Page 1 PART NO. ENMNCH-NA1-4 Operator's Manual Wheel Loader URL:http://www.hitachi-c-m.com Serial No. 005001 and up This book is printed on recycled paper. PRINTED IN JAPAN (K) 2020, 12...
Page 2 INTRODUCTION Read this manual carefully to learn how to operate and Warranty is provided as a part of Hitachi’s support service your machine correctly. Failure to do so could program for customers who operate and maintain their result in personal injury or machine damage.
Page 3 INDEX MACHINE NUMBERS SAFETY SAFETY SIGNS COMPONENTS NAME GETTING ON/OFF THE MACHINE OPERATOR’S STATION BREAK-IN OPERATING ENGINE DRIVING MACHINE OPERATING MACHINE TRANSPORTING MAINTENANCE MAI N TENANCE UNDER SPECI A L ENVI R ONMENTAL CONDI T I O NS STORAGE TROUBLESHOOTING SPECIFICATIONS OPTIONAL ATTACHMENTS INDEX...
Page 5: Table Of Contents
CONTENTS MACHINE NUMBERS ................1 Evacuating in Case of Fire ............S-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 Changing the Hydraulic Oil Hour Meter ......1-23 Sun Visor ..................1-59 Changing Hydraulic Oil Filter Hour Meter 1 ....1-24 Drink Holder ................... 1-59 Changing Hydraulic Oil Filter Hour Meter 3 ....1-25 Coat Hook ..................1-60 Changing Engine Oil Hour Meter ........1-26 Rearview Mirror ................
Page 7 CONTENTS Precautions for Driving on Slopes ..........4-9 Replace Axle Oil ............... 7-29 Precautions for Driving Speeds ..........4-10 Check Oil Level ................. 7-30 Precautions to be Taken if Machine Failure Occurs ..4-11 Clean the Oil Breather of the Transmission ....7-31 Stop ....................
Page 8 CONTENTS Check Lines ................7-79 Check Air Conditioner Condenser ........7-80 Check the AC Drive Belt ............7-80 Check Refrigerant Level ............7-81 Check the Compressor and Pulley ........7-81 Switch Operation ..............7-81 L. Miscellaneous ................7-82 Check for Looseness/Wear to the Bucket’s Bolt-On Cutting Edge ...............
Page 10: Machine Numbers
MACHINE NUMBERS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 12: Safety
Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine...
Page 13: Prepare For Emergencies
SAFETY Prepare for Emergencies Be prepared if a fire starts or if an accident occurs. Keep a first aid kit and fire extinguisher on hand. Thoroughly read and understand the label attached on the fire extinguisher to use it properly. To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire...
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 Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.
Page 15: General Precautions For Cab
SAFETY General Precautions for Cab Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.
Page 16: Use Handrails And Steps
SAFETY Use Handrails and Steps Falling is one of the major causes of personal injury. When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. Do not use any controls as hand-holds. Never jump on or off the machine.
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). It warns people when the machine starts to move.
Page 19: Operate Only From Operator's Seat
SAFETY Operate Only from Operator’s Seat Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. Start the engine only when seated in the operator's seat. NEVER start the engine while standing on the tire or on ground.
Page 20: Investigate Job Site Beforehand
SAFETY Investigate Job Site Beforehand When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.
Page 21: Equipment Of Head Guard, Rops, Fops
SAFETY Equipment of Head Guard, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) Any modification of the ROPS structure will modify its performances and its certification will be lost.
Page 22: Keep Riders Off Machine
SAFETY Keep Riders Off Machine Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. Only the operator should be on the machine. Keep riders off. Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.
Page 23: Drive Machine Safely (Work Site
SAFETY Drive Machine Safely (Work Site) Before driving the machine, always confirm that the steering wheel / and forward / reverse lever (switch) direction corresponds to the direction you wish to drive. Be sure to detour around any obstructions. Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.
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 to 400 mm (11.8 to 15.7 in) above the road surface as illustrated. SA-4EK-010 Avoid Injury from Rollaway Accidents Death or serious injury may result if you attempt to mount...
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. Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length. SA-4EK-019 Precautions for Operation If the front attachment or any part of the machine comes in...
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. Run the engine at low idle speed without load for 5 minutes.
Page 33: Transport Safely
SAFETY Transport Safely Take care that the machine may turn over when loading or unloading the machine onto or off of a truck or trailer. Observe the related regulations and rules for safe transportation. Select an appropriate truck or trailer for the machine to Less than 15 °...
Page 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. Keep hands, feet and clothing away from power-driven parts.
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. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire. SA-037 Warn Others of Service Work Unexpected machine movement can cause serious injury.
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 Explosive separation of a tire and rim parts can cause serious injury or death.
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. Periodically replace the rubber hoses.
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. Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and 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. Check and clean high temperature parts such as the exhaust outlet and mufflers earlier than the normal interval.
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. Exit the machine.
Page 43: Avoid Heating Near Pressurized Fluid Lines
Keep the units away from open flames and fire. Do not bore a hole, do not cut by torch. Avoid giving shocks by hitting or rolling the unit. Before disposing the unit, sealed gas must be released. Consult your nearest Hitachi dealer. S-33...
Page 44: Remove Paint Before Welding Or Heating
Keep bystanders out of the work site during operation. Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. S-34...
Page 45: Prevent Battery Explosions
SAFETY Prevent Battery Explosions Battery gas can explode. Keep sparks, lighted matches, and flame away from the top of battery. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm the battery to 16 °C (60 °F) first.
Page 46: Handle Chemical Products Safely
Dispose of Waste Properly 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 48: Safety Signs
SAFETY SIGNS 1. Both sides of bucket SS-4152 SS-4EK-017_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 unexpectedly be lowered, possibly resulting in personal injury. Lower the front SS-4FGE-003 attachment to the ground before inspecting/maintaining the machine.
Page 49 SAFETY SIGNS 4. Left Side of Front Console SS-4EK-005 E SS-4EK-021_E 5. Right Side of Front Console SS-4EK-022_E SS-4EK-005 E 6. Left side of steering wheel support WARNING: To minimize the injury due to an overturning accident, be sure to fasten the seat belt prior to operating the SS-4FGE-004 machine.
Page 50 SAFETY SIGNS 7. Steering wheel support SS-4FGE-004 SS-4EK-026_E 8. Steering wheel support SS-4FGE-004 SS-4EK-024_E S-40...
Page 51 SAFETY SIGNS 9. Both Side Vicinity of Step’s SS-4EK-027_E SS-4FGE-005 SS-4FGE-006 10. Left Side of Fender SS-4151 SS-4EK-028_E If the engine is started following an incorrect method, the machine suddenly may begin to move. Start the engine from the operator’s seat only. S-41...
Page 52 SAFETY SIGNS 11. Vicinity of Battery SS-4151 SS-4EK-029_E Skin contact with electrolyte will cause burns. Splashed electrolyte into eyes will cause blindness. Take care not to touch electrolyte. 12. Vicinity of Radiator Cap SS-4151 SS-4EK-031_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 SS-4151 SS-4EK-033_E SSYA00008686 Side indicates a hazard of rotating parts, such as belt fan. Turn off before inspection and maintenance. 15. Vicinity of Brake Oil Tank SS-4EK-035_E SS-4151 16. Both Sides of Counterweight SS-4EK-039_E SS-4FGE-009 Avoid machine reversing injuries.
Page 54 SAFETY SIGNS 17. Left Side of Front Frame SS-4EK-040_E SS-4FGE-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 SAFETY SIGNS 20. Vicinity of Fuel Tank Cap SS-4FGE-005 SS-4FGE-012 S-45...
Page 56 SAFETY SIGNS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................S-46...
Page 58: Components Name
COMPONENTS NAME 1- Bolt-On Cutting Edge (BOC) 2- Bucket 3- Bucket Link 4- Bell Crank 5- Bucket Cylinder 6- Front Combination Lamp (Turn Signal/Clearance Light/Hazard Lamp) 7- Headlight 8- Outside Rearview Mirror 9- Front Work Light 10- Cab 11- Rear Work Light MNCH-01-545 12- Fuel Filler Port 13- Articulation Lock Bar...
Page 60: Operator's Station
OPERATOR'S STATION Overall View of Operator’s Cab M4FG-01-005 1- Front Console 2- Right Console 3- Operator’s Seat 4- Floor Mat...
Page 62: Right Console
OPERATOR'S STATION Right Console Mono-Lever Type 1- Loader Control Lever 2- Attachment Control Lever 3- Control Lever Lock (for Attachment) 4- Spare (Optional) 5- Ride Control Switch (Optional) 6- Throttle Limit Switch 7- Key Switch 8- Control Lever Lock (for Front Control Lever) MNCH-01-548...
Page 63: Monitor Panel
OPERATOR'S STATION Monitor Panel 7 9 10 MNCH-01-531 1- Coolant Temperature Gauge 12- Brake Level Low Indicator 2- Left Turn Signal Indicator 13- (Not Being Used) 3- High Beam Indicator 14- Discharge Indicator 4- Monitor Display 15- Monitor Display Selector 5- Work Light Indicator (Optional) 16- Preheat Indicator 6- Right Turn Signal Indicator...
