydraulic Equipment CAUTION: During operation, the parts of the hydraulic system become very hot. Allow the machine to cool down before beginning inspection or maintenance. 1. Park the machine following the same procedures as described on page 7-6 for preparation of inspection/ maintenance work.
Page 326 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 327: Check Hydraulic Oil Level
MAINTENANCE Check Hydraulic Oil Level --- every 10 hours (daily) IMPORTANT: If the oil level is not viewed in the level gauge, immediately refill hydraulic oil up to the correct level. Failure to do so may result in a serious failure in the hydraulic system.
Page 328: Change Hydraulic Oil
MAINTENANCE Change Hydraulic Oil --- every 4000 hours WARNING: Hydraulic oil becomes hot during operation. Severe burns may result if skin comes in contact with hot hydraulic oil. Wait for the oil to cool before starting any maintenance work. Release trapped hydraulic circuit pressure by using the loader control levers.
Page 329: Bleed Air From The Hydraulic System
MAINTENANCE 7. Supply hydraulic oil through filling port (3) while checking the oil level at level gauge (6). Refer to "Kinds of Oils" - "Hydraulic Oil" on page 7-16. * Capacity of Total oil capacity in hydraulic oil tank the hydraulic system 300 liters 550 liters (79 gallons)
Page 330: Clean Suction Filter
MAINTENANCE Clean Suction Filter --- each time the hydraulic oil is changed. IMPORTANT: This upper tank area must be very clean prior to beginning this procedure. Failure to clean the top of tank may lead to hydraulic system problems due to system contamination. Two suction filters are located on the bottom of the hydraulic oil tank.
Page 331: Clean Pilot Oil Filter
MAINTENANCE Clean Pilot Oil Filter --- every 2000 hours WARNING: Hydraulic oil becomes hot during operation. Severe burns may result if skin comes in contact with hot hydraulic oil. Wait for the oil to cool before starting any maintenance work. IMPORTANT: Remove trapped hydraulic circuit pressure by using the loader control levers.
Page 332: Line Filter In Brake Circuit
MAINTENANCE [ Line Filter in Brake Circuit ] 7. Place a suitable container under combination valve (6). 8. Disconnect hoses (7, 8) and remove bolt (9). WARNING: Be sure to wear safety glasses when cleaning the air breather with compressed air. 9.
Page 333: Replace Hydraulic Oil Return Filter
MAINTENANCE Replace Hydraulic Oil Return Filter --- every 1000 hours WARNING: Hydraulic oil becomes hot during operation. Severe burns may result if skin comes in contact with hot hydraulic oil. Wait for the oil to cool before starting any maintenance work. Especially when removing the filter, be careful that the remaining oil in the filter does not spill.
Page 334: Replace Air Breather Element
MAINTENANCE Replace Air Breather Element --- every 2000 hours WARNING: Hydraulic oil becomes hot during operation. Severe burns may result if skin comes in contact with hot hydraulic oil. Wait for the oil to cool before starting any maintenance work. Replacement Procedures 1.
Page 335: Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, And Damage
MAINTENANCE Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, and Damage --- every 2000 hours NOTE: The loading pilot pressure is supplied from the accumulators in the brake circuit. WARNING: Allow only qualified personnel to handle the accumulator.  High-pressure nitrogen gas is enclosed in the accumulator.
Page 336: Check Ride Control Accumulator Function, Gas Leakage, Looseness, And Damage (Option)
MAINTENANCE Check Ride Control Accumulator Function, Gas Leakage, Looseness, and Damage (Option) --- every 500 hours WARNING: Allow only qualified personnel to handle the accumulator.  High-pressure nitrogen gas is enclosed in the accumulator. (N is inert.)  Never strike the accumulator. Keep the accumulator away from heat sources.
Page 337: Check Hoses And Lines
MAINTENANCE Check Hoses and Lines --- every 10 hours (daily) for leaks --- every 250 hours for cracks, bends, etc. WARNING: High pressure fluid can penetrate the skin causing serious injury. To avoid this hazard, search for leaks with a piece of cardboard.
Page 338 Hose ends and Deformation or Replace fittings Corrosion (10) M115-07-147 NOTE: Refer to the illustrations in Fig. 1 for each check point location or for a description of the abnormality. Use genuine Hitachi parts. M115-07-148 M115-07-149 Fig. 1 7-54...
Page 339 Welded surfaces on Crack (12) Replace joints Clamps Missing Replace Deformation Replace Loose Retighten M4GB-07-060 NOTE: Refer to the illustrations in Fig. 2 for each check point location or for a description of Fig. 2 the abnormality. Use genuine Hitachi parts. 7-55...
