Page 1 ENMNBD-1-2 PART NO. Operator's Manual Wheel Loader URL:http://www.hitachi-c-m.com Serial No. 020001 and up This book is printed on recycled paper. PRINTED IN JAPAN (E) 2021, 09...
Page 2 INTRODUCTION Read this manual carefully to learn how to operate and Warranty is provided as a part of Hitachi’s support service your machine correctly. Failure to do so could program for customers who operate and maintain their result in personal injury or machine damage.
Page 3 INDEX MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME GETTING ON/OFF THE MACHINE OPERATOR’S STATION BREAK-IN OPERATING THE ENGINE DRIVING 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...
Page 5: Table Of Contents
CONTENTS MACHINE NUMBERS ................1 Evacuating in Case of Fire ............S-32 Beware of Exhaust Fumes............S-32 SAFETY ....................S-1 Precautions for Welding and Grinding ......... S-32 Recognize Safety Information ............S-1 Avoid Heating Near Pressurized Fluid Lines ....... S-33 Understand Signal Words .............S-1 Avoid Applying Heat to Lines Containing Flammable Follow Safety Instructions ............S-2 Fluids ...................
Page 6 CONTENTS Switches, Steering Wheel and Pedals ........1-20 Vandal-Resistant Devices............1-52 Forward/Reverse Lever ............... 1-21 Radio Unit (CAB) (Optional) ............1-53 Neutral Lever Lock (Forward/Reverse Lever) ...... 1-21 Control Panel ................1-53 Steering .................... 1-22 LCD Display ................1-54 Horn Switch ..................1-22 Basic Operation ...............
Page 7 CONTENTS Transporting by Trailer ..............6-1 Clean Radiator, Oil Cooler and Inter Cooler Core ..7-56 Loading/Unloading on Trailer .............6-1 H. Electrical System ..............7-57 Transporting ..................6-3 Check Monitor Function and All Other Instrument Transporting Wheel Loader Operation ................7-57 (Urgent Situation) ..............6-4 Check Work Lights ..............
Page 8 CONTENTS Retighten Front Axle and Rear Axle Support Mounting Bolts ..............7-86 Tightening and Retightening Torque of Nuts and Bolts ..................... 7-87 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS ..................9-1 Maintenance Under Special Environmental Conditions ...9-1 Precautions for Maintenance During Cold Weather Season ....................9-2 STORAGE ..................
Page 9: Product Identification Number
MACHINE NUMBERS The manufacturing Nos. explained in this group is the individual number (serial No.) given to each machine and hydraulic components. These numbers are requested when inquiring any information on the machine and/or components. Fill these serial Nos. in the blank spaces in this group to immediately make them available upon request.
Page 10: Machine Numbers
MACHINE NUMBERS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 11: Safety
SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices. SA-2644 Understand Signal Words ...
Page 12: Follow Safety Instructions
Hitachi Warranty Policy.  Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine...
Page 13: Prepare For Emergencies
SAFETY Prepare for Emergencies  Be prepared for a fire or an accident.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly. ...
Page 14: Protect Against Noise
SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. SA-434 Inspect Machine ...
Page 15: General Precautions For The Cab
SAFETY General Precautions for the Cab  Before entering the cab, thoroughly remove all dirt and/ or oil such as mud, grease, soil or stones from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.
Page 16: Use Handrails And Steps
SAFETY Use Handrails and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.  Do not use any controls as handholds. ...
Page 17: Ensure Safety Before Rising From Or Leaving Operator's Seat
SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open / close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position.
Page 18: Move And Operate Machine Safely
SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped).
Page 19: Operate Only From Operator's Seat
SAFETY Operate Only from Operator’s Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator's seat.  Never start the engine while standing on the tire or on ground.
Page 20: Investigate Job Site Beforehand
SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.
Page 21: Equipment Of Head Guard, Rops, Fops
SAFETY Equipment of Head Guard, ROPS, FOPS If the machine is operated in areas where the possibility of falling stones or debris, 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 performance and its certification will be lost.
Page 22: Keep Riders Off Machine
SAFETY Keep Riders Off Machine  Riders on the machine are subject to injury such as being struck by foreign objects and being thrown off the machine.  Only the operator should be on the machine. Keep riders off.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.
Page 23: Drive Machine Safely (Work Site
SAFETY Drive Machine Safely (Work Site)  Before driving the machine, always confirm that the steering wheel / and forward / reverse lever (switch) direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions. ...
Page 24: Drive Safely With Bucket Loaded
SAFETY Drive Safely with Bucket Loaded  If the machine is incorrectly operated while driving with the bucket loaded, turning over of the machine may result. Be sure to follow all the instructions indicated below.  When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility.
Page 25: Travel On Public Roads Safely
SAFETY Travel on Public Roads Safely  This machine is not allowed to drive on public roads with the bucket loaded.  Be sure to empty the bucket.  Hold the bucket at mark (A) 300 mm above the road surface as illustrated.
Page 26: Avoid Accidents From Backing Up And Turning
SAFETY Avoid Accidents from Backing Up and Turning  Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and/or death by being run over or entangled in the machine.
Page 27: Avoid Positioning Bucket Or Attachment Over Anyone
SAFETY Avoid Positioning Bucket or Attachment Over Anyone  Never allow the bucket or attachment to pass over co- workers and/or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket or attachment may cause serious personal accidents and/or damage to the machine.
Page 28: Never Undercut A High Bank
SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death. SA-4EK-016 Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.
Page 29: Avoid Power Lines
SAFETY Avoid Power Lines Serious injury or death can result from contact with electric lines. When operating near an electric line, never move any part of the machine or load to within 3 m plus twice the line insulator length of overhead wires. SA-4EK-019 Precautions for Operation ...
Page 30: Object Handling
SAFETY Object Handling CRANING OPERATION USING THE MACHINE IS NOT ALLOWED.  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. Never attach a sling or chain to the bucket teeth or to the attachment (fork or grapple for example).
Page 31: Protect Against Flying Debris And Falling Object
SAFETY Protect Against Flying Debris and Falling Object  During hammer operation, debris from earth, rock or metal may fly in all directions, resulting in a serious personal injury or death.  When driving the connecting pins in or out, wear goggle or safety glasses, hard hat and face shield.
Page 32: 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 33: Transport Safely
SAFETY Transport Safely  Be aware care that the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.  Observe the related regulations and rules for safe transportation. Less than 15 ° ...
Page 34: 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 35: 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 36: 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. If the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.
Page 37: 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 38: 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 39: 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 40: 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 41 SAFETY Clean up Flammable Materials:  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammable materials may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammable materials immediately.
Page 42: Evacuating In Case Of Fire
SAFETY Evacuating in Case of Fire  If a fire breaks out, evacuate the machine in the following way:  Stop the engine by turning the key switch to the OFF position if there is time.  Use a fire extinguisher if there is time. ...
Page 43: Avoid Heating Near Pressurized Fluid Lines
SAFETY Avoid Heating Near Pressurized Fluid Lines  Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.  Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. ...
Page 44: 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-34...
Page 45: Prevent Battery Explosions
SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. ...
Page 46: Handle Chemical Products Safely
 Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Hitachi equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.  Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
Page 47: Safety Signs
SAFETY SIGNS All safety signs and their locations affixed on the machine are illustrated in this group. Make sure of the contents described in the safety signs through reading actual ones affixed on the machine to ensure safe machine operation. Always keep the safety signs clean.
Page 48 SAFETY SIGNS 1. Both sides of bucket SS-4EK-017_E SS-E804-002_E  Sign indicates a hazard of falling.  Do not stand on this place. 2. Front Maintenance Access Cover for Front Frame SS-4EK-019_E  The front attachment may automatically be lowered, possibly resulting in personal injury.
Page 49 SAFETY SIGNS 4. Left Side of Front Console SS-4EK-005 E SS-4169 5. Right Side of Front Console SS-4170 SS-4EK-005 E 6. ROPS Canopy Right Rear Column Cab Inside Right Front Column (Option) ROPS CANOPY WARNING:  ROPS CAB To minimize the injury due to an overturning accident, be sure to fasten the seat belt prior to operating the machine.
Page 50 SAFETY SIGNS 7. Steering Cover SS-4172 SS-4EK-026_E 8. Steering Cover SS-4172 SS-4EK-024_E S-40...
Page 51 SAFETY SIGNS 9. Both Side Vicinity of Step’s SS-4EK-027_E SS-4EK-009_E SS-4EK-006_E 10. Relay Box Cover SS-4173  If the engine is started following an incorrect method, the machine suddenly may begin to move. Start the engine SS-NBD-001 from the operator’s seat only. S-41...
Page 52 SAFETY SIGNS 11. Vicinity of Battery SS-4174  Skin contact with electrolyte will cause burns. Splashed SS-NBD-001 electrolyte into eyes will cause blindness. Take care not to touch electrolyte. 12. Vicinity of Radiator Cap SS-4175 SS-E804-004_E  Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot.
Page 53 SAFETY SIGNS 14. Both Sides of Radiator Frame SSYA00008686 M4ER-00-001 SS-4EK-033_E  Side indicates a hazard of rotating parts, such as belt fan. Turn off before inspection and maintenance. 15. Vicinity of Air Cleaner SS-4EK-035_E SS-NBD-001 16. Both Sides of Counterweight SS-4EK-039_E SS-E804-005_E ...
Page 54 SAFETY SIGNS 17. Left Side of Front Frame SS-4176 SS-4EK-010  The articulation area becomes a pinch point when steering the machine. Be sure to install the articulate lock bar during the inspection/maintenance work and transportation of the machine. Remove link when finished. 18.
Page 55: Components Name
COMPONENTS NAME Components Name Canopy Vehicle 1- Cutting Edge 2- Bucket 3- Bucket Link 4- Bell Crank 5- Bucket Cylinder 6- Head Light/Turn Signal/Clearance Light 7- Rear View Mirror 8- ROPS/FOPS Canopy 9- Fuel Filler Port 10- Articulation Lock Bar (Left Side only) 11- Lift Arm Cylinder 12- Lift Arm 13- Hydraulic Oil Tank...
Page 56: Cab Vehicle (Optional)
COMPONENTS NAME Cab Vehicle (Optional) 1- Cutting Edge 2- Bucket 3- Bucket Link 4- Bell Crank 5- Bucket Cylinder 6- Head Light/Turn Signal/Clearance Light 7- Rear View Mirror 8- Front Work Light 9- ROPS/FOPS Cab 10- Rear Work Light 11- Fuel Filler Port 12- Articulation Lock Bar (Left Side only) 13- Lift Arm Cylinder 14- Lift Arm...