Page 64: 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 STOP indicator lights or the alarm sounds. Then check and service the part indicated. The STOP indicator comes on and the buzzer sounds in the following cases.
Page 65: Parking Brake Indicator (Red)
OPERATOR'S STATION Parking Brake Indicator (Red) The parking brake indicator lights when the parking brake is When the parking brake is ON, if the F-N-R lever is put in Forward (F) or Reverse (R), the buzzer sounds. Return the F-N-R lever to Neutral (N) and turn the parking brake OFF.
Page 66: Discharge Indicator (Red)
OPERATOR'S STATION Discharge Indicator (Red) If the voltage from the alternator is low, the discharge indicator comes ON. If the voltage from the alternator is abnormally high, the discharge indicator and the service indicator turn on. Check the alternator and the battery systems. M4GB-01-018 Engine Error Alarm (Red) Lit:...
Page 67: Engine Oil Pressure Indicator (Red)
OPERATOR'S STATION Engine Oil Pressure Indicator (Red) WARNING: If the engine is run with its engine oil pressure low, it may damage the engine. If the indicator comes ON, immediately stop working and stop the engine. If the engine oil pressure drops, the engine oil pressure indicator and service indicator come ON and the buzzer sounds.
Page 68: Coolant Temperature Gauge
OPERATOR'S STATION Coolant Temperature Gauge The engine coolant temperature is indicated with a needle. Normally the needle is within range (1) during operation. If the engine coolant temperature gets abnormally hot, the service indicator comes on and the buzzer alarm sounds. Stop operations and run the engine at slow idle speed to lower the coolant temperature.
Page 69: 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 High Beam Indicator When the head lights are put in the high beam position, this indicator comes on. M4GB-01-033 Work Light Indicator (Yellow) When the work lights are turned ON, this indicator comes ON.
Page 70: Clearance Light Indicator
OPERATOR'S STATION Clearance Light Indicator When the clearance lights are turned ON, this indicator comes M4GB-01-035 Maintenance Light (Yellow) This light indicates the time for a replacement is approaching. It lights for 30 seconds each time the key switch is turned ON, starting at 20 hours before the set time.
Page 71: Monitor Display
OPERATOR'S STATION Monitor Display 1- Monitor Display 2- Monitor Display Selector 3- Monitor Display Selector (Up) 4- Monitor Display Selector (Down) 5- Speedometer 6- Ride Control Enabled Indicator (Optional) MNCH-01-531 7- Vehicle Information Display 8- F-N-R/Shift Position Indicator MNCH-01-532 1-15...
Page 72: F-N-R/Shift Position Indicator
OPERATOR'S STATION F-N-R/Shift Position Indicator F-N-R/shift position indicator (1) displays the selected travel mode. F-N-R Indicator The square corresponding to the position of F-N-R lever (4), either Forward (F), Neutral (N) or Reverse (R), lights in F-N-R indicator (2). MNCH-01-532 (F-N-R always indicates the position of the F-N-R lever.) Shift Position Indicator Shift position indicator (3) displays the speed range selected...
Page 73: Speedometer
OPERATOR'S STATION Speedometer Speedometer (1) indicates the current vehicle travel speed. MNCH-01-531 Ride Control Enabled Indicator (Optional) Ride control enabled indicator (2) is displayed when ride control switch (3) is ON. MNCH-01-532 MNCH-01-533 1-17...
Page 74: Machine Information Display
OPERATOR'S STATION Machine Information Display When the key switch is turned ON, the machine information area (4) displays information about the machine. MNCH-01-531 The engine start-ready screen (5) is displayed on the machine information display when the key switch is turned ON. Symbols disappear from the left of display (6) every 0.5 seconds.
Page 75: Toggling Through The Vehicle Information Display
OPERATOR'S STATION Toggling through the Vehicle Information Display Each time monitor display selector (2) is pressed, the monitor toggles through the content of the machine information display, starting from the hour meter. MNCH-01-531 : When monitor display selector ( ) (2) is pressed once Hour Meter : When monitor display selector ( ) (3) is pressed once Indicates the number of hours the machine has been operated...
Page 76: Hydraulic Oil Hour Meter
OPERATOR'S STATION IMPORTANT: When each oil and filter is replaced, reset its hour meter by pressing monitor display selector (1) for 2 seconds or so. Please note that if monitor display selector (1) is pressed while a replacement time is displayed, the replacement time ceases to be displayed correctly.
Page 77: Engine Oil Hour Meter
OPERATOR'S STATION Engine Oil Hour Meter This display alternates with the hours to engine oil change. When the hour meter passes through 0 hours, maintenance lamp (4) lights. When on this screen, if monitor display selector (2) is pressed once, it returns to the hour meter. If monitor display selector (3) is pressed, it switches to the engine oil filter hour meter.
Page 78 OPERATOR'S STATION Engine Oil Filter Hour Meter This display alternates with the hours to engine oil filter change. When the hour meter passes through 0 hours, maintenance lamp (4) lights. When on this screen, if monitor display selector (2) is pressed, it returns to the hour meter.
Page 79: Method Of Changing Replacement Interval For Oils And Filters
OPERATOR'S STATION Method of Changing Replacement Interval for Oils and Filters The displayed interval for changing oil and filters can be changed. MNCH-01-531 Changing the Hydraulic Oil Hour Meter The replacement interval can be changed to 1000.0, 500.0 or 250.0 hours. When shipped the interval is set to 1000.0 hours.
Page 80 OPERATOR'S STATION Changing Hydraulic Oil Filter Hour Meter 1 The replacement interval can be changed to 1000.0 or 500.0 hours. When shipped the interval is set to 1000.0 hours. Press and hold switch (1) while the replacement interval is displayed. NOTE: Once switch (1) is released, it sets the change in hours, so do not release it until the desired replacement interval is displayed.
Page 81: Changing Hydraulic Oil Filter Hour Meter 3
OPERATOR'S STATION Changing Hydraulic Oil Filter Hour Meter 3 The replacement interval can be changed to 1000.0, 500.0 or 250.0 hours. When shipped the interval is set to 1000.0 hours. Press and hold switch (1) while the replacement interval is displayed.
Page 82: Changing Engine Oil Hour Meter
OPERATOR'S STATION Changing Engine Oil Hour Meter The replacement interval can be changed to 500.0, 250.0 or 200.0 hours. When shipped the interval is set to 500.0 hours. Press and hold switch (1) while the replacement interval is displayed. NOTE: Once switch (1) is released, it sets the change in hours, so do not release it until the desired replacement interval is displayed.
Page 83: Changing Engine Oil Filter Hour Meter
OPERATOR'S STATION Changing Engine Oil Filter Hour Meter The replacement interval can be changed to 500.0, 250.0 or 200.0 hours. When shipped the interval is set to 500.0 hours. Press and hold switch (1) while the replacement interval is displayed. NOTE: Once switch (1) is released, it sets the change in hours, so do not release it until the desired replacement interval is displayed.
Page 84: Changing Fuel Filter Hour Meter
OPERATOR'S STATION Changing Fuel Filter Hour Meter The replacement interval can be changed to 1000.0 or 500.0 hours. When shipped the interval is set to 1000.0 hours. Press and hold switch (1) while the replacement interval is displayed. NOTE: Once switch (1) is released, it sets the change in hours, so do not release it until the desired replacement interval is displayed.
Page 85: Changing Axle Oil Hour Meter
OPERATOR'S STATION Changing Axle Oil Hour Meter The replacement interval can be changed to 1000.0, 500.0 or 250.0 hours. When shipped the interval is set to 1000.0 hours. Press and hold switch (1) while the replacement interval is displayed. NOTE: Once switch (1) is released, it sets the change in hours, so do not release it until the desired replacement interval is displayed.
Page 86: Switches, Steering Wheel And Pedals
OPERATOR'S STATION Switches, Steering Wheel and Pedals 1- Steering Wheel 2- Horn 3- Monitor Panel 4- Accelerator Pedal 5- Brake, Inching Pedal (L/R Interlocked) 6- Brake, Inching Pedal (L/R Interlocked) 7- Neutral Lever Lock (for F-N-R lever) 8- F-N-R lever 9- Hi-Lo Selector Switch MNCH-01-508 10- Work Light Switch (Cab-Equipped Machine)
Page 87: F-N-R Lever
OPERATOR'S STATION F-N-R lever IMPORTANT: The F-N-R lever is set up so it is easy to operate. Refrain from pushing on it hard or operating it with excessive force. Doing so may damage the machine. This lever changes the direction of the machine to forward or reverse.
Page 88: Steering Wheel
OPERATOR'S STATION Steering Wheel IMPORTANT: When steering wheel (1) is turned all the way, the stoppers hit the front and rear frames, so it cannot be turned further. Trying to continue turning past that point will cause the engine to stall and/or damage the steering system.