Page 340: Service Recommendations For Hydraulic Fittings
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 341: Fuel System
MAINTENANCE E. Fuel System Check Fuel Level --- every 10 hours (daily) WARNING: 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 342: Refueling
MAINTENANCE Refueling 1. Park the machine following the same procedures as described on page 7-6 for preparation of inspection/ maintenance work. IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down. WARNING: Handle fuel carefully. Shut the engine off before fueling.
Page 343: Drain Fuel Filter
MAINTENANCE Drain Fuel Filter --- every 10 hours (daily) IMPORTANT: Drain fuel filter daily before starting operation. The engine may be damaged if you do not drain fuel filter daily. Drained water should contain fuel. Follow the local regulations when disposing it.
Page 344: Bleed Air From The Fuel System
MAINTENANCE 5. After draining water, securely tighten drain (1) and plug (3). Draining off of two pre-filters. Pre-Filter Tightening torque: Drain (1): 2.5±0.5 N·m (0.25±0.05 kgf·m, 1.8±0.4 lbf·ft) Plug (3): 10±2 N·m (1.0±0.2 kgf·m, 0.74±0.15 lbf·ft) 6. Start the engine. Check drain (1) and plug (3) for fuel leaks.
Page 345: If Air Mixed After Common Rail
MAINTENANCE 3. Keep the key switch at ON position while operating priming pump (9) of supply pump (7) until fuel with no air bubbles comes out from air bleed plug (6) at the outlet port of fuel priming solenoid pump (5). Tighten air bleed plug (6).
Page 346: Replace Fuel Main Filter Element
(such as pilot lights, electrical switches, or welding equipment) in the work area. IMPORTANT:  Be sure to use only genuine Hitachi elements for Main Filter the fuel main filter element and the pre-filter 115Z7B-7-58-1 element.
Page 347 MAINTENANCE WARNING: When servicing the engine, do not rotate engine with a high pressure fuel system joint open. Rotating the engine can create highly pressurized fuel in the fuel system. High-pressure fuel spray can penetrate the skin, resulting in serious personal injury or death. 6.
Page 348: Replace Fuel Pre-Filter Element
---every 500 hours or when fuel filter restriction indicator is lit 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 lower engine performance and/or shorten the engine service life.
Page 349 MAINTENANCE 7. Tighten air bleed plug (7) and drain (5). m (5): 2.5±0.5 N·m (0.25±0.05 kgf·m, 1.8±0.4 lbf·ft) Pre-Filter m (7): 10±2 N·m (1.0±0.2 kgf·m, 0.74±0.15 lbf·ft) 8. Repeat for the other filter. 9. Turn the starter key to the ON position. IMPORTANT: Do not start the engine.
Page 350: Clean Fuel Pump Strainer
MAINTENANCE Clean Fuel Supply Pump Strainer --- every 500 hours IMPORTANT:  The supply pump strainer is assembled into the joint bolt located at the inlet side of the supply pump. This joint bolt is a component which cannot be disassembled, so do not pull out the strainer inside.
Page 351: Clean Fuel Priming Solenoid Pump Strainer
MAINTENANCE Clean Fuel Priming Solenoid Pump Strainer --- every 1000 hours Cleaning When the strainer is disassembled, be sure to replace the gasket. Install the cover and the magnet only after thoroughly cleaning them. After being assembled, closely check the air-tightness of the strainer.
Page 352 MAINTENANCE Disassembling/ Assembling 1. To remove cover (1), loosen with a wrench. After cover (1) is removed, gasket (2), strainer (3), and gasket (4) are easily removed in order. 2. Wash strainer (3) with solvent. Magnet M1GR-07-004 3. Install the strainer in the reverse order of 36 mm 2.7 mm 1 mm...
Page 353: Check Fuel Hoses
MAINTENANCE Check Fuel Hoses --- every 10 hours (daily) CAUTION: Fuel leaks can lead to fires that may result in serious injury.  Escaping combustible fluid can cause fires. Check for kinked hoses, hoses that chafe against each other, and signs of fuel leaks. ...
Page 354 MAINTENANCE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7-70...
Page 355: Air Cleaner
MAINTENANCE F. Air Cleaner Replace Air Cleaner Element Outer element --- each time the monitor indicator illuminates. Inner element --- at the time of the fifth replacement (or every 2 years) of the outer element Air cleaner (1) is comprised of double elements, outer element (6) and inner element (5).
Page 356: Cooling System
Use fresh water or normal tap water as the coolant water. Do not use strong acid or alkaline water. Use of the genuine Hitachi Long-Life Coolant (LLC) mixed by 33 to 50 % is recommended. If the air temperature is expected to fall below 0 °C (32 °F), fill the cooling system with Long-Life Coolant (LLC) and soft water mix.