Page 57: Getting On/Off The Machine
GETTING ON/OFF THE MACHINE Getting ON/OFF the Machine Foot holds (1) and handrails (2) are provided in and around the machine. These are used to get on and off the cab safely as well as to do inspection and maintenance of the machine safely. Never jump on or off the machine as it is very dangerous.
Page 58: Operator's Station
OPERATOR’S STATION Features MNBC-01-006 1- Front Console 2- Right Console 3- Operator’s Seat 4- Fuse Box 5- Floor Mat...
Page 59: Front Console
OPERATOR’S STATION Front Console 1- Steering Wheel 2- Horn Switch 3- Monitor Panel 4- Accelerator Pedal 5- Brake/Inching Pedal (Both right and left sides are interlocked) 6- Forward/Reverse Lever 7- Neutral Lever Lock (Forward/Reverse Lever) MNBC-01-007 8- Rear Work Light Switch (CAB: Optional) 9- Front Work Light Switch (CAB) 10- Hazard Switch (Optional) 11- Turn Signal Switch...
Page 60: Right Console
OPERATOR’S STATION Right Console 1- Loader Control Lever Front 2- Loader Control Lever Lock 3- Auxiliary 4- Travel Mode Switch (Optional) 5- Heater Switch (Optional) 6- Key Switch M4EK-01-007A...
Page 61: Monitor Panel
OPERATOR’S STATION Monitor Panel MNBC-01-020 1- Left Turn Signal Indicator 13- Seat Belt Indicator 2- Work Light Indicator 14- Set Switch 3- Engine Error Alarm 15- Select Switch 4- Monitor Display 16- Select Switch 5- Service Indicator 17- Overheat Indicator 6- Right Turn Signal Indicator 18- Preheat Indicator 7- Clearance Light Indicator...
Page 62: Service Indicator (Yellow)
OPERATOR’S STATION Service Indicator (Yellow) WARNING: To prevent potential injury and/or damage to the machine, immediately stop operating the machine if the service indicator lights or the alarm sounds. Then check and service the part indicated. The service indicator comes on and the buzzer sounds in the following cases.
Page 63: Parking Brake Indicator (Red)
OPERATOR’S STATION Parking Brake Indicator (Red) The parking brake indicator lights when the parking brake is M4GB-01-012 Brake Level Low Indicator WARNING: Personal injury may result from continuing to operate the machine when the brake fluid level is low. If the red light comes ON, immediately stop the machine.
Page 64: Overheat Indicator (Red)
OPERATOR’S STATION Overheat Indicator (Red) The warning light comes on if the engine coolant becomes abnormally hot. The overheat indicator and service indicator come on and the buzzer alarm sounds. Stop operations and run the engine at slow idle speed to lower the coolant temperature.
Page 65: Preheat Indicator (Yellow)
OPERATOR’S STATION Preheat Indicator (Yellow) When lit, it indicates that the engine is preheating; once it goes out, preheating is complete. M4GB-01-031 Seat Belt Indicator (Red) The indicator comes on if the engine is started without the seat belt being fastened; once the belt is fastened the light goes out.
Page 66: Turn Signal Indicator (Green)
OPERATOR’S STATION Turn Signal Indicator (Green) When the turn signal lever is operated, the turn signal and the indicator start flashing. M4GB-01-032 Work Light Indicator (Yellow) When the work lights are turned ON, this indicator comes ON. MNBC-01-023 Clearance Light Indicator (Green) When the clearance lights are turned ON, this indicator comes M4GB-01-035 1-12...
Page 67: Maintenance Light (Yellow)
OPERATOR’S STATION Maintenance Light (Yellow) This light indicates that the time for a replacement is approaching. Once the set time is reached, it lights for 30 seconds each time the key switch is turned ON. Items with Replacement Times M4GB-01-037 ...
Page 68: Monitor Display
OPERATOR’S STATION Monitor Display 1. Monitor Display 2. Set Switch 3. Select Switch 4. Select Switch 5. Clock 6. Engine Tachometer 7. Fuel Gauge 8. Travel Mode Indicator (Optional) MNBC-01-024 9. Hour Meter 10. Coolant Temperature Gauge 11. F-N-R Indicator MNBC-01-025 1-14...
Page 69: F-N-R Indicator
OPERATOR’S STATION F-N-R Indicator The square corresponding to the position of F-N-R lever (3), highlights either Forward (F), Neutral (N) or Reverse (R) in F-N-R indicator (1). Neutral is highlighted whenever the parking brake switch is ON, regardless of the lever position. MNBC-01-025 M4EK-01-008 Travel Mode Indicator (Optional)
Page 70: Hour Meter
OPERATOR’S STATION Hour Meter The total accumulated operating hours since the machine started working are displayed in hours (h). One digit after the decimal point indicates tenths of an hour (6 minutes). MNBC-01-026 Clock Indicates the current time. (Refer to “Clock” for instructions on setting the clock.) MNBC-01-027 Fuel Gauge Indicates the amount of remaining fuel.
Page 71: Time
OPERATOR’S STATION Time Setting the Clock 1. Press and hold set switch (1) and selector switch (3) together for about 1 second on the basic screen to enter the clock setting mode, causing hour display (4) to flash. 2. Push selector switch (2) or (3) to adjust the hour in hour display (4).
Page 72: Maintenance
OPERATOR’S STATION Maintenance The remaining hours until next maintenance can be checked and reset on the maintenance screen. Checking Hours until Next Maintenance 1. Press selector switch (1) from the basic screen to open the maintenance screen. : Hours until next maintenance MNBC-01-024 Push selector switch (1).
Page 73: Resetting Hours Until Next Maintenance
OPERATOR’S STATION Resetting Hours until Next Maintenance When an item reaches its maintenance time, maintenance lamp (4) lights. A wrench mark (5) is displayed on the maintenance screen above items that have reached their maintenance times. Perform the required maintenance for items that have reached their maintenance times and then reset the remaining time after completing the maintenance.
Page 74: Switches, Steering Wheel And Pedals
OPERATOR’S STATION Switches, Steering Wheel and Pedals 1- Steering Wheel 2- Horn Switch 3- Monitor Panel 4- Accelerator Pedal 5- Brake/Inching Pedal (Both right and left sides are interlocked) 6- Forward/Reverse Lever 7- Neutral Lever Lock (Forward/Reverse Lever) MNBC-01-007 8- Rear Work Light Switch (CAB: optional) 9- Front Work Light Switch (CAB) 10- Hazard Switch (Optional) 11- Turn Signal Switch...
Page 75: Forward/Reverse Lever
OPERATOR’S STATION Forward/Reverse Lever Changes the machine drive direction from forward to reverse and vice versa. Move forward/reverse lever (1) to the F position to travel the machine forward. Move forward/reverse lever (1) to the R position to drive the machine in reverse. IMPORTANT: Do not shift forward/reverse lever (1) while driving the machine at high speed.
Page 76: Steering
OPERATOR’S STATION Steering IMPORTANT: When steering wheel (1) is fully turned, the front frame and the rear frame come in contact with the stoppers so that the steering wheel can not turn further. If forced to turn further, engine stall and/or damage to the steering system may result.
Page 77: Light Switch
OPERATOR’S STATION Light Switch Light switch (1) has three positions, OFF, Small, and Main. As shown below, each light comes ON ( ) or OFF ( ) according to the selected position of the light switch. 2- Headlight 3- Turn Signal/Clearance Light/Hazard Light 4- Turn Signal/Hazard Light 5- Brake Light/Tail Light M4EK-01-012...
Page 78: Hazard Switch (Optional)
OPERATOR’S STATION Hazard Switch (Optional) IMPORTANT: Do not hold hazard switch (1) in the “ “ position for a long time with the engine stopped. The batteries will be discharged. When a machine failure occurs, use this switch to inform other vehicles that the machine is in an emergency situation.
Page 79: Front Work Light Switch (Cab)
OPERATOR’S STATION Front Work Light Switch (Cab) With the light switch (3) in either position, press the ON side of front work light switch (1) to turn front work lights (2) ON. Press the OFF side of front work light switch (1) to turn front work lights (2) OFF.
Page 80: Rear Work Light Switch (Cab, Optional)
OPERATOR’S STATION Rear Work Light Switch (Cab, Optional) With the light switch (3) in either position, press the ON side of rear work light switch (1) to turn rear work lights (2) ON. Press the OFF side of rear work light switch (1) to turn rear work lights (2) OFF.
Page 81: Parking Brake Switch
OPERATOR’S STATION Parking Brake Switch WARNING: To prevent accidents due to rolling of the machine, after parking the machine or before leaving the machine, be sure to apply the parking brake. Never apply the parking brake while traveling the machine. Failure to do so may cause sudden deceleration of the machine travel speed, possibly creating a dangerous situation.
Page 82: Front Window Wiper Switch (Cab)
OPERATOR’S STATION Front Window Wiper Switch (Cab) Operate front window wiper switch (1) to move the windshield wiper. OFF: The wiper stops moving and the wiper blade is returned to the pre-start position. The wiper operates at slow speed The wiper operates at fast speed. PUSH: As long as wiper switch (1) is depressed, the washer fluid is dispensed.
Page 83: Accelerator Pedal
OPERATOR’S STATION Accelerator Pedal When accelerator pedal (1) is stepped on, the engine speed increases. When released, the engine speed decreases. MNBC-01-007 Brake/Inching Pedal 2, 3 WARNING: Avoid sudden brake application during travel operation, possibly creating a hazardous situation. The machine may lose its balance. Unless necessary, do not place your foot on the brake/inching pedal to prevent the brake/inching pads and discs from wearing out prematurely.
Page 84: Right Console
OPERATOR’S STATION Right Console 1- Loader Control Lever 2- Loader Control Lever Lock 3- Auxiliary 4- Travel Mode Switch 5- Key Switch MNBC-01-010 1-30...
Page 85: Loader Control Lever
OPERATOR’S STATION Loader Control Lever Mono-Lever Type Front Is used to operate the lift arm and/or bucket. (C) Float: The lift arm free falls and can be moved as loads are applied. (B) Lift arm Lower (N) Hold: The lift arm and bucket are stopped and held in that position.
Page 86: Lever Locks
OPERATOR’S STATION Lever Locks WARNING: When locking the loader control lever and the auxiliary control lever (optional), securely shift lever locks (2) and (4) to the LOCK position. Unless lever locks (2), (4) are fully moved to the LOCK position, LOCK the control levers are not locked, possibly creating a hazardous situation.