Page 89: Light Switch
OPERATOR'S STATION Light Switch Light switch (1) has 2 levels and the different devices light ( or turn off (X) according to the level as follows. 2- Headlight 3- Turn Signal Light, Hazard Lamp, Clearance Light 4- Turn Signal Light, Hazard Lamp 5- Brake Light, Tail Light License Monitor...
Page 90: Dimmer Switch
OPERATOR'S STATION Dimmer Switch The dimmer switch is for switching between high beam and low beam. CAUTION: Drive with the headlights on low beam when following or meeting another vehicle. When the headlights are ON, lowering turn signal lever (1) shifts the headlight to high beam and the high beam indicator (2) lights.
Page 91: Hazard Lamp Switch
OPERATOR'S STATION Hazard Lamp Switch IMPORTANT: If hazard lamp switch (1) is left for a long time in the position with the engine stopped, it will drain the battery. Take care to avoid this. This switch is for indicating to other vehicles that the machine presents a hazard, such as when it has broken down.
Page 92: Work Light Switch (Cab-Equipped Machine)
OPERATOR'S STATION Work Light Switch (Cab-Equipped Machine) The light switch has two positions, . Pressing switch (1) on the side turns the front work light (2) ON. The rear work light (3) does not light. Pressing the side turns the front (2) and rear (3) work lights ON.
Page 93: Hi-Lo Selector Switch
OPERATOR'S STATION Hi-Lo Selector Switch Switch (1) is used to select the travel speed. Select the position according to the travel or work situation. : 0 to 12 km/h (0 to 7.5 mph) : 0 to 34 km/h (0 to 21.1 mph) NOTE: When the Hi-Lo selector switch (1) is in the Hi position and throttle limit switch (2) is ON, the travel speed is as follows.
Page 94: Parking Brake Switch
OPERATOR'S STATION Parking Brake Switch WARNING: Always apply the parking brake when parking or leaving the machine to prevent an accident from it running away. Do not apply the parking brake while the machine is moving, except in emergency. Apply the parking brake after the machine stops. Applying while moving is dangerous due to the rapid deceleration.
Page 95: Wiper Switch
OPERATOR'S STATION Wiper Switch Using the Wipers IMPORTANT: Note that the surface of the glass and parts of the wiper system, such as the wiper blades, wiper motors and relays may be damaged or malfunction due to the state of the wipers and glass (when dry or frozen).
Page 96: Front Wiper Switch (Cab-Equipped Machine)
OPERATOR'S STATION Front Wiper Switch (Cab-Equipped Machine) Actuating front wiper switch (1) turns the wiper on the front window ON. IMPORTANT: The motor in the washer tank may burn out if washer fluid is used continuously for more than 20 seconds, or if operated when washer fluid is not being sprayed.
Page 97: Operator's Station
OPERATOR'S STATION Accelerator Pedal Depressing accelerator pedal (1) accelerates the engine speed and releasing it lowers engine speed. Brake, Inching Pedal WARNING: Avoid braking suddenly while driving as doing so is dangerous. It may unbalance the machine. To prevent wear on the brake discs do not rest a foot on the pedal, except when needed.
Page 98: Right Console (Work Equipment-Related)
OPERATOR'S STATION Right Console (Work Equipment-Related) Mono-Lever Type 1- Loader Control Lever 2- Attachment Control Lever 3- Control Lever Lock (for Attachment) 4- Control Lever Lock (for Front Control Lever) MNCH-01-548 1-42...
Page 99: Front Control Lever
OPERATOR'S STATION Front Control Lever Mono-Lever Type This lever is used to operate the lift arm and bucket. Lever Bucket Action Position Float: The lift arm falls freely; once on the ground, the bucket is free to move in response to external forces.
Page 100: Control Lever Locks
OPERATOR'S STATION Control Lever Locks WARNING: When locking the lever, put control lever locks (2) and (4) all the way into their LOCK positions. If in an intermediate position, they are not locked, which is dangerous. When leaving the machine, stop the engine and put control lever locks (2) and (4) in their LOCK positions.
Page 101: Right Console/Switch Panel
OPERATOR'S STATION Right Console/Switch Panel 1- Spare (Optional) 2- Ride Control Switch (Optional) 3- Throttle Limit Switch 4- Key Switch MNCH-01-535 1-45...
Page 102: Key Switch
OPERATOR'S STATION Key Switch WARNING: Before starting the engine, put the F-N-R lever in the neutral (N) position, actuate the parking brake, lock the neutral lever lock and the front control lever. For further details, see Operating the Engine. Do not turn key switch (1) OFF during travel. Doing so actuates the parking brake and makes the steering wheel unusable, so it is extremely dangerous.
Page 103: Ride Control Switch (Optional)
OPERATOR'S STATION Ride Control Switch (Optional) Ride control switch (1) dampens vertical pitching of the work equipment during travel, to provide a more comfortable ride. It also provides a more stable ride, which helps prevent spilling of the material in the bucket. WARNING: Turn ride control switch (1) OFF when using work equipment in the float mode (scooping,...
Page 104: Air Conditioner Operation (Optional On Cab-Equipped Machines)
OPERATOR'S STATION Air Conditioner Operation (Optional on Cab- Equipped Machines) Name of Components 1- Control Panel 2- Defroster Vent 3- Rear Vents Name of Parts on the Control Panel 4- LCD Panel 5- AC Switch 6- Power Switch 7- Fan Switch MNCH-01-542 8- Temperature Control Switch NOTE:...
Page 105: Control Panel Names And Functions
OPERATOR'S STATION Control Panel Names and Functions Power Switch (6) Pressing switch (6) lights the temperature setting and fan speed indicators on LCD panel (4) and starts the fan. To turn it OFF, press switch (6). Fan Switch (7) The fan can be adjusted to 3 levels from Lo to Hi. The fan speed is indicated on the right side of LCD panel (4).
Page 106: Tips For Optimal Air Conditioner Usage
OPERATOR'S STATION Tips for Optimal Air Conditioner Usage For Rapid Cooling The temperature in the cab may rise to over 80 °C (176 °F) when the machine is left in the sun in the summer. In such case, the quickest way to cool it down is to open the door and allow the hot air inside the cab to escape.
Page 107: Adjusting The Operator's Seat (Standard Seat)
OPERATOR'S STATION Adjusting the Operator's Seat (Standard Seat) 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- Damper Adjustment 2- Slide Lever M4FG-01-026 1.
Page 108: Adjusting The Operator's Seat (Full Suspension Seat)
OPERATOR'S STATION Adjusting the Operator’s Seat (Full Suspension Seat) 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- Suspension Handle 2- Slide Lever 3- Armrest 4- Backrest Lever...
Page 109 OPERATOR'S STATION 2. Fore-Aft Adjustment The seat can be adjusted forward or backward. Lift up slide lever (2) and slide the seat to the desired position; it can be adjusted in 10 mm increments across a range of 160 mm. Release the lever when in the desired position and then make sure the seat is locked and does not move.
Page 110: Seat Belt
OPERATOR'S STATION Seat belt WARNING: Always fasten the seat belt when operating the machine. Before operating the machine, be sure to examine the seat belt and its hardware for any failure. If any damage and/or wear are found, replace the part concerned.
Page 111: 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. Fuse Box A (Body) The purpose of fuses is to provide a safety valve for the electrical system and prevent excessive current from flowing through its circuits;...
Page 112: Fuse Box A (Body)
OPERATOR'S STATION Fuse Box A (Body) 10- SPARE 20- HI BEAM 15 A 9- SPARE 19- HEAD LAMP 15 A 8- SPARE 18- ROOM LAMP (CAB) 7- RIDE CONTROL (OPT.) 17- FLASHER (10 A) 10 A 6- HST 2 16- CONTROLLER Fuse Box B (Cab) 5- HST 1 15- ECM...
Page 113: Rops Cab
OPERATOR'S STATION ROPS Cab 1- ROPS Cab 2- Room Light 3- Rearview Mirror 4- Sun Visor NOTE: Vehicles with special specifications, such as snow removal equipment, may not be so equipped. M4FG-01-032 M4EK-01-030 M4FG-01-055 1-57...
Page 114 OPERATOR'S STATION (Continued from previous page) 5- Radio(Optional) 6- Cab Switch Panel(Optional) 7- Drink Holder 8- Speaker(Optional) 9- Coat hook M4EK-01-066 M4EK-01-032 M4EK-01-033 1-58...
Page 115: Room Light
OPERATOR'S STATION Room Light Room light (1) comes ON when in the ON position and goes off in the Neutral position. When the left cab door is opened and the switch is in the DOOR position, room light (1) comes ON; it turns OFF when the door is closed.
Page 116: Coat Hook
OPERATOR'S STATION Coat Hook Use coat hook (1) for hanging up clothing, like jackets and hats. Rearview Mirror M4EK-01-033 WARNING: Do not rely solely on rearview mirror (2) when backing up. Use the rearview mirror as an aid and look behind when backing up. Sit in the operator’s seat and adjust it so the rear of the vehicle can be visually checked.