Page 357: Check Coolant Level
MAINTENANCE Check Coolant Level --- every 10 hours (daily) Check the coolant level at reservoir tank (1). The normal coolant level is between the FULL and LOW marks on side surface of reservoir tank (1). In case no coolant is present in reservoir tank (1), add the coolant mixture via cap hole (2) on reservoir tank (1).
Page 358: Check Drive Belt
MAINTENANCE Check Drive Belt --- every 10 hours (daily) Generator Adjust, Replace --- as necessary Press the center of the belt with a hand, and check whether the belt deflects only slightly. Also, check the belt for a damage. Measurement of Deflection Amount and Vibration Frequency 1.
Page 359: Replacing Drive Belt
MAINTENANCE Replacing Drive Belt 1. Loosen idler pulley's lock nut (1) and adjusting bolt (3). 2. Remove the belt. 3. Install a new belt, and adjust the belt tension. 4. Turn the generator and idler pulley adjusting bolts (2, 3) to adjust the belt tension to be within the standard value range.
Page 360: Change Coolant
MAINTENANCE Change Coolant --- every 3000 hours or two years WARNING: Do not remove the radiator cap (1) until the coolant temperature in the radiator has cooled. Hot steam and coolant may spout out, possibly causing severe burns. After the coolant temperature cools, slowly loosen the cap to release the inside pressure before removing cap (1).
Page 361 MAINTENANCE 6. Slightly loosen air bleeder valve (7) of the EGR (Exhaust Gas Recirculation) cooler. IMPORTANT: Be sure to loosen the plug before supplying the coolant. 7. Prepare a container of more than 5 liters (1.3 gallons) capacity under the outlet (8) of the hose from air bleeder valve (7).
Page 362 MAINTENANCE 18. Start the engine. Press power mode selector switch (9) to activate the power mode. 19. Select "Information Menu" - "Monitoring" menu to display the coolant temperature on the monitor. (Refer to p. 1-80 Monitoring.) 20. Wait until the engine temperature reach the normal operation range.
Page 363: Clean Radiator/Oil Cooler Cores And Other Cooling System
MAINTENANCE Clean Radiator/Oil Cooler Cores and Other Cooling System --- every 500 hours or when the core is clogged. WARNING: When using compressed air pressure [less than 0.2 MPa (2 kgf/cm , 30 PSI)], wear safety glasses or goggles. IMPORTANT: If compressed air with the pressure of more than 0.2 MPa (2 kgf/cm , 30 PSI) or tap water with high delivery pressure is used for cleaning,...
Page 364: Electrical System
MAINTENANCE H. Electrical System IMPORTANT:  Improper radio communication equipment and associated parts, and/or improper installation of radio communication equipment may effect 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 365 MAINTENANCE If you spill acid on yourself, call 911, then: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. If splashed in eyes, flush with water for 10 to 15 minutes. Get medical attention immediately. If acid is swallowed, call 911, then: 1.
Page 366: Electrolyte Level Check
MAINTENANCE Electrolyte Level Check --- every 100 hours (Do this when machine is cold.) 1. Check the electrolyte solution level at least once a month. 2. Park the machine on level ground and stop the engine. 3. Check the electrolyte solution level. U.L (Upper Level) 3.1 When checking the level from the battery side: L.L (Lower Level)
Page 367: Check Electrolyte Specific Gravity
MAINTENANCE Check Electrolyte Specific Gravity If you spill acid on yourself, call 911, then: --- every 250 hours 1. Flush your skin with water. CAUTION: 2. Apply baking soda or lime to help neutralize  Battery gas can explode. Keep sparks and flames the acid.
Page 368: Replace Batteries
MAINTENANCE Replace Batteries IMPORTANT: Before adjusting electrical system or welding on the machine, disconnect the negative side of the battery, or turn the battery disconnect switch to OFF position. Your machine has two 12-volt batteries (1) with negative (-) ground. If one battery in a 24-volt system has failed but the other is still good, replace the failed battery with an operable battery of the same type.
Page 369: Check Work Lights
MAINTENANCE Check Work Lights --- every 10 hours (daily) CAUTION: If any burned-out light is found, immediately replace it with a new one. Visually check all work lights (1) that they normally illuminate and/or flash from the front and rear sides of the machine.
Page 370: Check Electrical Harnesses And Fuses
MAINTENANCE Check Electrical Harnesses and Fuses --- every 50 hours Fuse box B Fuse box A CAUTION: If dirt or dust is adhered on the wirings or relays, it may cause fire. Check the electrical harness and terminals of the batteries, starter motor, and alternator for loose connection and/ or short circuit (broken shield).