Page 87: Key Switch
OPERATOR’S STATION Key Switch WARNING: Before starting the engine, return the forward/reverse lever to neutral, apply the parking brake, and lock the loader control lever lock. Refer to the descriptions in the OPERATING THE ENGINE section for the detail information. WARNING: Never turn key switch (6) OFF while traveling the machine.
Page 88: Travel Mode Switch
OPERATOR’S STATION Travel Mode Switch Switch (1) is used to shift the travel speed stage. Select the position to match the desired travel/work mode. LOW (Work) Mode: Travel speed is kept maintained to the first stage. Available travel speed range: 0 to 7.5 km/h AUTO (Travel) Mode: Travel speed is automatically shifted within the range of the first to 2nd speed stage by operating the accelerator pedal.
Page 89: Air Conditioner (Optional) Operation
OPERATOR’S STATION Air Conditioner (Optional) Operation Components Name 1- Control Panel 2- Defroster Vent 3- Foot Vent 4- Rear Vent MNBB-01-006 Control Panel Arrangement 5- Liquid Crystal Panel 6- Air Conditioner Switch 7- Power Switch 8- Blower Switch 9- Temperature Control Switch NOTE: Control Panel M4EK-AC-001...
Page 90: Control Panel Switch Designation And Function
OPERATOR’S STATION Control Panel Switch Designation and Function Power Switch (7) Press power switch (7) to light the set indicators of the air temperature and the blower speed on liquid crystal panel (5). The blower will start running. Press power switch (7) again to stop the blower.
Page 91: 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 kept exposed to sunlight in the summer. For rapid cooling, open the door to ventilate hot air in the cab first.
Page 92: Adjusting The Operator's Seat (Reclining Type)
OPERATOR’S STATION Adjusting the Operator’s Seat (Reclining Type) CAUTION: Adjust the seat to a position that allows pedals, levers and switches to be operated easily. Adjust the seat while the machine is parked. Name of Components 1- Slide Lever 2- Backrest Lever 1.
Page 93: Seat Back Pocket
OPERATOR’S STATION Seat Back Pocket A pocket is provided on the back of the operator’s seat. Keep the user’s manual and other information in the pocket. NOTE: It is not completely waterproof. If necessary, use a plastic bag or the like to keep it dry. 1.
Page 94: Fuse Box
OPERATOR’S STATION Fuse Box IMPORTANT: If a fuse blows, turn the key switch OFF and investigate the problem with the power off. Replace the fuse with a new one. Disconnect the minus terminal of the battery before replacing a slow-blow fuse. The purpose of fuses is to provide a safety valve for the electrical system and prevent excessive current from flowing through its circuits.
Page 95: Fuse Box (Cab-Equipped Machines) (Optional)
OPERATOR’S STATION Fuse Box Amperes Circuit 15 A Headlight (OP) 15 A Hazard Lamp (OP) Controller, Electronic Key (1) (OP), Tachograph (1) (OP) 30 A Engine (1), ECM Cab Light (Cab) Engine (3), Airflow Sensor 15 A Engine (2), EGR, Fuel Pump, Oil Separator 10 A Key On, Electronic Key (2) (OP), Tachograph (2) (OP) 10 A...
Page 96: Rops Cab (Optional)
OPERATOR’S STATION Rops Cab (Optional) ROPS Cab (1) is a optional equipment. 1- ROPS Cab 2- Room Light 3- Room Rear View Mirror 4- Sun Visor M4EK-01-029 M4EK-01-030 M4FG-01-055 1-42...
Page 97 OPERATOR’S STATION 5- Radio 6- Cab Switch Panel (Optional) 7- Drink Holder 8- Speaker 9- Coat Hook NOTE: The radio and speakers are locally procured optional equipment. The illustrations are example. MNCH-01-551 M4EK-01-032 M4EK-01-033 1-43...
Page 98: Room Light
OPERATOR’S STATION Room Light Press switch (1) to turn the room light ON. The room light switch has three operation positions.  ON: The light (2) comes and stays ON.  Neutral: The light (2) goes OFF.  DOOR: When the cab door is opened, the light (2) comes ON.
Page 99: Emergency Evacuation Hammer
OPERATOR’S STATION Emergency Evacuation Hammer In case of emergency in which the cab door cannot be opened, break the glass of a window with hammer (1) to escape. MNBB-01-002 Coat Hook Use coat hook (2) for hanging up clothing, like jackets and hats.
Page 100: Cab Switch Panel (Optional)
OPERATOR’S STATION Cab Switch Panel (Optional) 1- Auxiliary 2- Auxiliary MNCH-01-551 1-46...
Page 101: Cab Door
OPERATOR’S STATION Cab Door CAUTION: Securely close the door. If the door is unexpectedly opened, a hazardous situation may be created. Before leaving the operator’s seat, fully open the cab door and lock the door in position. 1- Door Lock 2- Door Open/Close Lever NOTE: Unless the cab door is securely closed, the room light...
Page 102: Door Lock Knob
OPERATOR’S STATION Door Lock Knob CAUTION: After closing the door, always check that the door lock is securely engaged. Depress door lock knob (5) to engage the door lock. Door Open/Close Lever When opening the door, while lif ting door lock knob (5), pull lever (6) to disengage the door lock.
Page 103: When Fully Opening The Door
OPERATOR’S STATION When Fully Opening the Door Push the door toward the outside of the cab to fully open the door (180°). Door Lock Disengage Lever CAUTION: When keeping the door open, open the door until latch (8) on the cab securely locks the door. When disengaging the door lock, push door lock disengage lever (9) or (10) downward.
Page 104: Articulation Lock Bar
OPERATOR’S STATION Articulation Lock Bar WARNING: Before servicing or transporting the machine, be sure to engage lock bar (1). Before driving the machine, be sure to disengage the lock bar (1) from the front frame (3) and fasten the lock bar to the rear frame with pin (1) and lock pin (2).
Page 105: Engine Hood
OPERATOR’S STATION Engine Hood WARNING: Open/close engine hood (1) only when the engine is stopped. Failure to do so may cause personal injury or death due to entanglement into the engine fan. Before using the machine, check that engine hood (1) does not open.
Page 106: Vandal-Resistant Devices
OPERATOR’S STATION Vandal-Resistant Devices A lock key can be installed to fuel tank cap (1) and engine hood (2). M4EK-01-058 M4ER-01-004 1-52...
Page 107: Radio Unit (Cab) (Optional)
OPERATOR’S STATION Radio Unit (CAB) (Optional) Control Panel 1- POWER button Turns the device ON/OFF. 2- SRC button Switches the source (FM1FM2AMBluetooth®USB). 3- Search button MNCH-01-551 Makes auto presets (FM/AM). 4- Return button Returns to the previous screen while setting operation. 5- Hands-Free button Receives mobile phone signal.
Page 108: Lcd Display
OPERATOR’S STATION LCD Display 1- Information section Indicates the source name, frequency, service name, etc. in characters and/or numbers. 2- Source label Indicates the selected source name. 3- ST label Lights to indicate stereo reception when FM are selected. 4- USB label MNUD-01-448 Lights when a USB device is connected.
Page 109: Basic Operation
OPERATOR’S STATION Basic Operation Turn ON the device When the machine starter key is set to ON or ACC, the previously selected source is displayed on LCD (2). If the LCD displays nothing, press power button (1). The previously selected source appears on the LCD. NOTE: When the starter key is turned to OFF when the radio unit is in the standby mode, the radio unit starts up in the standby mode when the key is turned to ON or ACC.
Page 110: Selecting Source
OPERATOR’S STATION Selecting Source Long depressing SRC button (1) displays the source selection screen (4). MNUD-01-402 MNUD-01-450  Rotate rotary switch (2) to highlight a desired source (FM1DFM2DAMDBluetooth®DUSBDSETTINGDFM1).  Press rotary switch (2) while selecting a source to display its sub-sources. ...
Page 111: Volume Control
OPERATOR’S STATION Volume Control The volume control can be done individually for each source and for hands-free calling. Rotating rotary switch (1) clockwise increases the volume. Rotating rotary switch (1) counterclockwise decreases the volume. The volume level is selected between 0 (mute) and 32. MNUD-01-402 NOTE: The screen returns to the source screen when no operation is made for 3 seconds.
Page 112 OPERATOR’S STATION About Trademark The Bluetooth® wordmark and logo are registered trademarks owned by Bluetooth SIG, Inc., and Scribble Design Inc. uses these marks under license. Other trademarks and trade names belong to their respective owners. CAUTION:  Do not operate the radio or other audio equipment while driving or working.
Page 113: Fm/Am Radio Operation
OPERATOR’S STATION FM/AM Radio Operation CAUTION: Refrain from listening to the radio while operating the machine. Receives both FM and AM radio. NOTE: The only difference between FM1 and FM2 is the grouping of preset numbers; the function is the same. Control Panel 1- POWER button Turns the radio ON/OFF.
Page 114 OPERATOR’S STATION Station Presetting Procedure 1. Select the desired station. Refer to the following page "Tuning Procedure". 2. Press and hold a desired PRESET button (1) for more than 1 second. The current station is preset to the selected number of button. When the station is preset, the "PRESET-x"...
Page 115: Tuning Procedure
OPERATOR’S STATION Tuning Procedure  Automatic Search Function (Auto Seek) Press and hold SEEK BAND+ button (1) and/or SEEK BAND- button (2) for more than half a second, then release. Automatic search for the station starts to run and stops when a station is received.
Page 116: Bluetooth® Input
OPERATOR’S STATION Bluetooth® Input IMPORTANT: A special Bluetooth® unit is necessary to use this function. Specified Characteristics Frequency 2.4 GHz Version Class Applicable profile A2DP, AVRCP, HFP, HSP, SPP Max. Number of Pairing Device MNUD-01-402 The audio files can be played via Bluetooth® connection with a cell phone or Bluetooth®...
Page 117 OPERATOR’S STATION Change Track Press [2] button (2) to start playing the next track. Press [1] button (1) to play the previous track. According to the connected device setting, pressing [1] button (1) returns to the top of the currently playing track. Then press [1] again to play the previous track.
Page 118 OPERATOR’S STATION Pause/Playback Pressing [3] button (1) while playing a track pauses playback. PAUSE label (4) is displayed. Pressing [3] button (1) again starts playing from where it was paused. MNUD-01-402 MNUD-01-419 Repeat Pressing [4] button (2) plays the same track repeatedly. REPEAT label (5) is displayed.
Page 119 OPERATOR’S STATION Hands-free Call IMPORTANT: A special Bluetooth® connected cellphone is necessary to use this function. Allows handsfree conversations when using a Bluetooth® (HFP protocol) compatible cellphone.  Making a Call When calling from the cellphone, "DIALING" is displayed MNUD-01-402 on LCD (2) and the sound from dialing is heard from the speakers.