Page 117: Am/Fm Radio Operation (Optional)
OPERATOR'S STATION AM/FM Radio Operation (Optional) Serial No. 005001 to 005315 Radio Controls 1- PWR/SRC Button Pressing button (1) turns the power ON. Pressing button (1) for 2 seconds or so when the power is ON turns it back OFF. Each time the audio input source button (1) is pressed, it toggles through the sources in the order Radio AU1 (AUX1) AU2 (AUX2).
Page 118 OPERATOR'S STATION Tuning Manual Tuning Procedure Press SEEK button (7) briefly (less than 1 second) to tune to the desired frequency. The frequency changes 1 step each time the button is pressed (in AM, by 9 kHz; FM by 0.1 MHz at a time).
Page 119 OPERATOR'S STATION Using the Auto-Preset Function This function registers stations tuned using auto-tuning to preset memory. 1. Press BAND button (5) and select to tune either AM or M4EK-01-073 2. The radio beeps when AS button (6) is pressed, then registers the 6 stations with the best reception automatically.
Page 120: Radio Unit (Optional)
OPERATOR'S STATION Radio Unit (Optional) Serial No.005316 and up 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.
Page 121: 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 122: 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 123 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 (FM1 FM2 AM Bluetooth® USB SETTING FM1). Press rotary switch (2) while selecting a source to display its sub-sources. Pressing SRC button (1) on each source screen moves to the screen to the next source screen (FM1 FM2 AM Bluetooth®...
Page 124 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 125 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 126: 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 127: Operator's Station
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 128 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. Press SEEK BAND+ button (1) to search a higher frequency.
Page 129: 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 16 MNUD-01-402 The audio files can be played via Bluetooth® connection with a cell phone or Bluetooth®...
Page 130 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 131 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 132 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 133 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 134: 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 MP3, WMA, AAC, WAV Format MNUD-01-402 NOTE: MP4 or other formatted files may not be played and...
Page 135 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 136 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 137: 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 1-67 "Selecting Source" for details. MNUD-01-402 There are 7 setting menu and their submenu.
Page 138 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 139 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 140 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 1-87 for procedure. 1.
Page 141 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 142 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 143 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 1-87...
Page 144 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 145 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 146: Overhead Switch Panel (Optional)
OPERATOR'S STATION Overhead Switch Panel (Optional) 1- Reserved M4EK-01-066 1-90...
Page 147: Cab Door
OPERATOR'S STATION Cab Door CAUTION: Close the door securely when shutting it. It is dangerous if it opens suddenly. When getting down from the operator’s seat onto the ground, lock the cab door with it fully open. 1- Door Lock Key 2- Door Opening Lever M4EK-01-045 1-91...
Page 148: Door Lock Knob
OPERATOR'S STATION Door Lock Knob CAUTION: After locking the door, make sure it has locked. Press door lock knob (5) down to lock the door. Door Opening Lever To open the door, lift up door lock knob (5) to unlock it and then pull lever (6).
Page 149: To Fully Open The Door
OPERATOR'S STATION To Fully Open the Door To open the door all the way (180 °), open the door and press it against the outside of the cab. Door Lock Release Lever M4EK-01-049 CAUTION: When leaving the door open, open it until it securely locks in latch (8) on the cab.
Page 150: Articulation Lock Bar
OPERATOR'S STATION Articulation Lock Bar WARNING: Always lock the articulation lock bar (1) prior to maintenance or transport. Before traveling or operating the machine, always remove articulation lock bar (1) from the rear frame (4) side, then mount it on the front frame (3) and secure it with a ring pin (2).
Page 151: Engine Cover
OPERATOR'S STATION Engine Cover WARNING: Allow the engine to cool before performing any inspections around it. Only open or close engine cover (1) when the engine is stopped. Getting caught in the fan of the engine is extremely dangerous. Make sure engine cover (1) will not open while traveling.
Page 152: Steps
OPERATOR'S STATION Steps WARNING: Use both hands when getting on and off the machine and maintain at least 3 points of contact. It is easy to slip when getting on/off with 2 or fewer points of contact, and may result in falling off. Although there are steps on both sides of the machine (left and right), it is best to use those on the left side.
Page 153: Battery Disconnect Switch
OPERATOR'S STATION Battery Disconnect Switch IMPORTANT: Do not turn the battery disconnect switch OFF while the engine is running or the key switch is in any position other than OFF. Doing so may damage the electrical system. The battery disconnect switch differs from the engine start key switch.
Page 154 OPERATOR'S STATION Switch Operation 1. Open the engine cover. When lever (1) is pointing to the right, battery disconnect switch (2) is ON. When lever (1) is pointing to the right, lever (1) cannot be removed. To operate the machine with battery disconnect switch (2) in the ON position, close the engine cover.
Page 156: Break-In
BREAK-IN MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 158: Operating Engine
OPERATING ENGINE Check Points Check For 9. Chassis 1. Oil leaks from the transmission or axles 2. Fuel level, leaks and contamination of fuel in tank, drain water 3. Level and leaks of hydraulic oil tank 4. Movement, play and operating force of all control levers and steering wheel 5.
Page 159: Before Starting The Engine
OPERATING ENGINE Before Starting the Engine 1. Check and make sure that F-N-R lever (1) is in neutral (N) and neutral lever lock (2) is in its LOCK position. NOTE: The engine will not start if F-N-R lever (1) is not in neutral (N).
Page 160 OPERATING ENGINE 5. Adjust the rearview mirrors outside (7) and inside the cab (8) to the position that provides the best view to the rear. M4FG-01-033 Cab-Equipped Machine Canopy-Equipped Machine 6. Sit in the operator’s seat so your back is against the backrest and adjust the various seat functions so the brake pedal can be fully depressed.
Page 161: Starting The Engine
OPERATING ENGINE Starting the Engine Start the engine in the following order. 1. Make sure F-N-R lever (2) is in neutral (N). 2. Make sure parking brake switch (1) is in the ON position. 3. Turn key switch (3) to the ON position. 4.
Page 162 OPERATING ENGINE IMPORTANT: Never operate the starter for more than 10 seconds at a time. If the engine fails to start, return the key switch to the OFF position. Wait for at least 30 seconds, then try again. Failure to follow instructions may cause damage to the starter and/or discharge the batteries.
Page 163: Starting In Cold Weather
OPERATING ENGINE Starting in Cold Weather Preheating 1. Turn key switch (2) to the ON position. The coolant temperature sensor detects the temperature of the coolant and automatically actuates engine preheating. 2. Preheat indicator (1) lights. The engine is preheating as long as preheat indicator (1) is lit.
Page 164: Check Instruments After Starting The Engine
OPERATING ENGINE Check Instruments After Starting the Engine IMPORTANT: If any abnormality is noticed on the monitor unit, immediately stop the engine. Investigate the cause of the problem. Monitor Operation Checks 1. Check that discharge indicator (3) is OFF. If the discharge indicator stays ON, immediately stop the engine.
Page 165: Starting With Booster Cables
OPERATING ENGINE Starting with Booster Cables IMPORTANT: The electrical system of the machine is 12 volt DC. Only jump from a machine with a 12 volt DC system that has enough extra capacity. WARNING: An explosive gas is produced while batteries are in use or being charged.
Page 166 OPERATING ENGINE Connecting the Booster Cables 1.1. Stop the engine of the machine providing the jump. 1.2 Connect one end of red cable (1) to the positive (+) terminal of the machine batteries, and the other end to the positive (+) terminal of the booster battery. 1.3 Connect one end of black cable (2) to the negative (-) terminal of the battery providing the jump, and then attach the other end to a radiator mounting bolt of the...
Page 167: Warming Up Operation
OPERATING ENGINE Warming Up Operation WARNING: After starting the engine, make sure the engine speed is changed by operating accelerator pedal (3), and then start working or travel. Tilt Failure to take this step may result in an accident, such as a collision, due to the machine starting to move unexpectedly or sudden movement of the front attachment.
Page 168: Warming Up In Cold Weather
OPERATING ENGINE Warming Up in Cold Weather WARNING: After starting the engine, make sure the engine speed is changed by operating accelerator pedal (3), and then start working or travel. Failure to take this step may result in an accident, such as a collision, due to the machine starting to move unexpectedly or sudden movement of the front attachment.
Page 169 OPERATING ENGINE 2. Run the engine at a medium speed for 5 minutes. IMPORTANT: At such time, do not run the engine at high or low speed. 3. Slowly lift the bucket about 1 meter off the ground. 4. Slowly extend the bucket cylinder to stroke end. IMPORTANT: When doing so, do not continue relieving the control lever for over 10 seconds.
Page 170: Stopping The Engine
OPERATING ENGINE Stopping the Engine Stop the engine in the following order. IMPORTANT: Do not stop the engine during travel. Stopping the engine not only makes the steering wheel unusable, it also actuates the parking brake, so doing so is dangerous. It may also cause damage to the electrical and/or mechanical systems.