Page 371: Fuse Box A
MAINTENANCE Fuse Box A 10- Parking solenoid 20- Option 4 (Joystick steering) (5 A) 9- Air conditioner 1 19- Option 3 (Fuel pump) 10 A 15 A 8- Stop lamp, Turn signal 18- SCR DCU 20 A 7- Back lamp, Back buzzer 17- ECM DCU (POWER ON) 10 A 6- Head lamp (left)
Page 372: Brake System
MAINTENANCE I. Brake System Check Right and Left Brake Interlocking Performance --- every 10 hours (daily) WARNING: Put up a do not enter sign for the range of 100 m (110yd) ahead in the forward machine travel direction. Arrange a safety monitor person. WARNING: Do not allow dust and/or soil to accumulate in vicinity (3) of the brake pedal.
Page 373: Check Parking Brake Force
MAINTENANCE Check Parking Brake Force --- every 10 hours (daily) WARNING: Check the machine in a place where no one is present or ahead in the drive traveling direction. Keep bystanders away from the machine. After confirming the service brakes work normally, test the parking brake.
Page 374: Check Parking Brake Gear Oil Level
MAINTENANCE Check Parking Brake Gear Oil Level --- every 250 hours 1. Park the machine following the same procedures as described on page 7-6 for preparation of inspection/ maintenance work. 2. Install articulation stopper (lock bar) (1) to the front and rear of the chassis by following the procedures described on page 7-8.
Page 375: Change Parking Brake Gear Oil
MAINTENANCE Change Parking Brake Gear Oil --- every 2000 hours WARNING: Be cautious about the following items.  Starting repair work immediately after operation may cause burns. Wait for oil temperature to lower.  Lock the front and rear chassis with the articulation stopper (lock bar).
Page 376: Check Accumulator Function, Gas Leakage
MAINTENANCE Check Accumulator Function, Gas Leakage, Looseness, and Damage --- every 500 hours WARNING: Allow only qualified personnel to service the accumulator.  High-pressure nitrogen gas is enclosed in the accumulator. (N is inert, and will not burn.)  Never strike the accumulator. Keep the accumulator away from heat sources.
Page 377: Check Brake Disks (Service And Parking)
MAINTENANCE Check Brake Disks (Service and Parking) --- every 2000 hours Service brake (1) is a closed wet type multi-plate hydraulic brake, and is incorporated in the axle housing. Parking brake (2) is also a closed wet type brake. Parking brake (2) is mounted in the front axle.
Page 378: Tire
MAINTENANCE J. Tire Check and Replace Tire (Tire Pressure) Check appearance --- 10 hours (daily) NOTE: Check tire pressure when appearance is questionable or each week (50 hours) Replace --- as necessary WARNING:  Secure the front and rear chassis with the articulation stopper (lock bar and pins).
Page 379: Check Tire For Damage
MAINTENANCE Check Tire for Damage --- every 10 hours (daily) CAUTION: If tire has external damaged such as deep cuts, an accident due to puncture or burst of the tire may occur, possibly resulting in injury or death. Check the external appearance of tires for damage. Check Wheel Bolt Torque --- every 500 hours (50 hours at fist time only)
Page 380: Tire Sizes To Be Used
MAINTENANCE Radial tire Air pressure Size Front Rear 471~490 kPa (4.8~5.0 373~392 kPa (3.8~4.0 35/65R33 kgf/cm ) (68~71 PSI) kgf/cm ) (54~57 PSI) Bias ply tire Air pressure Size Pattern Front Rear 520~539 kPa 422~441 kPa 29.5-29- (5.3~5.5 kgf/cm (4.3~4.5 kgf/cm 28PR (75~78 PSI) (61~64 PSI)
Page 381: Tire Rotation
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 (Right) (Wrong) recommended to achieve uniformity of wear on tires for good tire service life. WARNING: This must have no external damage, such as heavy cuts, large bubbled protrusions or other damage that can lead to tire failure.
Page 382: Removal And Installation Of Tire
MAINTENANCE Removal and Installation of Tire WARNING: A wheel and tire assembly 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 383: Air Conditioner
MAINTENANCE K. Air Conditioner Clean/Replace Air Conditioner Circulation/Fresh Air Filters Clean filters --- every 100 hours (or once a week whichever come first) Replace filter --- after cleaning filters 10 times (or when the filters are severely clogged) Clean Fresh Air Filter 1.
Page 384: Clean Circulation Air Filter
MAINTENANCE Clean Circulation Air Filter 1. Loosen knob (5) and remove retainer (6) to tilt cover (7) forward. 115Z7-7-99-1 2. Hold handle (8) and pull handle (8) toward you to remove circulation air filter (9). IMPORTANT: Do not use compressed air or water to clean filter (9) as damage to the filter fins may result.