Page 120 OPERATOR’S STATION  Incoming Call When a call comes in, "CALLING" is displayed on LCD (2), regardless of the band (or operation), and the speaker rings with the call. Press Hands-Free button (1) to answer. NOTE:  Even if the source of the radio unit is OFF when a call comes MNUD-01-402 in, the source automatically turns ON, and "CALLING"...
Page 121: Usb Device Input
OPERATOR’S STATION USB Device Input Plays audio files via USB connection with a cell phone or audio playback device. USB Specifications Rated Current Max. 2 A Output Voltage 5.00 V when USB cable is not connected. Applicable Data Format MP3, WMA, AAC, WAV NOTE: MP4 or other formatted files may not be played and MNUD-01-402 skipped.
Page 122 OPERATOR’S STATION Change Track Press [2] button (2) to start playing the next track. Press [1] button (1) to play the previous track. According to the connected device setting, pressing [1] button (1) returns to the top of the currently playing track. Then press [1] again to play the previous track.
Page 123 OPERATOR’S STATION Pause/Playback Pressing [3] button (1) while playing a track pauses playback. PAUSE label (4) is displayed. Pressing [3] button (1) again starts playing from where it was paused. MNUD-01-402 MNUD-01-430 Repeat Pressing [4] button (2) plays the same track repeatedly. REPEAT label (5) is displayed.
Page 124: Setting Screens
OPERATOR’S STATION Setting Screens Allow changes to the various settings. Press rotary switch (1) from any source screen to display setting screen (2). Or select SETTING from the source selection operation. Refer to page 1-56 "Selecting Source" for details. MNUD-01-402 There are 7 setting menu and their submenu.
Page 125 OPERATOR’S STATION Sound Setting 1. From "SOUND" setting menu, highlight the desired item to adjust by rotating rotary switch (1) and push rotary switch (1). 2. The setting screen appears. 3. Make adjustment by rotating rotary switch (1). 4. Push rotary switch (1) to fix the adjustment. MNUD-01-402 5.
Page 126: Brightness Adjustment
OPERATOR’S STATION Brightness Adjustment 1. From "BRIGHTNESS" setting menu, highlight the desired item to adjust by rotating rotary switch (1) and push rotary switch (1). 2. The setting screen appears. 3. Make adjustment by rotating rotary switch (1). 4. Push rotary switch (1) to fix the adjustment. MNUD-01-402 5.
Page 127 OPERATOR’S STATION Pairing The pairing authenticates up to 16 Bluetooth® devices for use with this radio unit. NOTE: When the pairing is tried for the 17th device, it replaces any of the current 16 devices. To delete a Bluetooth® device, refer to page 1-76 for procedure. 1.
Page 128 OPERATOR’S STATION Handfree Setting 1. Highlight "HANDSFREE" menu by rotating rotary switch (1) and push rotary switch (1). 2. AUTO ANSWER setting appears on LCD (2). 3. Select "OFF" and push rotary switch (1) to disable the auto-answering to an incoming call. 4.
Page 129 OPERATOR’S STATION Bluetooth® Connection This specifies the connection method to the device after Bluetooth® pairing. 1. From "Bluetooth® CONNECT" menu, highlight "AUTO CONNECT" by rotating rotary switch (1) and push rotary switch (1). 2. Select either OFF or ON and push rotary switch (1). OFF: Disable auto-connection to a Bluetooth®...
Page 130 OPERATOR’S STATION Deleting Bluetooth® Device The selected device is deletec from the device list from Bluetooth® CONNECT - DELETE menu. Highlight a desired device and push rotary switch (1). Select "YES" and push rotary switch (1) to delete the selected device. MNUD-01-402 MNUD-01-441 1-76...
Page 131: Time Adjustment
OPERATOR’S STATION Clock Display The current time is displayed on LCD (2). 1. From "CLOCK" menu, highlight "DISP" by rotating rotary switch (1) and push rotary switch (1). 2. Highlight a desired setting and push rotary switch (1). OFF: No time display MNUD-01-402 Time display in 24-hour format MNUD-01-442...
Page 132 OPERATOR’S STATION Information The current setting values are displayed. 1. From "INFORMATION" menu, highlight a desired setting by rotating rotary switch (1) and push rotary switch (1). 2. The current setting(s) are displayed. If there are 4 or more submenu, rotate rotary switch (1) to display them. MNUD-01-402 NOTE: The REGION setting and VERSION information are additionally displayed in this menu.
Page 133: Break-In
BREAK-IN Observe Engine Operation Closely IMPORTANT: Be extra cautious during the first 100 hours, until you become thoroughly familiar with the sound and feel of your new machine. 1. While operating the machine, limit the maximum engine horsepower to about 80 % of full load. 2.
Page 134 BREAK-IN MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 135: Operating The Engine
OPERATING THE ENGINE Check Before Starting 1. Check that forward/reverse lever (1) is in the neutral (N) position and that neutral lever lock (2) is in the lock position. NOTE: Unless both forward/reverse lever (1) is in neutral (N), the engine will not start. MNBC-01-011 2.
Page 136 OPERATING THE ENGINE 5. Adjust the position of outside rear view mirror (9) and room rear view mirror (10) so that the best rear visibility can be obtained. M4EK-01-035 6. While seated on the operator’s seat with your back in contact with the backrest, adjust each function of the seat so that the brake pedal can be fully applied.
Page 137: Starting Engine
OPERATING THE ENGINE Starting Engine Start the engine following the procedures below. 1. Check that parking brake switch (1) is in the ON position. 2. Check that forward/reverse selector lever (2) is placed in neutral (N). 3. Check for burned indicator bulbs When key switch (3) is turned to ON position (6), all indicators and warning lights will come and stay ON.
Page 138 OPERATING THE ENGINE Starting in Cold Weather Preheating 1. Turn key switch (3) to ON position (6) to preheat the engine. 2. Preheat indicator (8) turns ON. The engine is preheated until the preheat indicator goes OFF. NOTE: Preheating time differs depending on the coolant temperature.
Page 139: 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 the monitor operation: 1. Check that discharge warning indicator (1) is off. In case the discharge warning indicator stays ON, immediately stop the engine.
Page 140: Using Booster Batteries
OPERATING THE ENGINE Using Booster Batteries DANGER: An explosive gas is produced while batteries are in use or being charged. Keep open flames and sparks away from the battery area. Park the machine and a machine with the booster batteries on a dry or concrete surface, not on steel plates.
Page 141 OPERATING THE ENGINE 1. Connecting the booster battery 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 142: Warm Up Operation
OPERATING THE ENGINE Warm Up Operation If the machine is operated excessively with the hydraulic oil temperature below 20 °C (68 °F), damage to the hydraulic components may result. After starting the engine, warm up the hydraulic system as described below before operating the Front machine until the hydraulic temperature is above 20 °C (68 °F).
Page 143: Warm Up Operation In Cold Weather
OPERATING THE ENGINE Warm Up Operation in Cold Weather IMPORTANT: In case the hydraulic oil temperature is low, perform warm-up. Operate the machine only after the loader boom and bucket operating speeds are normal. Be sure to warm up not only to protect the hydraulic components from being damaged but also to ensure safe operation.
Page 144: Stopping Engine
OPERATING THE ENGINE Stopping Engine Stop the engine in the following procedures. 1. Lower the bucket before stopping the engine. 2. Run the engine at low idle speed for 5 minutes to cool the engine. Do not idle for excessively long periods. Observe local and federal engine idling regulations.
Page 145: Driving The Machine
DRIVING THE MACHINE Driving Machine Driving Correct operation will result in extending the service life of each part and component as well as saving fuel and oil. Always be sure to safely and efficiently operate the machine while paying attention to the following points. Precautions for Starting to Move 1.
Page 146: Starting To Move
DRIVING 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. 1. Check that none of the warning indicators except parking brake indicator (1) on the monitor panel is ON. 2.
Page 147 DRIVING THE MACHINE 4. Step on brake pedal (5) and depress parking brake switch (6) to the OFF position to release the parking brake. Check that at this time parking brake indicator (1) go OFF. NOTE: When starting to move on a slope. While stepping on the brake pedal, depress the accelerator pedal (7).
Page 148: Parking Brake Switch
DRIVING THE MACHINE Parking Brake Switch WARNING: To prevent the occurrence of accidents due to runaway of the machine, be sure to apply the parking brake when parking the machine and before leaving the machine. Never apply the parking brake switch (1) while the machine is moving except in an emergency.
Page 149: Changing Travel Speed
DRIVING THE MACHINE Changing Travel Speed Travel speed of this machine is automatically shifted. Travel modes, LOW (work) and AUTO (Travel), are shifted by operating Travel mode switch (1). When Travel mode switch (1) is in the LOW (Work) mode position, green light (2) comes ON. LOW (Work) mode: Used to drive at the first speed stage, or to perform excavation or loading...
Page 150: Steering
DRIVING THE MACHINE Steering WARNING: Avoid sudden steering changes while driving the machine at high speeds, while driving on a steep slope, or while raising the lift arm to the maximum position. Failure to do so may cause the machine to turn over. Never attempt to stop the engine while steering the machine.
Page 151: Stop And Restart Of Travel
DRIVING THE MACHINE Stop and Restart of Travel Follow the tips described below when required to provisionally stop or restart driving. 1. Slowly release the accelerator pedal. Depress the service brake pedal to stop the machine. 2. Slowly depress the accelerator pedal while releasing the service brake pedal to move the machine again.
Page 152 DRIVING THE MACHINE  Make it a habit to periodically scan the gauges and instruments. If any abnormality is recognized, immediately stop the machine and check the machine for the cause of the trouble.  When required to drive on the road shoulder or in tight spaces, use a signal person.
Page 153: Precautions For Driving On Slopes
DRIVING THE MACHINE Precautions for Driving on Slopes WARNING: When descending a slope, do not drive the machine at a speed faster than the maximum travel speed. Damage to the machine and/or serious personal accident may result. When steering on a slope, lower the loader front to increase the machine stability.
Page 154: Precautions To Be Taken If The Machine Failure Occurs
DRIVING THE MACHINE Precautions to Be Taken if the Machine Failure Occurs  Remain alert. While paying attention to the vehicles following you, slowly reduce the travel speed and park the machine on the road shoulder as closely to the shoulder edge as possible.
Page 155: Stop/Parking
DRIVING THE MACHINE Stop/Parking 1. Avoid sudden deceleration. Smoothly reduce the travel speed. Release accelerator pedal (1) and step on brake pedal (2) to stop the machine. 2. Stop and park the machine on level surface. Lower the bucket level to the ground. 3.