Page 172: Driving Machine
DRIVING MACHINE Starting to Move WARNING: Start to move the machine only after checking that no personnel and/or obstacles are present around the machine. Never turn ride control switch (4) (Optional) to ON position while traveling the machine or raising the front attachment.
Page 173 DRIVING MACHINE 4. Step on brake pedal (9) and depress parking brake switch (7) to the OFF position to release the parking brake. Check that at this time service indicator (2) and parking brake indicator (3) go OFF. 5. Move F-N-R lever (10) to either forward (F) or reverse (R) position.
Page 174: Parking Brake Switch
DRIVING 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 175: Drive Speed Change
DRIVING MACHINE Drive Speed Change Travel speed of this machine is automatically shifted. Auto shift 2-Speed mode or 1-Speed mode is selected by using Hi-Lo selector switch (1). Lo : 1-Speed mode. To be used for excavation and loading work Hi : Auto shift 2-Speed mode.
Page 176: Steering Wheel
DRIVING MACHINE Steering Wheel WARNING: Avoid quick steering while driving the machine at high speeds, while driving on a steep slope, or while raising the lift arms. Failure to do so may cause the machine to turn over. Never attempt to stop the engine while steering the machine.
Page 177: Stop And Restart Of Travel
DRIVING 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 service brake pedal to move the machine again.
Page 178 DRIVING MACHINE Even after break-in operation is complete, avoid running the engine at fast speed under no load. If any abnormal condition such as an abnormal noise, vibration, or smell is noticed during drive operation, immediately stop the engine and inspect the machine for any trouble.
Page 179: Precautions For Driving On Slopes
DRIVING MACHINE Precautions for Driving on Slopes WARNING: When descending a slope, use engine braking. Apply the brakes only when absolutely required. If the brake is continuously used while descending a slope, the brake temperature will increase, possibly decreasing the braking performance. If overheating of the brake system is recognized, immediately park the machine in a safe location.
Page 180: Precautions For Driving Speeds
DRIVING MACHINE Precautions for Driving Speeds CAUTION: Descend the machine on a steep slope with the Hi-Lo selector switch in Lo while applying engine brake sufficiently. Apply the normal brakes only when absolutely required. Traveling for a long time without reducing the speed will create the causes of various machine troubles.
Page 181: Precautions To Be Taken If Machine Failure Occurs
DRIVING MACHINE Precautions to be Taken if Machine Failure Occurs Keep alert. While paying attention to the vehicles following you, slowly reduce the travel speed and park the machine on the road shoulder as closely to the shoulder edge as possible.
Page 182: Stop
DRIVING MACHINE Stop 1. Avoid sudden deceleration. Smoothly reduce travel speed. Release accelerator pedal (8) and step on brake pedal (9) to stop the machine. 2. Return F-N-R lever (10) to neutral (N). Place neutral lever lock (4) to the LOCK position. 3.
Page 183: Parking
DRIVING MACHINE Parking IMPORTANT: When parking the machine with cab door and windows open, cab electrical components may be damaged by bad weather. Always close windows, roof vent and cab doors when parking the machine. When parking a canopy vehicle, cover the electrical components and the operator’s seat with plastic covers to protect them from bad weather.
Page 184 DRIVING MACHINE IMPORTANT: If the key switch (6) is left in ON position, Front the batteries will discharge. LOCK UNLOCK Be sure to turn key switch to OFF position before leaving the machine. 7. Turn the key switch (6) to OFF position to stop the engine.
Page 185: Emergency Evacuation
DRIVING MACHINE Emergency Evacuation When the Engine Has Stalled During Driving The service brake applies by depressing the brake pedal and the pressurized oil in the master cylinder acts on the brake system. If the machine does not stop even if the brake pedal is applied, press the parking brake switch ON side to stop the machine.
Page 186 DRIVING MACHINE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................4-16...
Page 188: Operating Machine
OPERATING MACHINE Control 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 189: Ride Control Switch (Optional)
OPERATING MACHINE Ride Control Switch (Optional) Ride control switch (1) dampens vertical pitching of the work equipment during travel, to provide a more comfortable ride. It also provides a more stable ride, which helps prevent spilling of the material in the bucket. WARNING: Turn ride control switch (1) OFF when using work equipment in the float mode (scooping,...
Page 190: Adjustment Of Bucket Auto Leveler
OPERATING 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 in the hydraulic circuits.
Page 191: Before Operation
OPERATING MACHINE Before Operation WARNING: Be sure to install only authorized buckets and other work tools on the front attachment. Never modify or increase the capacity of the bucket or other work tools without first receiving authorization. Do not overload the machine by installing additional counterweights.
Page 192: Avoid Overloading
OPERATING MACHINE Avoid Overloading WARNING: Do not penetrate the bucket into piles of soil and/ or gravel at fast travel speed to avoid personal accidents. Avoid excavating or scooping loads when the machine is articulated, which could possibly cause the machine to turn over. IMPORTANT: Avoid abusive machine operation by allowing the bucket or attachment to receive biased loads at only one side.
Page 193: Excavation
OPERATING MACHINE Excavation Loading Accumulated Soil IMPORTANT: Avoid operating the machine with the front wheels raised off the ground. Machine traction force is reduced and excessive loads are applied to the undercarriage. Scoop load while traveling forward as described below. As M4EK-05-001 load increases the wheels begin to slip, slightly raise the bucket to reduce the load.
Page 194 OPERATING 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.
Page 195: Grading
OPERATING MACHINE Grading WARNING: Turn the ride control switch OFF, if the machine is so-equipped, when using work equipment in the float mode (scooping, grading, snow removal). If it is left ON, the work equipment may rise or come down during ride control operation. 1.
Page 196: Loading
OPERATING 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. 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 197 OPERATING MACHINE Load and Carrying Method WARNING: Be sure to provide tire stopper (1) in front of the dumping port. Before raising the lift arm, slightly tilt the bucket back and forth to stabilize the load in the bucket to avoid personal injury or damage to the machine due to material loss.
Page 198 OPERATING MACHINE Loader and Dump Track Combination Method WARNING: Be aware of the following points: Always maintain a flat work site surface. Avoid rapid swing and/or sudden braking while raising the lift arm with the bucket loaded to prevent the machine from tipping over.
Page 199 OPERATING MACHINE I-Shape Loading Park a dump truck in a direction parallel to the loading face. After loading material into the bucket, travel the wheel loader straight in reverse. Then, move a dump truck to a spot between the loading face and the wheel loader. Travel the wheel loader forward to load material onto the dump body.
Page 200: Dozing
OPERATING MACHINE Dozing IMPORTANT: Never attempt to forcibly push piled material higher than the bucket capacity. Premature wear of the tires due to slipping and/or waste of fuel may result. Do not perform dozing with the bucket dumped. Abnormal excessive stress will be applied on the front attachment.
Page 201: Removing Snow
OPERATING MACHINE Removing Snow WARNING: When operating the machine with the front attachment control lever in the float position when performing such works as soil scooping, land grading, or snow removal, be sure to turn the ride control switch OFF. Failure to do so may allow the ride control system to operate so that the front attachment may automatically move up and down.
Page 202: Precautions For After Operation
OPERATING MACHINE Precautions for After Operation 1. After finishing operation, move the machine to firm, level ground where no possibility of falling stones, ground collapse, or floods are present. Park the machine referring to the “Parking” in the “DRIVING MACHINE” chapter.) 2.
Page 203 OPERATING MACHINE CAUTION: When removing the batteries, first disconnect the ground cable from the battery terminal. 4.4 Remove the batteries and store them in a dry cool place. Do not put the batteries on the ground. When the batteries are not removed, disconnect the ground terminal cable.
Page 204 OPERATING MACHINE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................5-18...
Page 206: Transporting
TRANSPORTING Loading/Unloading on Trailer WARNING: Be sure to use a loading dock or a ramp for loading/unloading. Always load and unload the machine on a firm, level surface. M4FG-06-001 Ramp/Loading Dock 1. Before loading, thoroughly clean the ramps, loading dock and flatbed. Dirty ramps, loading docks, and flatbeds with oil, mud, or ice on them are slippery and dangerous.
Page 207 TRANSPORTING Loading/Unloading WARNING: Be aware of the following points: NEVER steer while driving up or down a ramp as it is extremely dangerous and may cause the machine to turn over. If the travel direction must be changed on a slope, back the machine to flat ground. Then, after changing the travel direction, begin to move again.
Page 208: Transporting
TRANSPORTING Transporting CAUTION: Securely fasten the machine to the trailer flatbed with appropriate accessories (wire ropes/ chains, tighteners.) The machine may move back and forth and/or laterally during transportation. 1. Apply the parking brake. Slowly rest the bucket on the M4FG-06-003 trailer deck or load-carrying platform.