Page 385: Check Air Conditioner
MAINTENANCE Check Air Conditioner --- every 6 months Check the air conditioner switch panel, air conditioner unit, and condenser mounting areas for any troubles, 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 386: Check Air Conditioner Condenser
MAINTENANCE Check Air Conditioner Condenser --- every 6 months If condenser (1) is covered with dirt and/or insects, air conditioner cooling performance will be reduced. Remove dirt or stain foreign material from fins of condenser (1) using tap water. In case the condenser has been severely contaminated, use a soft brush or a plastic fin comb tool.
Page 387: Check Refrigerant
MAINTENANCE Check Refrigerant --- every 6 months 1. Start the engine and run at approximately 1500 min (rpm). 2. Turn the air conditioner switch to ON. Set the blower switch to HI and set the temperature control switch to the coolest position (18 °C (65 °F) on the monitor screen).
Page 388: Aftertreatment Device
MAINTENANCE L. Aftertreatment Device Check and Clean Aftertreatment Device --- as required IMPORTANT:  Check and clean flammable objects on the area around the aftertreatment device daily.  Do not disassemble the machine support parts and sensors. NOTE: When the machine is operated in dusty areas, refer to "9-1 Maintenance Under Special Environmental Conditions".
Page 389: Urea Scr System
MAINTENANCE M. Urea SCR System IMPORTANT: WARNING:  Use dedicated container recommended by the  Fill the specified DEF into the DEF tank. business entity who is handling DEF to store DEF.  If improper DEF is refilled, fire or system failure Do not use general container, a container used may result.
Page 390: Check Def Level
MAINTENANCE Check DEF Level ---daily Park the machine on a level surface. Lower the bucket to the ground. Check the DEF level with DEF gauge (1). Add DEF if necessary. Refill DEF CAUTION: MNHG-01-103EN  Refill DEF/AdBlue® which meets Japanese Industrial Standards (JIS K2247), International Organization for Standardization (ISO 22241) or Deutsche Industrie Normen (DIN 70070) in DEF...
Page 391: Clean Def Strainer
MAINTENANCE 5 . Install cap (5) after refilling DEF. Close the tank cover (3). IMPORTANT:  Do not get on top of DEF tank (2) or sensors and piping on the tank. Failure to do so may damage the machine.  White deposition may be observed when DEF is dried naturally;...
Page 392: Def Exchange Procedure
MAINTENANCE DEF Exchange Procedure --- As required CAUTION: Use rubber gloves and goggles or safety glasses for protection during operation. Wash DEF with clean water when it contacts on the skin. IMPORTANT: When contaminated or deteriorated DEF is used, malfunction may result. Change DEF periodically to keep cleanliness in the tank.
Page 393: Replace Def Supply Module Main Filter
MAINTENANCE Replace DEF Supply Module Main Filter --- every 4500 hours A filter (4) is mounted in the DEF pump. Periodically replace filter (4). CAUTION: Use rubber gloves and goggles or safety glasses for protection during operation. Wash DEF with clean water when it contacts on the skin.
Page 394: Check Dosing Module
MAINTENANCE Check Dosing Module --- every 4500 hours Contact your nearest authorized dealer for checking. 115Z7B-7-104-2 Replace DEF Tank Inlet Filter --- every 4500 hours, or when DEF spills out while filling IMPORTANT: Do not clean or reuse DEF tank inlet filter (1).
Page 395: Miscellaneous
MAINTENANCE N. Miscellaneous Check Bucket Teeth --- every 10 hours (daily) Check bucket teeth for wear and looseness, and replace them as needed. Replace WARNING: Guard against injury from flying pieces of metal. Wear goggles or safety glasses, hard hat and face shield.
Page 396: Check And Replace Seat Belt And Lower Tether
MAINTENANCE 5. Tap lock pin (1) into the flush ear using a hammer. 6. Replace segments (6) with new ones. Segment mounting bolt tightening torque: 1-1/4-7UNC bolt: 2402 N·m (245 kgf·m, 1772 lbf·ft) 7. Retighten nuts (6) after a few hours of operation. 95ZV0017 Check and Replace Seat Belt and Lower Tether Check --- every 10 hours (daily)
Page 397: Check Windshield Washer Fluid Level
MAINTENANCE Check Windshield Washer Fluid Level --- every 10 hours (daily) IMPORTANT: Keep all dirt, dust and other foreign materials out of the tank. Check the fluid level. If necessary, add the fluid. 115Z7B-7-112-3 Check Play Amount in Joystick Steering Movement --- every 10 hours (daily) Check that play (1) in joystick steering movement is correct.