Page 156 DRIVING THE MACHINE 7. Turn the key switch (10) to OFF position (11) to stop the Front engine. Remove the key from the switch. IMPORTANT: If the key switch (10) is left in ON position (12), the batteries will discharge. Be sure to turn key switch to OFF position (11) before leaving the machine.
Page 157: Emergency Occasions
DRIVING THE MACHINE Emergency Occasions If the Engine Stalls During Traveling The parking brake is automatically applied so that the machine is stopped. As the hydraulic system becomes deactivated, the steering system becomes very difficult to operate. Horizontally lower the front attachment such as the bucket to the ground to ensure safety.
Page 158 DRIVING THE MACHINE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 159: Operating The Machine
OPERATING THE MACHINE Loader Control Lever Single-Lever Type Is used to operate the lift arm and/or bucket. (C) Float: The lift arm free falls and can be moved as loads Front are applied. (B) Lift arm Lower (N) Hold: The lift arm and bucket are stopped and held in that position.
Page 160: Lever Locks
OPERATING THE MACHINE Lever Locks WARNING: When locking the loader control lever and the auxiliary control lever (3) (optional), securely shift lever locks (2), (4) to the LOCK position. Unless lever locks (2), (4) are fully moved to the LOCK position, the control levers are not locked, possibly creating a LOCK hazardous situation.
Page 161: Adjustment Of Bucket Auto Leveler
OPERATING THE MACHINE Adjustment of Bucket Auto Leveler WARNING: Be careful to avoid personal injury and/ or death when adjusting the bucket auto leveler. Stop the engine. Lower the loader front attachment to the ground to release the remaining pressure the hydraulic circuits.
Page 162: Before Operation
OPERATING THE MACHINE Before Operation WARNING: Be sure to install only authorized buckets and other work tools on the front attachment. Never modify or increase the capacity of the bucket or other work tools without first receiving authorization. Do not overload the machine by installing additional counterweights.
Page 163: Avoid Overloading
OPERATING THE MACHINE Avoid Overloading WARNING: Do not penetrate the bucket into piles of soil and/or gravel at fast travel speed to avoid accidents. Avoid excavating or scooping loads when the machine is articulated, which could possibly cause the machine to turn over. Avoid Rapid Steering Changes and/or Sudden Braking WARNING: Always maintain a flat work site surface.
Page 164: Excavation
OPERATING THE MACHINE Excavation Loading Accumulated Soil Scoop load while traveling forward as described below. As load increases the wheels begin to slip, slightly raise the bucket to reduce the load. 1. Level the bucket with the surface of the ground. Penetrate the bucket into the accumulated soil while M4EK-05-001 traveling forward.
Page 165: 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 degrees. This may result in cracking or damaging the work tools. Slightly position the bucket teeth downward (0 to 10 degrees) and dig the ground while traveling forward as described below.
Page 166: Grading
OPERATING THE MACHINE Grading IMPORTANT: Be sure to perform grading work while traveling in reverse. If grading work is performed by traveling forward, severe loads are applied to the front attachment, possibly creating cracks or damage to the front attachment. 1.
Page 167: Loading
OPERATING THE MACHINE Loading IMPORTANT: Always maintain a clean travel surface. Cleaning of materials such as soil spilled on the driving surface will reduce wear and/or damage on tires. IMPORTANT: When carrying loads in the bucket, pay attention to the travel surface conditions. Travel at such speed so that the load will not spill out of the bucket, while positioning the bucket at the lowest possible height.
Page 168 OPERATING THE MACHINE Loader and Dump Track Combination Method A loader carries out loading and carrying and dumping is carried out by a dump truck. Either V- or I-shape loading method is employed in this method. Depending on the work site conditions encountered and matching with available trucks, select the most efficient method.
Page 169: Dozing
OPERATING THE MACHINE Dozing Dozing stands for a working method performed by a wheel loader using the wheel loader bucket in place of a bulldozer blade. This operation method is employed when reclaiming land or dumping material into a hopper that is below ground level.
Page 170: Removing Snow
OPERATING THE MACHINE Removing Snow CAUTION: Remove snow in the same method as employed in general loading work. However, pay attention to slippage of tires and obstacles covered with snow. Precautions for removing snow  Avoid sudden starting and stopping as well as rapid steering of the machine.
Page 171: 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 THE MACHINE” in the “DRIVING THE MACHINE” section. 2.
Page 172 OPERATING THE MACHINE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 173: Transporting
TRANSPORTING Transporting by Road When transporting the machine on public roads, be sure to first understand and follow all local regulations.  For transporting using a trailer, check the width, height, length and weight of the trailer when the machine is loaded.
Page 174: Transporting
TRANSPORTING Loading/Unloading CAUTION: Pay attention to the following points:  Steering on a ramp is hazardous. Never attempt to steer the machine on a ramp. Personal injury or death may result due to loss of machine stability. If the travel direction must be changed on a slope, back machine to flat ground.
Page 175 TRANSPORTING Transporting CAUTION: Securely fasten the machine to the trailer flatbed with appropriate accessories (wire ropes/ chains, tighteners.) Do not use the optional lifting tools. The machine may move back and forth and/or laterally during transportation. M4FG-06-001 1. Apply the parking brake. Slowly rest the bucket on the trailer deck or load-carrying platform.
Page 176: 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.
Page 177 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 is to be unavoidably towed, beware of the following points.
Page 178 TRANSPORTING Removal of Propeller Shafts WARNING: After removing the propeller shafts, the machine becomes impossible to stop even if the brake system is activated, possibly resulting in personal injury or death. Before removing or installing the propeller shafts, chock the tires. The propeller shafts are removed only when the machine must be towed with the engine inoperable.
Page 179 TRANSPORTING Relieving HST Hydraulic Pressure CAUTION: Do not tow the machine at travel speed faster than 2 km/h and in a distance longer than 1 km (0.6 mile). The HST hydraulic pressure must be reset to the original set pressure after towing is complete. Contact your nearest authorized dealer and have the machine inspected and serviced.
Page 180 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, securely chock the tires. CAUTION: As soon as towing operation is complete, connect the parking brake.
Page 181: Towing Method
TRANSPORTING Towing Method CAUTION: Use wire rope having the strength more than approx. 150 % of the machine weight.  Towing from the front side of the machine; When using wire ropes, be sure to attach wire ropes to the front frame. Always use soft material at the corners between the front frame and wire ropes to prevent damage to wire ropes.
Page 182: Lifting Machine
TRANSPORTING Lifting Machine WARNING: Pay attention to the following points:  The lifting tools are option. Install specific lifting tools at your nearest authorized dealer.  Use lifting cables and other lifting tools free from any damage and/or aging, and having sufficient strength.
Page 183: Maintenance
IMPORTANT:  Use only recommended fuel and lubricants.  Be sure to use only genuine Hitachi parts. Failure to do so may result in serious injury or death and/or machine breakdown.  Use only genuine Hitachi parts.
Page 184: Check The Hour Meter Regularly
 Lubricate, make service checks and adjustments at intervals shown on periodic maintenance guide table (see page 7-4). Use Correct Fuels and Lubricants IMPORTANT: Always use recommended fuels and lubricants. Failure to do so will result in machine damage and loss of Hitachi product warranty.
Page 185: Layout
MAINTENANCE Layout MNBD-07-001 1- Cutting edge 16- Engine 2- Lift arm cylinder rod pin 17- Battery 3- Bucket 18- Radiator/Oil cooler 4- Bell crank pin 19- Backup light 5- Bucket cylinder rod pin 20- Rear combination light 6- Bucket auto-leveler 21- Fuel filter 7- Bucket cylinder 22- Air cleaner...
Page 186: Maintenance Guide Table
MAINTENANCE Maintenance Guide Table Lubrication Interval (hours) MNBC-07-001 Item Page Item Page 1 Grease (Front Joint Pins) 7-18 8 Grease (Propeller Shaft) 7-21 2 Main Fuel Filter 7-47 9 Transmission Oil 7-26 3 Oil Separator (Blow-by Gases) 7-25 10 Hydraulic Oil 7-33 4 Engine Oil Filter 7-24...
Page 187: Preparations For Inspection And Maintenance
MAINTENANCE Preparations for Inspection and Maintenance CAUTION: If the machine is unexpectedly moved, a serious accident may result. Be sure to apply the parking brake when parking the machine. Unless especially specified, park the machine by following the procedures below before beginning the inspection and/or maintenance work.
Page 188: Lock Frames
MAINTENANCE Lock Frames CAUTION: Before beginning to work near the frame axle, install articulation lock bar (1) to securely lock and prohibit movement between the front and rear frames (3) and (4). Avoid accidents due to unexpected movement of the machine. 1.
Page 189: Engine Hood
MAINTENANCE Engine Hood WARNING: Open/close engine hood (1) only after stopping the engine. Failure to do so may create a very dangerous situation such as entanglement. Before traveling the machine, check that engine hood (1) does not open. Opening/Closing of Engine Hood  Canopy equipped machine 1.
Page 190: Periodic Replacement Of Parts
MAINTENANCE Periodic Replacement of Parts To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone.
Page 191: Maintenance Guide
MAINTENANCE Maintenance Guide Perform maintenance of items at the intervals shown by the shadowed areas in the table below. A. Greasing Intervals (Hours) Parts Quantity 1000 Daily 1 Month 3 Months 6 Months 1 Year Bucket pin   Bucket link pin ...
Page 192 MAINTENANCE B. Engine IMPORTANT: Be sure to use the specified oil. Change oil at the exactly specified intervals. If unspecified oil is used, or the oil change intervals are arbitrarily extended, serious engine failure or damage may result. Intervals (Hours) Parts Quantity 1000...
Page 193 MAINTENANCE D. Hydraulic System IMPORTANT: Be sure to use the specified oil. Change oil at the exact specified intervals. If unspecified oil is used, or the oil change intervals are arbitrarily extended, serious hydraulic system failure or damage may result. Intervals (Hours) Parts Quantity...
Page 194 MAINTENANCE G. Cooling System IMPORTANT: Be sure to use the specified LLC. Change LLC at the exact specified intervals. If unspecified LLC is used, or the LLC change intervals are arbitrarily extended, serious engine failure or damage may result. Intervals (Hours) Parts Quantity 1000...
Page 195 MAINTENANCE J. Tire Intervals (Hours) Parts Quantity 1000 Daily 1 Month 3 Months 6 Months 1 Year Check 1. Adjust tire pressure Adjust As needed 2. Check tires for Check damage 3. Check wheel bolt Retighten  tightening torque : Only first 50 hours K.