Page 209: Transporting Wheel Loader (Urgent Situation)
TRANSPORTING Transporting Wheel Loader (Urgent Situation) The following procedures shall only be applied to cases when urgently moving the wheel loader a short distance is required. When required to transport the wheel loader long distance, use a trailer. Precautions for Self-Traveling Avoid driving the wheel loader long distances at high-speed as much as possible as it may overheat the tires, possibly resulting in premature tire damage and/or wear.
Page 210 TRANSPORTING Precautions for Towing WARNING: Never attempt to tow the machine if the brake system is in need of repair. Ask your nearest authorized dealer to repair the machine. Operate the machine only after repair is completed. Avoid towing the machine as much as possible. If the machine is to be unavoidably towed, beware of the following points.
Page 211 TRANSPORTING If the engine becomes inoperable, steering operation Steering Cylinder becomes impossible. Switch the hydraulic hose connections between the rod end side and the head end side on one of the steering cylinders. Articulation between the front frame and the rear frame will be easily performed while towing of the machine.
Page 212 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, wedge the tire wheels. CAUTION: As soon as towing operation is complete, connect the parking brake.
Page 213 TRANSPORTING Relieving HST Hydraulic Pressure CAUTION: Do not tow the machine at travel speed faster than 2 km/h (1.2 mph) and in a distance longer than 1 km. The HST hydraulic pressure must be reset to the original set pressure after towing is complete. Contact your nearest authorized dealer for machine inspection: Procedures...
Page 214: 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 215: Lifting Machine
TRANSPORTING Lifting Machine WARNING: Be aware of 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 216 TRANSPORTING Lifting 1. Straighten the machine and horizontally rest the bucket on the ground. 2. Move the loader control lever lock to the LOCK position. 3. Rigidly secure the front and rear frames using the articulation lock bar. 4. Stop the engine. Remove the key from the key switch. 5.
Page 218: Maintenance
MAINTENANCE Handling of the Body Information Controller This machine provides a body information controller that stores machine operation information for preventive maintenance. During the course of maintaining the machine, our authorized service personnel may download the stored information. Consult with your authorized dealer for details on the function of this device. Handling of the Communication Terminal It is not necessary to check or operate the communication terminal;...
Page 219: Inspection And Maintenance
MAINTENANCE Check the Hour Meter Regularly Refer to the Maintenance Guide for information about lubricants, check and adjustment intervals. A maintenance guide table is affixed on the inside of the steps on the left side. (Refer to page 7-5) This manual recommends grouping the intervals into three categories as follows: Daily : To be conducted daily before operation...
Page 220: Names Of Components
MAINTENANCE Names of Components MNCH-07-064 Cutting Edge 14- Hydraulic Oil Tank/Suction Filter 27- Propeller Shaft Lift Arm Cylinder Pin 15- Brake Oil Tank 28- Fuel Tank Bucket 16- Engine 29- Steering Cylinder Bell Crank Pin 17- Fuel Pre-Filter 30- Front Axle Bucket Cylinder Pin 18- Radiator/Oil Cooler Bucket Auto-Leveler...
Page 221: Maintenance Guide Table
MAINTENANCE Maintenance Guide Table A maintenance guide table is affixed on the inside of the steps on the left side. Lubricate and/or service parts at the intervals indicated in the table so that all necessary maintenance can be performed regularly. Symbols The following symbols are used in the maintenance guide table.
Page 222 MAINTENANCE Explanation of Maintenance Guide Table Lubrication Interval (hours) MNCH-07-002 Item Page Item Page 1 Grease (Front Joint Pins) 7-22 8 Grease (Propeller Shaft) 7-24 2 Fuel Pre Filter 7-54 9 Transmission Oil 7-28 3 Engine Oil Filter 7-26 10 Hydraulic Oil 7-36 4 Main Fuel Filter 7-53...
Page 223: Preparation For Inspection And Maintenance
MAINTENANCE Preparation for Inspection and Maintenance Warning: The lift arm may rise if ride control switch (1) is left ON. If turned OFF, take care to avoid an accident due to the lift arm moving unexpectedly. LOCK CAUTION: A serious accident may occur due to UNLOCK unexpected movement of the machine.
Page 224 MAINTENANCE 9. Turn key switch (6) OFF to stop the engine. Remove the key. 10. Put a sign saying "Being Serviced" in an easy-to-notice place on the door or front control lever before starting work. WARNING: To prevent accidents, never attempt to perform maintenance on the machine when the engine is running.
Page 225: Frame Lock
MAINTENANCE Frame Lock WARNING: Prior to working around the joint between frames (3) and (4), mount articulation lock bar (1) to secure front and rear frames (3) and (4). This is to prevent an accident due to the machine moving unexpectedly.
Page 226: Side Inspection Covers
MAINTENANCE Side Inspection Covers CAUTION: Only open or close side cover (1) when the engine is stopped. Getting caught in moving parts is extremely dangerous. Install side cover (1) before traveling or operating the machine. When opening side cover (1), remove the 4 bolts (2). NOTE: There are side covers (1) on both sides of the machine.
Page 227: Engine Cover
MAINTENANCE Engine Cover WARNING: Only open or close engine cover (1) when the engine is stopped. Getting caught in the fan of the engine is extremely dangerous. Make sure engine cover (1) will not open while traveling. Opening the Engine Cover Press in lock key (2) of engine cover (1) and open it upwards for daily checks.
Page 228: Maintenance Guide
MAINTENANCE Maintenance Guide The shaded parts in the table indicate inspection timing. A. Greasing Interval (Hours) Inspection/Maintenance Items Qty. Page 1000 1. Bucket Pin 7-22 2. Bucket Link Pin 7-22 3. Bucket Cylinder Pin 7-22 4. Bucket Cylinder Rod Pin 7-22 5.
Page 229 MAINTENANCE B. Engine IMPORTANT: Use the specified oil and replace at the specified interval. Using anything other than the specified oil or continued use after the replacement interval will result in major malfunctions and/or damage to the engine. Interval (Hours) Inspection/Maintenance Items Qty.
Page 230 MAINTENANCE D. Hydraulic System IMPORTANT: Use the specified oil and replace at the specified interval. Using anything other than the specified oil or continued use after the replacement interval will result in major malfunctions and/or damage to the hydraulic system. Interval (Hours) Inspection/Maintenance Items Qty.
Page 231 IMPORTANT: Use fresh or tap water in the coolant. Do not use strongly acidic or alkaline water. When using genuine Hitachi coolant, do so at a ratio of 30 to 50%. If Genuine Hitachi coolant is used at a concentration below 30%, it will shorten the service life of devices in the cooling system due to freezing or corrosion of the devices.
Page 232 MAINTENANCE J. Tires Interval (Hours) Inspection/Maintenance Items Qty. Page 1000 Inspect 7-73 1. Check/Adjust Tire Pressure Adjust As required 7-73 2. Check for Damage to Tires Inspect 7-74 3. Retighten Wheel Nuts Adjust 7-74 : 50 hours the first time only. K.
Page 233 MAINTENANCE L. Miscellaneous Interval (Hours) Inspection/Maintenance Items Qty. Page 1000 4500 Check for Looseness/Wear to the Bucket’s Bolt-On 7-82 Cutting Edge 2. Check and Replace Seat Belt Every 4 years 7-83 3. Damage or Deformation of Canopy or Cab, Loose Bolts 7-83 4.
Page 234: 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 235: Kind Of Oils
Specifications Machinery IMPORTANT: Use the genuine Hitachi product as it was selected for use in this machine, based on testing. We recommend using genuine Hitachi products. If a genuine Hitachi product is not used, use a grease that conforms to the above specification. Do not use a non-conforming product as doing so may result in damage to the machine.
Page 236 MAINTENANCE Engine Oil IMPORTANT: Use the genuine Hitachi product as it was selected for use in this machine, based on testing. We recommend using genuine Hitachi products. Use an engine oil equivalent to JASO standard DH-2. Using any other engine oil may impact the performance or life of the engine or aftertreatment device. Do not use a non-conforming product as doing so may result in damage to the machine.
Page 237 Change Interval 1000 Hr IMPORTANT: Use the genuine Hitachi product as it was selected for use in this machine, based on testing. We recommend using genuine Hitachi products. If a genuine Hitachi product is not used, use an oil that conforms to JCMAS HK VG46W.
Page 238: Greasing
MAINTENANCE A. Greasing WARNING: Engage the parking brake and secure the front and rear frames with the articulation lock bar. NOTE: Grease daily during first 50 hours of break-in operation to establish smooth run-in. If excavation is performed in mud, water or snow, grease after operation is complete.
Page 239 MAINTENANCE 6. Lift arm cylinder rod pins (6) (left and right, 1 pin each) --- every 250 hours (During daily checks in the first 50 hours) 7. Lift arm cylinder pins (7) (left and right, 1 pin each) --- every 250 hours (During daily checks in the first 50 hours) 8.
Page 240 MAINTENANCE 13. Axle support pin (front and rear, 1 pin each) --- every 100 hours 17- Front 18- Rear Grease with molybdenum grease. 14. Propeller shaft universal joint (19) 2 places --- every 500 hours M4FG-07-008 NOTE: When working under severe conditions or continuous operation, grease more frequently.