Page 398: Check Accelerator Pedal Operation, And Exhaust Gas Color And Noise
MAINTENANCE Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise --- every 10 hours (daily) WARNING: Move the forward/reverse switch (or lever) to neutral. Apply the parking brake. After resting the bucket level to the ground, block the wheels. While slowly stepping on accelerator pedal (1), check that the engine speed smoothly increases.
Page 399: Check Rearview Mirror And Inside Rearview Mirror
MAINTENANCE Check Rearview Mirror and Inside Rearview Mirror --- every 10 hours Check that inside rearview mirror (1) and rearview mirror (2) are adjusted correctly. Check inside rearview mirror (1) and rearview mirror (2) for contamination or damage to the mirror glass. Clean if needed.
Page 400: Clean Engine Compartment And Hood
MAINTENANCE Clean Engine Compartment and Hood --- every 10 hours (daily) CAUTION: Dust or debris accumulated in the engine compartment or around the hood may come in contact with high temperature sections near the exhaust filter, muffler, engine or hood, possibly causing fires.
Page 401: Check Fuel Injector
MAINTENANCE Check Fuel Injector --- 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. Check and Adjust Engine Controller (ECM) --- every 4500 hours Consult your nearest authorized dealer for check and repair.
Page 402: Cleaning Of Rear View Camera Lens
MAINTENANCE Cleaning of Rear View Camera Lens --- every 10 hours (daily) Oil, dust, moisture band, or others may obscure the image from the camera lens. If image is not clear, clean the lens by gently wiping surface of the camera lens with a damp cloth. IMPORTANT: Never use organic solvent.
Page 403: Check Tightening Torque Of Nuts And Bolts
MAINTENANCE Check Tightening Torque of Nuts and Bolts --- every 2000 hours (50 hours at first time only) Check tightness after the first 50 hours then every 2000 NOTE: Check nuts and bolts for looseness and missing hours. daily before and after operation. If any loose or missing Tighten or retighten nuts and bolts to the torque specified nuts and/or bolts are found, retighten or supply on the following pages.
Page 404 MAINTENANCE 1. Front axle mounting bolt Bolt diameter 30 mm (1.2 in) Quantity Wrench size 46 mm Tightening torque 1420 N·m (145 kgf·m, 1045 lbf·ft) MNHE-07-057 2. Rear axle support mounting bolt Bolt diameter 24 mm (0.95 in) Quantity Wrench size 36 mm Tightening torque 721 N·m (73.5 kgf·m, 532 lbf·ft)
Page 405 MAINTENANCE 4. Propeller shaft mounting bolt First propeller shaft Bolt diameter 12 mm (0.47 in) Quantity Wrench size 19 mm Tightening torque 142 N·m (14.5 kgf·m, 105 lbf·ft) NOTE: Apply Loctite #262 or equivaent. View from Top (Open Deck) 115Z7-7-114-1 Second propeller shaft Bolt diameter 14 mm (0.55 in)
Page 406 MAINTENANCE 5. Propeller shaft support bearing mounting bolt Bolt diameter 20 mm (0.8 in) Quantity Wrench size 30 mm Tightening torque 400 N·m (40 kgf·m, 295 lbf·ft) NOTE: Apply Loctite #262 or equivaent. 115Z7-7-114-2 6. Transmission mounting bolt: Bracket Bolt A Bolt diameter 20 mm (0.8 in) Quantity...
Page 407 MAINTENANCE 7. Transmission mounting bolt: Cushion rubber Bolt A Bolt diameter 20 mm (0.8 in) Quantity Torque Wrench size 30 mm converter Tightening torque 550 N·m (55 kgf·m, 406 lbf·ft) Bolt B Bolt diameter 16 mm (0.63 in) Quantity Transmission Wrench size 24 mm Tightening torque...
Page 408 MAINTENANCE 10. Aftertreatment device mounting bolt Bolt A Bolt diameter 12 mm (0.5 in) Quantity Wrench size 19 mm Tightening torque 90 N·m (9 kgf·m, 66 lbf·ft) Bolt B Bolt diameter 10 mm (0.4 in) Quantity Wrench size 17 mm Tightening torque 50 N·m (5 kgf·m, 37 lbf·ft) Bolt C...
Page 409 MAINTENANCE 12. Top center pin upper flange lock Bolt diameter 20 mm (0.8 in) Quantity Wrench size 30 mm Tightening torque 400 N·m (40 kgf·m, 295 lbf·ft) 13. Top center pin lower bushing lock Bolt diameter 20 mm (0.8 in) Quantity Wrench size 30 mm...