Page 196 MAINTENANCE L. Miscellaneous Intervals (Hours) Parts Quantity 1000 Daily 1 Month 3 Months 6 Months 1 Year 1. Check bucket bolt-on-cutting edge for tightness and/or wear 2. Check and replace seat belt Every 4 years (Replace) 3. Check canopy/cab damage and bolt tightness 4.
Page 197: Kind Of Oils
NLGI 2 EP IMPORTANT:  Hitachi Genuine Greases are specially designed and tested to provide optimum performance for Hitachi construction machinery, hence we recommend to use Hitachi Genuine Greases.  Do not use greases which do not meet the above specification or requirements. Use of unsuitable grease may lead to damage which is excluded from Hitachi Warranty Policy.
Page 198 TKTT15150-4th IMPORTANT:  Hitachi Genuine Axle Oils are specially designed and tested to provide optimum performance for Hitachi construction machinery, hence we recommend to use Hitachi Genuine Axle Oils. If other oil is used, which may lead to damage on the machine.
Page 199: List Of Consumable Parts
MAINTENANCE List of Consumable Parts 1. Filter Elements Part No. Engine Oil Filter 4454527 Fuel Main Filter YA00046445 Oil Separator Element (Blow-by Gases) YA00046446 Air Cleaner Element (outer) 3050211113 Air Cleaner Element (inner) 3050211112 Suction Filter 62J7812112 Return Filter 3367813111 HST Oil Filter 4630525 2.
Page 200: Greasing
MAINTENANCE A. Greasing CAUTION: Apply the parking brake and hold the front and rear frames rigidly with the articulation lock bar. NOTE: During break-in operation more than 50 hours until initial operational break-in is finished, grease the machine every day. In case excavations are performed in mud, water or snow, grease the machine after operation is complete.
Page 201 MAINTENANCE Bell Crank Pin (6) [1 point] --- every 250 hours or 3 months [Daily during first 50 hours] Lift Arm Cylinder Rod Pins (7) [Each 1 point on the right and left sides] --- every 250 hours or 3 months [Daily during first 50 hours] M4EJ-07A-002 Lift Arm Cylinder Pins (8) [Each 1 point on the right and left...
Page 202 MAINTENANCE Frame Center Hinge Pin (12) [1 point] --- every 250 hours or 3 months M4EJ-07A-006 Rear Axle Support Pins (13: Front Pin, 14: Rear Pin) (Each 1 point on the front and rear pins) ---every 100 hours or 1 month M4EK-07A-001 7-20...
Page 203 MAINTENANCE Front Propeller Shaft Universal (15) [1 point] --- every 500 hours or 6 months NOTE: When the machine is continuously operated under severe conditions for a long time, shorten the greasing intervals. In case the machine is operated in mud and/or water, grease the machine after operation is complete.
Page 204: Engine
MAINTENANCE B. Engine Check Engine Oil Level --- every 10 hours (before starting the engine) Check the oil level before starting the engine. Remove dipstick (1). Check for mixing of foreign matter or contamination in the oil. Wipe oil off the dipstick with a clean cloth. Reinsert dipstick (1) and remove it again.
Page 205: Change Engine Oil
MAINTENANCE Change Engine Oil --- every 250 hours or 3 months (Only first time at 100 hours or 1 month) This interval applies only when ultra low sulfur diesel fuel (ULSD) is not used. If ULSD is used (with less than % 0.05 ppm), the oil change interval can be extended to 500 hours.
Page 206: Replace Engine Oil Filter
MAINTENANCE Replace Engine Oil Filter --- every 250 hours or 3 months (Only first time at 100 hours or 1 month) WARNING: Immediately after the machine was operated, all engine parts are hot. Wait for the engine to cool before starting any maintenance work. Failure to do so may cause severe burns.
Page 207: Oil Separator Element (Blow-By Gases)
MAINTENANCE Oil Separator Element (Blow-by Gases) --- every 1000 hours or 1 year WARNING: Engine oil may be hot just after operation. Wait for oil to cool before starting work. Failure to do so may result in a burn. 1. Park the machine according to Preparations for Inspection and Maintenance (7-5).
Page 208: Power Train
MAINTENANCE C. Power Train Change Transmission Oil --- every 1000 hours or 1 year (Only first time at 250 hours or 3 months) WARNING: Unexpected movement of the machine may cause serious accident. When parking the machine, place Forward/Reverse lever (1) in neutral LOCK and neutral lever lock (2) in the lock position.
Page 209: Change Axle Oil
MAINTENANCE Change Axle Oil --- every 1000 hours or 1 year (only first time at 250 hours or 3 months) WARNING: Pay attention to the following points.  Immediately after the machine has been operated, all engine parts will be hot. Wait for the engine to cool before starting any maintenance work.
Page 210 MAINTENANCE Check Oil Level 1. Park the machine following the same procedures as described on page 7-5 for preparation of inspection/ maintenance work. 2. Install articulation lock bar (1) to the front and rear of the frame by following the procedures described on page 7-6.
Page 211: Clean Transmission Air Breather
MAINTENANCE Clean Transmission Air Breather --- every 500 hours or 6 months Air breather (1) is located at the upside of the transmission HST motor mounting section. 1. Clean the vicinity around air breather (1) before removing the air breather. 2.
Page 212: Check Surrounding Areas Around Axles And Covers For Oil Leaks
MAINTENANCE Check Surrounding Areas Around Axles and Covers for Oil Leaks --- every 1000 hours or 1 year Check the surrounding areas around the axles and covers for oil leaks. If any oil leaks are found, check the bolts in the oil leaking area for tightness.
Page 213: Hydraulic System
MAINTENANCE D. Hydraulic System Inspection and Maintenance of Hydraulic Equipment CAUTION: During operation, the parts in 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 7-5 for preparation of inspection/ maintenance work.
Page 214: 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 appropriate level. Failure to do so may result in serious failure in the hydraulic system. If the oil level is higher than the level gauge, remove oil down to the appropriate level.
Page 215: Change Hydraulic Oil/Clean Hydraulic Oil Tank
MAINTENANCE Change Hydraulic Oil/Clean Hydraulic Oil Tank --- every 1000 hours or 1 year Change/Cleaning WARNING: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation. Wait for the oil to cool before starting any maintenance work.
Page 216 MAINTENANCE 9. Remove oil filler port plug (2). Refill hydraulic oil while checking oil level with level gauge (6). Specified Oil Amount: Hydraulic Oil Tank Hydraulic System 33 L 38 L 10. Install oil filler port plug (2). 11. Start the engine. Slowly raise or lower the arm and tilt the bucket forward and backward.
Page 217: Clean Suction Filter
MAINTENANCE Clean Suction Filter --- each time when hydraulic oil is changed A suction filter is located on the bottom of the hydraulic oil tank. Clean the suction filter when changing hydraulic oil. 1. After draining hydraulic oil, remove suction hose (2) from the inside of hydraulic oil tank (1).
Page 218: Replace Hst Oil Filter Element
MAINTENANCE Replace HST Oil Filter Element --- every 1000 hours or 1 year (Only first time at 100 hours or 1 month) WARNING: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation.
Page 219 MAINTENANCE 6. Pour new hydraulic oil into filter (2) 7. Coat gasket (4) on new filter (2) with hydraulic oil. Install filter (2) to filter head (3) by turning the hexagonal section on the bottom of filter (2) with a wrench. After gasket (4) comes in contact with the seal surface on filter head (3), further tighten the element 3/4 turns.
Page 220: Replace Return Filter
MAINTENANCE Replace Return Filter --- every 1000 hours or 1 year (Only first time at 100 hours or 1 month) WARNING: Hydraulic oil becomes hot and pressurized during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil immediately after operation.
Page 221 MAINTENANCE 6. Pour new hydraulic oil into filter (2). 7. Coat gasket (4) on new filter (2) with hydraulic oil. Install filter (2) to filter head (3) by turning the hexagonal section on the bottom of filter (2) with a wrench. After gasket (4) comes in contact with the seal surface on filter head (3), further tighten the element by 3/4 turns.
Page 222: Check Hoses And Lines
MAINTENANCE Check Hoses and Lines --- every 10 hours (daily)/every 250 hours or 3 months WARNING: Escaping combustible fluid can cause fires. Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, and oil leaks. Escaping oil under pressure can penetrate the skin causing serious injury.
Page 223: Maintenance
MAINTENANCE Interval (hours) Check Points Abnormalities Remedies Every 250 hours Hose covers Crack (4) Replace Hose ends Crack (5) Replace Hose covers Exposed reinforcement (6) Replace Hose ends Blister (7) Replace M4GB-07-055 Hose Bend (8), Collapse (9) Replace Hose ends and Deformation or corrosion (10) Replace Fittings...
Page 224 MAINTENANCE Service Recommendations for Hydraulic Fittings Kinds of Hose/Line fittings Two hydraulic fitting designs are used on this machine. Flat Face O-ring Seal Fittings An O-ring is used on the sealing surface to prevent oil leakage. M4GB-07-062 1. Metal Face Seal Fittings Tight contact between metal flares on adaptor (1) and connector (3) of hose (5) prevents pressure oil leakage.
Page 225: Fuel System
MAINTENANCE E. Fuel System Check Fuel Level --- every 10 hours (daily) WARNING: Beware of fire. Fuel is flammable. Keep fuel away from fire hazards. Recommended Fuel Use only super high quality or high quality DIESEL FUEL (JIS K-2204) (ASTM D-975). Besides, using bad quality fuel, drainage agent, fuel MNBC-01-028 additives, gasoline, kerosene or alcohol refueled or mixed...
Page 226: Drain Water And Sediment From Fuel Tank
MAINTENANCE Drain Water and Sediment from Fuel Tank --- every 1000 hours or 1 year Before starting to operate the machine, loosen drain plug (1) on the fuel tank bottom to drain water and/or sediment from the fuel tank. Tighten plug when no more water is draining, and only fuel drainage is seen.
Page 227: Drain Water Separator
MAINTENANCE Drain Water Separator --- every 10 hours (check daily) IMPORTANT: Drain water separator daily before starting operation. The engine may be damaged if you do not drain it daily. The water separator acts to separate water from the fuel and functions via a float which rises when water accumulates.
Page 228 MAINTENANCE Bleed Air from the Fuel System NOTE: Air in the fuel system may cause the engine to become difficult to start or other engine trouble. In case the machine runs out of fuel in the fuel tank, after the fuel filter is drained, or the element is replaced, bleed air from the fuel system.