Page 241: Engine
MAINTENANCE B. Engine Engine Oil Level ...every 10 hours (check daily) (before starting the engine) IMPORTANT: If the engine oil level is anything other than that specified, it may cause problems with the engine. (The oil level should be between the high and low marks on oil level gauge (1).) If the engine oil level exceeds the upper limit, adjust it to the proper quantity before starting the engine.
Page 242: Change Engine Oil
MAINTENANCE Change Engine Oil Replace Engine Oil Filter --- every 500 hours 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. When engine oil filter cartridge (4) is loosened, oil drips onto oil tray (1) and there is a risk of oil getting on muffler (2).
Page 243 MAINTENANCE 7. Apply a thin film of engine oil to the gasket and O-ring of the new cartridge and then hand tighten the cartridge filter clockwise until its gasket touches the seal face. 8. From that point, tighten it a further 3/4 to 1 turn. Tightening Torque: 16.0 N·m (1.6 kgf·m, 12.0 lbf·ft) Clean Cloth Take care not to overtighten the cartridge as doing so...
Page 244: Powertrain
MAINTENANCE C. Powertrain Change Transmission Oil --- every 1000 hours (first time only, at 250 hours) WARNING: A serious accident may occur due to unexpected movement of the machine. After stopping the machine, put F-N-R lever (1) in (N), put neutral lever LOCK lock (2) in LOCK, actuate parking brake (3) and stop the engine.
Page 245: Replace Axle Oil
MAINTENANCE Replace Axle Oil --- every 1000 hours (first time only, at 250 hours) WARNING: There is a risk of being burned immediately after operation. Wait for the oil to cool before starting any maintenance work. Secure the front and rear frames with the articulation lock bar.
Page 246: Check Oil Level
MAINTENANCE 8. Check the oil level according to the procedure. 9. Use the same procedure to replace the oil in the remaining 3 oil level plugs (1) on the front and rear axles. Check Oil Level 1. Park the machine according to Preparations for Inspection and Maintenance (7-7).
Page 247: Clean The Oil Breather Of The Transmission
MAINTENANCE Clean the Oil Breather of the Transmission --- every 500 hours or 6 months CAUTION: When cleaning with compressed air, wear safety glasses or goggles. 1. Wipe clean the area around where air breather (1) is mounted and then remove it. 2.
Page 248: Check For Oil Leaks Around The Axle And Cover
MAINTENANCE Check for Oil Leaks Around the Axle and Cover --- every 10 hours (check daily) Check for oil leaks around the axle and cover. Check the bolt(s) where there are oil leaks and retighten them if loose. Clean the Air Breather on the Axle Housing --- every 500 hours CAUTION: When cleaning with compressed air, wear safety glasses or goggles.
Page 249: Hydraulic System
MAINTENANCE D. Hydraulic System Inspection and Maintenance of Hydraulic Equipment WARNING: When checking and/or servicing hydraulic components, pay special attention to the following points. The hydraulic equipment gets extremely hot while this machine is operating. Allow the machine to cool before inspection or maintenance.
Page 250 Do not use a mixture of different brands of hydraulic oils. When shipped the machine is using genuine Hitachi hydraulic oil WP46, so always use the same product. To use a different brand, replace all of the hydraulic oil.
Page 251: Check Hydraulic Oil Level
MAINTENANCE Check Hydraulic Oil Level --- every 10 hours (check daily) IMPORTANT: If the oil level is not visible in the level gauge, immediately replenish it to the proper level. Using it as-is will cause serious damage to the hydraulic system. If the oil level as seen from the level gauge is too high, use a pump to remove some to the proper level.
Page 252: Replace Hydraulic Oil/Clean Hydraulic Oil Tank
MAINTENANCE Replace Hydraulic Oil/Clean Hydraulic Oil Tank --- every 1000 hours Replacing and Cleaning WARNING: Hydraulic oil becomes hot and is under pressure during operation. Severe burns may result if skin comes in contact with escaping hydraulic oil just after operation. Wait for the oil to cool before starting any maintenance work.
Page 253 MAINTENANCE 9. Remove oil filler port plug (2) and refill with hydraulic oil. Use oil level gauge (6) to monitor the level while filling the tank. Oil Tank Only (Total Amount of Hydraulic Oil) Total Amount of Oil: 50 Liters, 13.2 US gal (72 Liters, 19.0 US gal) 10.
Page 254: Clean The Suction Filter
MAINTENANCE Clean the Suction Filter---at each hydraulic oil change The suction filter is mounted at the bottom of the hydraulic oil tank. Clean the suction filter when changing hydraulic oil. 1. After draining the hydraulic oil, remove cleaning cover (3) on the bottom of hydraulic oil tank (1). Carefully remove suction filter (2) from the opening.
Page 255: Replace Hst Oil Filter Element
MAINTENANCE Replace HST Oil Filter Element --- every 1000 hours (first time only, at 100 hours) WARNING: The hydraulic oil gets hot and is under high pressure during operation of the machine. Severe burns may result if skin comes in contact with escaping hydraulic oil just after operation.
Page 256 MAINTENANCE 6. Fill cartridge element (2) with fresh hydraulic oil. 7. Apply a thin film of hydraulic oil onto O-ring (4) of new cartridge element (2) and then use a tool (wrench) on the hexagonal part on the bottom of cartridge element (2) to install it until gasket (4) touches the seal face of filter head (3).
Page 257: Maintenance
MAINTENANCE Replace Return Filter --- every 1000 hours (first time only, at 100 hours) Replacement Guide WARNING: The hydraulic oil gets hot and is under high pressure during operation of the machine. Severe burns may result if skin comes in contact with the hot, escaping hydraulic oil just after operation.
Page 258 MAINTENANCE 6. Fill cartridge element (2) with fresh hydraulic oil. 7. Apply a thin film of hydraulic oil onto O-ring (4) of new cartridge element (2) and screw it on until O-ring (4) touches the seal face of filter head (3). Then tighten it a further 3/4 of a turn.
Page 259: Check Hoses And Lines
MAINTENANCE Check Hoses and Lines --- every 10 hours/250 hours WARNING: Escaping oil under pressure can penetrate the skin, causing serious injury. To avoid this hazard, use a piece of cardboard when searching for oil leaks. Take care to protect hands and body from high-pressure fluids.
Page 260 MAINTENANCE Hose Interval Check Points Check For Remedies (Hours) Hose covers Leak (1) Replace Hose ends Leak (2) Replace Every 10 hours Fittings Leak (3) Retighten or replace hose or O-ring M137-07-008 Hose covers Leak (4) Replace Hose ends Leak (5) Replace Hose covers Exposed reinforcement...
Page 261 MAINTENANCE Interval Check Points Check For Remedies (Hours) Contact surfaces of Leak (11) Replace flange joints Bolts Loose or leak (11) Retighten or replace Daily O-ring Welded surfaces on Leak (12) Replace M4GB-07-059 flange joints Flange joint neck Crack (13) Replace Welded surfaces on Crack (12)
Page 262 MAINTENANCE Types of Hydraulic Fittings Two hydraulic fitting designs are used on this machine. 1. Flat Face O-ring Seal Fittings (ORS Fittings) O-ring (1) is used on the sealing surfaces of adapter (2) to prevent oil leakage. Precautions for Use M104-07-033 1.
Page 263 MAINTENANCE 2. Metal Face Seal Fittings Metal face seal fittings are used on small diameter hoses and consist of an adapter seat face (9) and a hose seat face (10). 1. Tighten adapter (7) by hand. 2. Tighten adapter (7) and nut (8) to the torque values shown in the table below.
Page 264: Fuel System
MAINTENANCE E. Fuel System Amount of Fuel in the Tank ---every 10 hours CAUTION: Danger of Fire Fuel is dangerous as it can burn easily. Keep away from fire. IMPORTANT: Use the specified diesel in the fuel tank. Using any other fuel will cause engine problems as well as making the engine difficult to start.
Page 265: Refueling
MAINTENANCE Refueling 1. Park the machine according to 7-7 for Preparations for Inspection and Maintenance. IMPORTANT: The turbocharger may be damaged if the correct procedure is not used in stopping the engine. Danger: Handle fuel carefully. Stop the engine before refueling.
Page 266: Drain Fuel Tank Of Water And Sediment
MAINTENANCE Drain Fuel Tank of Water and Sediment ---when indicator is lit Before starting work, loosen drain plug (1) on the bottom of the fuel tank and drain off water and sediment. M4FG-07-028 7-50...
Page 267: Drain Fuel Pre-Filter
MAINTENANCE Drain Fuel Pre-Filter --- Daily check (before starting operation) IMPORTANT: Drain fuel pre-filter daily before starting operation. The engine may be damaged if you do not drain the fuel pre-filter daily. Fuel pre-filter (1) is a device that separates water mixed into the fuel and acts as a water drain.