Page 410 MAINTENANCE 16. Loader front pin lock Bolt A (indicated by bold arrows) Bolt diameter 20 mm (0.8 in) Quantity Wrench size 30 mm Tightening torque 550 N·m (55 kgf·m, 406 lbf·ft) Bolt B Bolt diameter 24 mm (0.95 in) Quantity Wrench size 36 mm Tightening torque...
Page 411 MAINTENANCE 17. Radiator mounting bolt Bolt A Bolt diameter 16 mm (0.63 in) Quantity [ View X ] Wrench size 24 mm Tightening torque 210 N·m (21 kgf·m, 155 lbf·ft) Bolt B (Radiator core) Bolt diameter 10 mm (0.39 in) Quantity Wrench size 17 mm...
Page 412 MAINTENANCE 19. Cooler assembly mounting bolt Bolt A: Air conditioner condenser Bolt diameter 8 mm (0.3 in) Quantity Wrench size 13 mm 10.2~15.2 N·m Tightening torque (1.0~11.7 kgf·m, 7.5~11.2 lbf·ft) Bolt B: Hydraulic oil cooler Bolt C: Fuel cooler Bolt D: Air cooler Bolt diameter 12 mm (0.47 in) 115Z7B-7-140-1...
Page 413 MAINTENANCE 21. Cab cushion rubber mounting bolt Bolt diameter 16 mm (0.63 in) Quantity Wrench size 22 mm Tightening torque 210 N·m (21 kgf·m, 155 lbf·ft) MNHE-07-066 22. ROPS mounting bolt Bolt diameter 30 mm (0.63 in) Quantity Wrench size 46 mm Tightening torque 1421 N·m (145 kgf·m, 1048 lbf·ft) MNHE-07-070...
Page 414 MAINTENANCE 23. Space edge (segment) mounting bolt Bolt diameter 1-1/4-7UNC in Quantity Wrench size 51 mm Tightening torque 2402 N·m (245 kgf·m, 1772 lbf·ft) 115Z7-7-95-1a 24. Wear plate mounting bolt Bolt diameter 7/8-9UNC in Quantity Wrench size 36 mm Tightening torque 834 N·m (85 kgf·m, 615 lbf·ft) 90Z7-7-113-2 25.
Page 415: Maintenance Under Special Environmental Conditions
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Maintenance Under Special Environmental Conditions WARNING:  Before operating the machine in a river, check  Avoid driving the machine into a river where the riverbed conditions in advance. the riverbed is steep and deep or the stream is rapid.
Page 416: Maintenance Under Special Environmental Conditions
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Precautions for Maintenance During Cold Weather Season Before the atmospheric temperature below -0 °C (32 °F), note the following points.  Water and oil in the machine will freeze. Never use water without antifreeze. Use correct windshield washing solution so that windshield washer tanks and pumps will not freeze.
Page 417 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS DANGER: Ventilate the area with fresh air when carrying out warm-up operation indoor. Failure to do so may cause asphyxiation from exhaust gas, resulting in death or severe injury. 7. After preheating, start and warm up the engine. 8.
Page 418 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 419: Storage
STORAGE Storing the Machine WARNING: When servicing indoors for long term storage, open windows and doors to maintain good air ventilation to prevent asphyxiation. Check all lubricants before operating the machine after bring stored. Apply the parking brake while storing. If the machine is to be stored for more than one month, observe the following precautions so that its function will not be impaired during storage.
Page 420: Removing The Machine From Storage
STORAGE Removing the Machine from Storage WARNING: When servicing indoors for long term storage, open windows and doors to maintain good air ventilation to prevent asphyxiation. Check all lubricants before operating the machine after bring stored. Apply the parking brake while storing. IMPORTANT:  Lubricants will deteriorate during storage of the machine.
Page 421 STORAGE 1. Remove 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 alternator and fan belt tension. 5. Check the oil level. Add oil as needed. 6.
Page 422 STORAGE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................10-4...
Page 423: Troubleshooting
TROUBLESHOOTING Troubleshooting If any machine trouble has occurred, immediately repair it. Make certain the cause of the trouble and take necessary measures to prevent the reoccurrence of the same trouble. In case troubleshooting is difficult, or measures marked with * must be taken, consult the nearest authorized dealer.
Page 424: Engine Does Not Start
TROUBLESHOOTING 3. Engine does not Start. Problem 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 or replace...
Page 425: Control Lever
TROUBLESHOOTING 4. Control Lever Problem Cause Solution Hard to move Rusted joint * Lubricate or repair Worn pusher * Replace Does not move smoothly Worn pusher * Repair or replace Faulty pilot valve * Replace Does not return to neutral Faulty pilot valve * Replace The lever is tilted in the neutral...