Page 229: Replace Main Fuel Filter Element
Fuel is dangerous as it can burn easily. Keep away from fire. IMPORTANT:  Only use genuine Hitachi elements for the main fuel filter element. Using a different element may adversely affect engine performance and/or shorten the engine service life. Note: any engine failure...
Page 230: Clean The Water Separator
MAINTENANCE Clean the Water Separator --- every 500 hours or 6 months CAUTION: Danger of Fire Fuel is dangerous as it can burn easily. Keep away from fire. IMPORTANT: Contact a recovery specialist or your authorized dealer to dispose of old oil and filters. Never dump waste illegally as doing so destroys our global environment.
Page 231: Check Fuel Hoses
MAINTENANCE Check Fuel Hoses --- every 10 hours (daily)/250 hours or 3 months 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 rub against each other, and fuel leaks.
Page 232: Air Cleaner
MAINTENANCE F. Air Cleaner Clean and Replace Air Cleaner Element Cleaning --- When the visual inspection type dust indicator becomes red. Replacement --- After cleaning 6 times (or every 1 year) CAUTION: Wear goggles or safety glasses when using compressed air [less than 0.2 MPa (2 kgf/cm MNBC-07-008 IMPORTANT: To clean element (2) (3), avoid bumping or striking element with other objects.
Page 233: Cooling System
MAINTENANCE G. Cooling System IMPORTANT: Use only long life coolant (LLC) described in the “Brand Names of recommended LLC”.Use fresh water or normal tap water. Do not use river-water, well- water or fountain–water which would have an adverse Cylinder Liner effect to the engine and radiator so that the cylinder liner would become corroded.
Page 234 MAINTENANCE Precautions for Handling Long Life Coolant (LLC) WARNING: Long life coolant (LLC) is poisonous.  If ingested by mistake, induce vomiting and get emergency medical attention immediately.  If antifreeze is accidentally splashed into eyes, freely flush with water and get emergency medical attention.
Page 235: Check Coolant Level
MAINTENANCE Check Coolant Level --- every 10 hours (daily) WARNING: Do not remove cap (4) 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 cap (4) to release the inside air pressure before removing cap (4).
Page 236: Check Fan Belt
MAINTENANCE Check Fan Belt --- every 10 hours (daily) Check fan belt (1) for any troubles. If any cracks are found, replace the belt with a new one. Check Fan Belt Tension --- every 250 hours or 3 months IMPORTANT: Loose fan belt may result in insufficient battery charging, engine overheating, as well as M4EJ-07G-003 premature belt wear.
Page 237: Change Coolant
MAINTENANCE Change Coolant --- every 1000 hours or 1 year CAUTION: Do not remove the radiator cap until the coolant temperature in the radiator cools. Hot steam and coolant may spout out, possibly causing severe burns. After the coolant temperature cools, slowly loosen the cap to release the inside air pressure before removing the cap.
Page 238: Clean Radiator, Oil Cooler And Inter Cooler Core
MAINTENANCE Clean Radiator, Oil Cooler and Inter Cooler Core --- every 100 hours, 1 month or when clogged WARNING: Wear safety glasses or goggles when using compressed air [less than 0.2 MPa (2 kgf/cm IMPORTANT: If air at a pressure higher than 0.2 MPa (2 kgf/cm ) or tap water under high pressure is used for cleaning, damage to the radiator/oil cooler/inter cooler...
Page 239: Electrical System
MAINTENANCE H. Electrical System Check Monitor Function and All Other Instrument Operation --- every 10 hours (daily) Run the engine at slow idle speed when checking the instruments. The monitor indicates alarm, caution and confirmation status in red, orange, and normal operative condition in blue or green respectively.
Page 240: Check Work Lights
MAINTENANCE Check Work Lights --- every 10 hours (daily) CAUTION: If any burned-out lights are found, immediately replace it with a new one. Visually check that all work lights normally light and/or blink from the front and rear sides of the machine. ME804-01-017 M4EK-01-014 Check Horn, Backup Alarm and Backup Light...
Page 241: Check Electrical Harnesses And Fuses
MAINTENANCE Check Electrical Harnesses and Fuses --- every 50 hours Check the electrical harness and terminals of the batteries, starter motor and alternator for loose connections and/ or short circuit (broken shield). If any burned mark or an abnormal smell is noticed on a harness, consult your nearest authorized dealer.
Page 242: Fuse Box
MAINTENANCE Fuse Box Amperes Circuit 15 A Headlight (OP) 15 A Hazard Lamp (OP) Controller, Electronic Key (1) (OP), Tachograph (1)(OP) 30 A Engine (1), ECM Cab Light (Cab) Engine (3), Airflow Sensor 15 A Engine (2), EGR, Fuel Pump, Oil Separator 10 A Key On, Electronic Key (2) (OP), Tachograph (2) (OP) 10 A...
Page 243 MAINTENANCE Battery WARNING: Explosive gas is generated during use and/or charging of batteries. Keep sparks and Open flames away from batteries. Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result. Charge the batteries in a well ventilated location.
Page 244 MAINTENANCE  Working around the battery immediately after operation may cause personal injury. Wait for the battery to cool.  When the battery is recharged, flammable hydrogen gas is created. Remove the battery from the machine. Recharge the battery after removing the caps in a well ventilated area.
Page 245 MAINTENANCE In case the batteries were discharged WARNING:  Hydrogen gas is generated from batteries. Incorrect handling of the batteries may cause fires and/or explosion. Keep tobacco and/or open flame away from the batteries.  If a metal tool is placed across the positive battery terminal and a vehicle component such as the engine block, sparks will fly, possibly resulting in fire and/or explosion.
Page 246 MAINTENANCE Method to Replace with Charged Auxiliary Batteries  Once the battery has been fully discharged, the service life of the battery is shortened. Replace such batteries with new ones at the earliest opportunity.  Correctly and securely connect battery plus (+) post to cable plus (+) terminal and battery minus (-) post to cable minus (-) terminal respectively.
Page 247: Check Electrolyte Level
MAINTENANCE Check Electrolyte Level --- every 100 hours or 1 month Check the electrolyte level at least once a month. 1. Park the machine on level ground and stop the engine. 2. Check the electrolyte solution level. 2.1 When checking the level from the battery side: Clean around the level check lines with a wet towel.
Page 248: Check Electrolyte Specific Gravity
MAINTENANCE Check Electrolyte Specific Gravity --- every 250 hours or 3 months The electrolyte specific gravity varies depending on the electrolyte temperature. The specific gravity should be kept within the range shown below. Charge the battery if the specific gravity is below the limit. Recommended range of specific gravity by electrolyte temperature 40 °C [104 °F]...
Page 249: Brake System
MAINTENANCE I. Brake System Check Brake Oil Level --- every 10 hours (daily) or when the brake oil indicator comes ON WARNING: Do not continue to operate the machine with the brake oil level reduced, possibly resulting in personal injury or death. If the brake oil indicator comes ON, immediately stop operation of the machine.
Page 250: Check Right And Left Brake Interlocking Performance
MAINTENANCE Check Right and Left Brake Interlocking Performance --- every 10 hours (daily) WARNING: Put up a No Entrance notice 100 m ahead of the machine forward travel direction. Arrange a safety monitor person. WARNING: Do not allow dust and/or soil to accumulate in vicinity of the brake pedal.
Page 251: 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 ahead in the traveling direction. Keep bystanders away from the machine. Condition: Empty bucket Park the machine with no load applied on a 15° inclined dry surface slope.
Page 252: Tire
MAINTENANCE J. Tire Check and Adjust Tire Pressure Check appearance --- every 10 hours (daily) Check tire pressure when appearance is questionable or each week (50 hrs.) Adjust --- as necessary WARNING: Secure the front and rear chassis with the articulation lock bar and pins.
Page 253: Check Tire For Damage
MAINTENANCE Check Tire for Damage --- every 10 hours (daily) WARNING: If tire has external damaged such as a score, an accident due to puncture or burst of the tire may occur, possibly resulting in personal injury or death. Check the external appearance of tires for any damage. Check Wheel Bolt Torque --- every 500 hours (Only first time at 50 hours) Be sure to check the wheel bolt torque by turning the bolt in...
Page 254 MAINTENANCE Tire sizes to be used NOTE: Consult with your nearest authorized dealer about the optional tire patterns. The machine may vibrate depending on tire pattern. This is caused by resonance of the machine with the tire pattern, not by failure. Standard size Standard air pressure 15.5/60-18-8PR...
Page 255 MAINTENANCE Tire Rotation Rotate tires when uneven or abnormal wear is recognized on either front or rear, or right and left tire. Tire rotation is recommended to achieve uniformity of wear on tires or equalization of tire service life. Correct Incorrect Rotation Method WARNING: Install tire with no external damage such...
Page 256: Removal And Installation Of Tire
MAINTENANCE Removal and Installation of Tire WARNING: Mounted tire assembly is a very heavy part so that removal and installation of tire is hazardous and difficult work. In addition, a crane to lift the tire is required when removing or installing the tire to the wheel.
Page 257: Air Conditioner
MAINTENANCE K. Air Conditioner Check Air Conditioner for Damage --- every 6 months Check the heater mounting and hoses for any damage. NOTE: When the cold season approaching, check the heater before it is actually required to be sure it is operable at any time.
Page 258: Clean And Replace Circulation Air Filter For Air Conditioner
MAINTENANCE Clean and Replace Circulation Air Filter for Air Conditioner Clean Circulation Air Filter --- every 250 hours (or once a month whichever comes first) Replace Circulation Air Filter --- after cleaning 6 times (or when restricted excessively) NOTE: When the machine is operated in dusty work site, shorten intervals of cleaning and/or replacement.
Page 259: Check Air Conditioner Unit
MAINTENANCE Check Air Conditioner Unit --- every 6 months Check the air conditioner switch panel, the air conditioner unit, the condenser and the hoses for any abnormality. NOTE: Inspect the air conditioner prior to the in-season to allow it to be operable at any time. During off-season when the air conditioner is not in use for a long period of time, perform cooling operation once a week to prevent the lubrication parts of the air conditioner from becoming dry...
Page 260: Check Air Conditioner Condenser
MAINTENANCE Check Air Conditioner Condenser --- every 6 months If condenser (1) is contaminated with dust or debris, cooling performance will be reduced. Remove cover (2) from the top of condenser (1). Wash fins on condenser (1) to remove dust and contamination with tap water.
Page 261: Check Refrigerant Quantity
MAINTENANCE Check Refrigerant Quantity --- every 6 months After performing cooling operation for 2 to 3 minutes with the engine running at 1500 min (rpm), check the refrigerant through sight glass (checking window) (1). Refrigerant R134a has been adapted on this machine as refrigerant. Supply new refrigerant by correct quantity only after withdrawing the residual refrigerant thoroughly.
Page 262: Miscellaneous
MAINTENANCE L. Miscellaneous Check Bucket Bolt-On Cutting Edge for Tightness and/or Wear --- every 10 hours (daily) Check the bucket cutting edge for wear and tightness. Replacement WARNING: Guard against injury from flying pieces of metal. Wear protection such as safety glasses and a hard hat when servicing the machine.
Page 263: Check And Replace Seat Belt
MAINTENANCE Check and Replace Seat Belt Check --- every 10 hours (daily) Replace --- every 3 years Examine seat belt tongue (1), buckle (2) and seat belt. Replace the damaged or worn parts. Check if the seat belt is correctly reeled in. Replace the seat belt every 3 years, regardless of appearance.
Page 264: Check Play In Steering Wheel Stroke
MAINTENANCE Check Play in Steering Wheel Stroke --- every 10 hours (daily) WARNING: When the steering wheel is turned, clearance between the front and rear chassis becomes narrower, possibly creating a pinch point hazard. Keep all personnel away from the articulation joint during inspection.
Page 265: 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 selector lever to neutral. Apply the parking brake. After leveling and resting the bucket on the ground, set the wheel chock blocks.
Page 266: Check Outside And Inside Rearview Mirrors
MAINTENANCE Check Outside and Inside Rearview Mirrors --- every 10 hours (daily) Check that inside rearview mirror (1) and outside rearview mirror (2) (on the cab equipped machine) are facing in the correct direction. Check inside rearview mirror (1) and rearview mirror (2) for contamination or damage.
Page 267: Check And Adjust Valve Clearance
MAINTENANCE Check and Adjust Valve Clearance --- every 1000 hours or 1 year Consult your nearest authorized dealer for inspection and repair. Check Sound Absorbing Mat Around Engine --- every 1000 hours or 1 year CAUTION: If the sound absorbing mat in the engine compartment loosens, the mat may come in contact with the high temperature sections of the engine, possibly resulting in fires.
Page 268: Check Engine Compression Pressure
MAINTENANCE Check Engine Compression Pressure --- every 1000 hours (or 1 year whichever comes first) Consult your nearest authorized dealer for inspection and repair. Check and Clean Starter and Alternator --- every 1000 hours or 1 year Consult your nearest authorized dealer for inspection and repair.
Page 269: Tightening And Retightening Torque Of Nuts And Bolts
MAINTENANCE Tightening and Retightening Torque of Nuts and Bolts Tighten or retighten nuts and bolts used on this machine in accordance with the torque values shown in the following table. Check nuts and bolts for tightness and verification that they are in place before and after operation. If any loose or missing nuts and/or bolts are found retighten or supply replacement parts.
Page 270 MAINTENANCE Tightening Torque Chart Hexagon Wrench Socket Bolt Bolt Dia. Socket Bolt Wrench size Wrench size N·m (kgf·m) N·m (kgf·m) N·m (kgf·m) N·m (kgf·m) 3.3 to 4.2 (0.3 to 0.4) (3.0) (2.0) (1.0) (2.0) (6.5) (5.0) (2.0) (5.0) (11) (9.0) (3.5) (9.0) (18)
Page 271 MAINTENANCE 1. Front axle mounting bolt Bolt diameter Quantity M4EJ-07M-001 2. Rear axle support mounting bolt Bolt diameter Quantity M4EJ-07M-002 3. Wheel rim mounting bolt Bolt diameter Quantity M4EJ-07M-003 7-89...
Page 272 MAINTENANCE 4. Propeller shaft mounting bolt Bolt diameter Quantity M4EJ-07A-010 M4EJ-07A-009 5. Rear propeller shaft mounting bolt Bolt diameter Quantity M4EJ-07A-011 6. Transmission mounting bolt: Bracket Bolt diameter Quantity M4EK-07M-003 7-90...
Page 273 MAINTENANCE 7. Transmission mounting bolt: Rubber cushion Bolt diameter Quantity M4EK-07M-003 8. Engine mounting bolt: Bracket (Rear) Bolt diameter Quantity 9. Engine mounting bolt: Bracket (Front) Bolt diameter Quantity M4EK-07M-002 10. Engine mounting bolt: Rubber cushion Bolt diameter Quantity M4EK-07M-002 7-91...
Page 274 MAINTENANCE 11. Counterweight mounting bolt Bolt diameter Quantity M4ER-07-004 12. Center pin top locking Bolt diameter Quantity M4EJ-07M-010 13. Center pin bottom locking Bolt diameter Quantity M4EJ-07M-011 14. Steering cylinder pin locking Bolt diameter Quantity M4EJ-07A-004 7-92...
Page 275 MAINTENANCE 15. Radiator frame mounting nut Bolt diameter Quantity M4EK-07M-001 16. Cutting edge mounting nut Bolt diameter Quantity M4EJ-07L-001 7-93...
Page 276 MAINTENANCE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................7-94...
Page 277: Maintenance Under Special Environmental Conditions
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Maintenance Under Special Environmental Conditions Operating Conditions Precautions for Maintenance Muddy Soil, Rainy or Before Operation: Check tightness of plugs and all drain cocks. Snowy Weather After Operation: Clean the machine and check for cracks and damage. Check for loose or missing bolts and nuts.
Page 278: Maintenance Under Special Environmental Conditions
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS Precautions for Maintenance During Cold Weather Season Before the atmospheric temperature lowers below 0 °C (32 °F), note the following points.  Water and oil in the machine will freeze.  Road surfaces will freeze so that tires may slip. Keeping the above points in mind, follow the advisement below: 1.
Page 279 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 8. After warming up the engine, cycle the front attachment system. Slowly operate the control levers to move the cylinders full stroke several times. 9. Road surfaces covered with snow, especially when snow has been compacted, will be frozen. Use tire chains on four wheels.
Page 280 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 281: Storage
STORAGE Storing the Machine WARNING: In case lubrication is performed indoors, open windows and doors to maintain good air ventilation to prevent asphyxiation. Lubricant property will deteriorate even if the machine is kept stored. Check all lubricants before operating the machine after 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 282: Removing The Machine From Storage
STORAGE Removing the Machine from Storage WARNING: In case lubrication is performed indoors, open windows and doors to maintain good air ventilation to prevent asphyxiation. Lubricant property will deteriorate even if the machine is kept stored and not run. Check all lubricants before operating the machine after bring stored.
Page 283: 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 284 TROUBLESHOOTING 4. Hydraulic Control Lever Symptom Cause Solution Hard to move Rusted joint * Lubricate or repair Worn pusher * Replace Does not move smoothly Worn pusher * Repair or replace Faulty control valve * Replace Does not return to neutral Faulty control valve * Replace The lever is tilted in the...
Page 285 TROUBLESHOOTING 6. Drive Function Problem Cause Solution Steering wheel is heavy to Faulty hydraulic pump * Repair, Replace operate. Faulty steering device * Repair, Replace Relief valve set pressure reduction * Adjust Faulty steering column * Repair, Replace Low tire air pressure * Inflate Steering wheel turns in Faulty steering device...
Page 286 TROUBLESHOOTING MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................11-4...
Page 287 SPECIFICATIONS Specifications MNBB-12-001 Model — ZW50-5B Bucket Capacity: heaped 0.6 (BOC) Operating Weight (Canopy/Cab) 3760/4000 Rated Loading Weight Engine Model — Kubota D1803-CR-TIE4B Engine Flywheel Power (SAE J1995 Gross) — 30.1 kW/2200 rpm A: Overall Length 4665 B: Overall Width (Bucket) 1690 C: Overall Height (Canopy/Cab) 2565 /2595...
Page 288: Specifications
SPECIFICATIONS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................12-2...
Page 289: Optional Attachments
OPTIONAL ATTACHMENTS Handling Quick Coupler (Mechanical Type) WARNING: During work, keep other persons away from the machine. The quick coupler is a system with which a front attachment work tool such as a bucket can be easily replaced with other work tool.
Page 290: Installation
OPTIONAL ATTACHMENTS Installation WARNING: Be sure to complete installation work only after checking that coupler pins (5) (both right and left) have been installed. WARNING: Before leaving the machine, apply the parking brake. 1. After checking that coupler pins (5) have been removed. Slowly approach the machine to the bucket (attachment) M4EJ-13-004 hooks (6) until the hooks are inserted into the quick...
Page 291 OPTIONAL ATTACHMENTS Disconnecting/connecting hydraulic hose quick connectors When activating an attachment with a hydraulic cylinder other than the lift arm cylinder or bucket cylinder using the machine hydraulic pressure oil, hydraulic quick connectors must be connected or disconnected. At this time, connect Plug (Male) Sleeve (Female) or disconnect the hydraulic hoses following the procedures...
Page 292 OPTIONAL ATTACHMENTS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................13-4...
Page 293 INDEX Check Air Conditioner Unit ............7-77 Check and Adjust Tire Pressure ..........7-70 Accelerator Pedal ................1-29 Check and Adjust Valve Clearance ......... 7-85 Adjust Fan Belt Tension .............. 7-54 Check and Clean Starter and Alternator ......7-86 Adjust Operator’s Seat ..............S-6 Check and Replace Seat Belt ............
Page 294: Index
INDEX Clean the Water Separator ............7-48 Front Work Light Switch (Cab) ..........1-25 Clean Transmission Air Breather ..........7-29 Fuel Gauge ..................1-16 Clearance Light Indicator (Green) .......... 1-12 Fuel Level Indicator (Orange) ........... 1-11 Clock....................1-16 Fuel System ..................7-43 Coat Hook ..................
Page 295 INDEX Maintenance of the Air Conditioner Being Not in Use: ....................1-37 Radio Unit (CAB) (Optional) ............1-53 Maintenance Under Special Environmental Conditions ...9-1 Rear Window Wiper Switch (Cab) ........... 1-28 Miscellaneous ................7-80 Rear Work Light Switch (Cab, Optional) ....... 1-26 Monitor Display ................
Page 296 INDEX Towing Method ................6-9 Towing Pin ..................1-50 Transport Safely ................S-23 Transporting ..................6-3 Transporting by Road ..............6-1 Transporting by Trailer ..............6-1 Transporting Wheel Loader (Urgent Situation) ....6-4 Travel Mode Indicator (Optional) ..........1-15 Travel Mode Switch ..............1-34 Travel on Public Roads Safely ........... S-15 Turn Signal Indicator (Green) ...........

Hitachi ZW 50-5B Operator's Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Hitachi ZW 50-5B

Summary of Contents for Hitachi ZW 50-5B