Page 426: Drive Function
TROUBLESHOOTING 6. Drive Function Problem Cause Solution Joystick steering lever is heavy Faulty steering pump * Repair, Replace to operate. Faulty steering device * Repair, Replace Malfunction of steering cylinder * Repair, Replace Relief valve set pressure reduction * Adjust Low tire air pressure * Inflate Steering turns in unexpected...
Page 427: Others
TROUBLESHOOTING 6. Drive Function (Continued) Problem Cause Solution Transmission is noisy. Lack or deterioration of gear oil Refill, replace Worn inner parts in transmission * Repair, Replace Broken gear or bearing * Repair, Replace Oil temperature increases. Faulty fan rotation * Repair or adjust Propeller shaft vibrates.
Page 428 TROUBLESHOOTING MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................11-6...
Page 429 SPECIFICATIONS Specifications Intended Use This product is designed for loading, excavation,grading, dozing and/or scooping. Refer to "OPERATING THE MACHINE" for further information. 115Z7B-AK-RVT Bucket Capacity: heaped 6.3 (8.3) Operating Weight kg (lb) 47430 (104565) Tipping Load (Full Turn) kg (lb) 27380 (60365) Engine ISUZU 6WG1...
Page 430 SPECIFICATIONS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................12-2...
Page 431 INDEX 24 V DC Electrical Outlet ............1-114 Automatic Regeneration .............1-5 2nd/3rd Speed Limit Switch (Option) .........1-105 Automatic regeneration (Auto-regeneration) ....1-35 Auxiliary Control Lever (Option) ...........1-101 Avoid Accidents from Backing Up and Turning ....S-16 Accelerator Pedal ................1-90 Avoid Applying Heat to Lines Containing Flammable Accelerator Pedal Operation, Check ........7-114 Fluids ...................
Page 432 INDEX Change Axle Oil................7-37 Check Parking Brake Gear Oil Level ........7-90 Change Coolant ................7-76 Check Pilot Circuit Accumulator Function, Gas Leakage, Change Differential Gear Oil ............ 7-37 Looseness, and Damage............7-51 Change Engine Oil ..............7-26 Check Planetary Gear Oil Level ..........7-36 Change Hydraulic Oil ..............
Page 433 INDEX Clearance Light Indicator (Green) .......... 1-18 Drive Belt, Adjusting ..............7-74 Coat/Hat Hook ................1-131 Drive Belt, Check ................7-74 Cold Weather Warm Up .............. 3-13 Drive Belt, Replace ............... 7-75 Communication Error Indicator (Yellow) ......1-14 Drive Function, Troubleshooting ..........11-4 Communication Terminal Equipment, Precaution ...
Page 434 INDEX Fan Reverse Rotation Switch, OFF ........1-106 Horn Switch .................1-113 Fan/AUTO Switch ................1-118 Horn, Check ..................7-85 Fasten Your Seat Belt ..............S-7 Hoses and Lines, Check .............. 7-53 Fastening Machine for Transporting ........6-4 Hot/Cool Box ................1-127 Fingertip Control Type ..........1-10, 1-96, 5-1 Hour Meter, Check Regularly ............7-3 Flat Face O-ring Seal Fitting (ORS Fitting) ......
Page 435 INDEX Loading Multi-Function Joystick Lever (Option) ..1-100, 5-3 Outside Rear View Mirror ............1-133 Loading/Unloading on Trailer .............6-2 Overheat Indicator (Red) ............1-15 Lock Bar .................... S-38 Lockup Setting ................1-61 Parallel/Tandem Switching Height Setting ......1-65 Low Steering Oil Pressure Indicator (Option) (Red) ..1-14 Park Machine Safely ..............
Page 436 INDEX Provide Signals for Jobs Involving Multiple Machines..S-11 Roll Over Protective Structure (ROPS) ........S-40 Pulley, Check ................7-103 ROPS, Check .................7-112 ROPS (Roll Over Protective Structure) ......S-11, S-40 ROPS Mounting Bolts, Check ..........7-112 Quick Power Switch ..............1-111 Rotary Light Switch (Option) ..........1-132 Rotation Procedure ..............
Page 437 INDEX Wear Protective Clothing..............S-3 Time Adjustment ................1-47 Welding, Precaution ..............S-31 Time Remains and Maintenance Interval ......1-78 Wheel Bolt Torque, Check ............7-95 Tips for Optimal Air Conditioner Usage ......1-122 When Windows Become Fogged..........1-122 Tire ..................... 7-94 When the Engine has Stalled During Operation ....4-19 Tire (Tire Pressure), Replace ............
Page 438 INDEX MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ZW550-6 US 14-8...

Hitachi ZW 550-6 Operator's Manual

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