Page 268: Bleeding Air From The Fuel System
MAINTENANCE Bleeding Air from the Fuel System Air in the fuel system may make the engine hard to start or run irregularly. After draining water and sediment from the fuel filter, replacing the main fuel filter or fuel pre-filter, or running the fuel tank dry, be sure to bleed the air from the fuel system.
Page 269: Replace Main Fuel Filter Element
Replace Main Fuel Filter Element --- every 500 hours IMPORTANT: Use genuine Hitachi elements for the fuel main filter element and the pre-filter element. Using a different element may adversely affect engine performance and/or shorten the engine service life. Note: any...
Page 270: Replace Fuel Pre-Filter Element
Replace Fuel Pre-Filter Element --- every 1000 hours IMPORTANT: Use genuine Hitachi elements for the fuel main filter element and the pre-filter element. Using a different element may adversely affect engine performance and/or shorten the engine service life. Note: any...
Page 271: Check Fuel Hoses
MAINTENANCE Check Fuel Hoses --- every 10 hours/250 hours WARNING: Fuel leaks can lead to fires that may result in serious injury. Check for twisted hoses, hoses that rub against each other or other parts and any fuel leaks. M4GB-07-071 Repair or replace any loose or damaged hoses.
Page 272: Air Cleaner
MAINTENANCE F. Air Cleaner Clean or Replace Air Cleaner Element Clean --- when indicator is lit Replace --- every 500 hours (after cleaning 6 times or after one year) Air cleaner (1) is a double element, consisting of an outer element and an inner element.
Page 273: Cooling System
MAINTENANCE G. Cooling System Coolant Use soft water as a coolant. Do not use strong acid or alkaline water. Use a coolant mixed with genuine Long-Life Coolant (LLC) at a concentration of 30 to 50%. If the temperature outside is 0°C or below, mix genuine Long-Life Coolant (LLC) with soft water and fill the cooling system with it.
Page 274: Check Coolant Level
MAINTENANCE Check Coolant Level --- every 10 hours WARNING: Do not remove cap (2) until the coolant in the radiator cools down. Hot steam may spout out, possibly causing severe burns. After the coolant cools down, slowly loosen cap (2) to release the air pressure inside before removing it.
Page 275: Check The Drive Belt
MAINTENANCE Check the Drive Belt --- every 10 hours (check daily) Check drive belts (1) and (2) for damage and replace with new ones if they are cracked. If loose, tighten the belt according to the section on adjusting belt tension. IMPORTANT: A loose belt may result in insufficient battery charging, engine overheating, as well as a rapid, abnormal belt wear.
Page 276: Change Coolant
After the coolant cools down, slowly loosen cap (1) to release the air pressure inside before removing it. IMPORTANT: Use genuine Hitachi coolant. Replace at 1,000 hours or 1 year, whichever comes first. 1. Park the machine according to 7-7 for Preparations for Inspection and Maintenance.
Page 277: Clean The Radiator And Oil Cooler
MAINTENANCE Clean the Radiator and Oil Cooler --- every 500 hours or when clogged CAUTION: When using compressed air (no higher than 0.2 MPa (2 kgf/cm , 29 psi)), wear safety glasses or goggles. IMPORTANT: If compressed air (0.2 MPa (2 kgf/cm , 29 psi) or lower), or tap water at high pressure is used for cleaning, damage to the radiator or oil cooler fins may...
Page 278: Electrical System
MAINTENANCE H. Electrical System IMPORTANT: Improper radio communication equipment and associated parts, and/or improper installation of radio communication equipment may affect the machine's electronic parts, causing unintended movement of the machine. Improper installation of electrical equipment may cause machine failure and/or a fire on the machine. Consult your authorized dealer when installing radio communication equipment or additional electrical parts.
Page 279 MAINTENANCE Avoid hazards by: 1. Charge the batteries in a well ventilated location. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Using proper booster battery starting procedures. If you spill acid on yourself: 1.
Page 280 MAINTENANCE Electrolyte Level Check --- every 100 hours 1. Check the electrolyte level at least once a month. 2. Park the machine on level ground and stop the engine. 3. Check the electrolyte level. 3.1 To check the level from the side of the battery: Clean the area around the level lines with a water- dampened cloth.
Page 281 MAINTENANCE Check Electrolyte Specific Gravity---every 250 hours WARNING: If you spill acid on yourself: 1. Flush your skin with water. Gas produced by the battery can be explosive. Keep 2. Apply baking soda or lime to help neutralize the sparks and flames away from batteries. acid.
Page 282: Monitor Functions, Instrument Operation
MAINTENANCE Replace Battery IMPORTANT: When making adjustments to the electrical system or welding on the machine, disconnect the negative cable from the battery. Turn the battery disconnect switch (optional) to OFF. This machine is equipped with one 12V battery, which is negatively grounded.
Page 283: Lamps Light Or Flash
MAINTENANCE Lamps Light or Flash --- every 10 hours (check daily) CAUTION: Replace burned out lamps as soon as possible with new ones. Check whether the various lamps light or flash, starting in the front of the machine, and then check the rear. M4FGE-01-021 Check Horns, Reverse Buzzer and Light --- every 10 hours (check daily)
Page 284: Check Electrical Wiring And Fuses
MAINTENANCE Check Electrical Wiring and Fuses --- every 50 hours Fuse Box A (Body) CAUTION: If electrical parts such as wiring and relays have dirt or dust on them, they may cause a fire. Check the battery, battery relays, starter motor, alternator wiring and terminals for looseness and check the contact of wiring (damage to coating).
Page 285: Fuse Box A (Body)
MAINTENANCE Fuse Box A (Body) 10- SPARE 20- HI BEAM 15 A 9- SPARE 19- HEAD LAMP 15 A 8- SPARE 18- ROOM LAMP (CAB) 7- RIDE CONTROL (OPT.) 17- FLASHER (10 A) 10 A 6- HST 2 16- CONTROLLER Fuse Box B (Cab) 5- HST 1 15- ECM...
Page 286: Brake System
MAINTENANCE I. Brake System Check Brake Oil Level --- every 10 hours (check daily) or when the indicator lights WARNING: If the brake level low indicator (1) lights on the monitor, stop the machine immediately and check the level in brake oil tank (2) and the braking system. Continuing to use the machine as-is runs the risk of the MNCH-01-531 brakes not working and causing a serious accident.
Page 287: Maintenance
MAINTENANCE Check Braking (Left/Right Interlocked) --- every 10 hours (check daily) WARNING: Set up a warning sign to stay and someone to monitor safety at a range of 100 m to the front. Do not allow dirt, sand or other debris to accumulate around where brake pedal (3) is mounted.
Page 288: Check The Parking Brake
MAINTENANCE Check the Parking Brake --- every 10 hours (check daily) WARNING: Conduct checks where no one is around or is in the direction the machine will travel. Also, do not allow anyone to approach the area. The parking brake is acceptable if the machine does not move with parking brake switch (1) ON, under no load, on a dry slope of 20% (11.3°).
Page 289: Tires
MAINTENANCE J. Tires Check/Adjust Tire Pressure Check --- every 10 hours Adjust---as required WARNING: Secure the front and rear frames with the articulation lock bar and pin. When inflating a tire, stand on the side of the tire where the tread is and use a self-attaching chuck. Be careful when welding near the tire as it may cause the tire to explode.
Page 290: Check For Damage To Tires
MAINTENANCE Check for Damage to Tires --- every 10 hours (check daily) WARNING: Tires with cuts or other damage can cause a puncture or the tires to burst. This may lead to a serious accident and/or injury and death. Inspect the appearance of tires for cuts, damage, metal fragments and other foreign matter.
Page 291 MAINTENANCE Usable Tire Sizes NOTE: Consult your authorized dealer about the tire patterns of optional tires. Some tire may vibrate during travel due to their tread pattern. This resonance is due to the tire pattern and is not a fault. Tire Size Standard Size Bias...
Page 292 MAINTENANCE Tire Rotation Rotate tires when uneven or abnormal wear is recognized on either front or rear, or right and left tires. The aim of rotating the tires is uniform wear on tires and to even out their service life. Rotation Method (Correct) (Wrong)
Page 293: Tire Removal And Mounting
MAINTENANCE Tire Removal and Mounting WARNING: The tires and wheels are extremely heavy and this work is dangerous and difficult. In addition, a crane is required to lift the tires for removal and installation, so have your authorized dealer or a professional tire shop perform this work.
Page 294: Air Conditioner (Cab-Equipped Machines)
MAINTENANCE K. Air Conditioner (Cab-Equipped Machines) Clean and Replace Circulating Air Filter Clean Circulating Air Filter ---every 250 hours or once/month, whichever comes first Replace Circulating Air Filter ---after cleaning 6 times (or when severely clogged) NOTE: When work sites are dusty, clean and replace sooner. Cleaning the Circulating Air Filter CAUTION: When using compressed air, wear safety glasses or goggles.
Page 295: Check Air Conditioner Unit
MAINTENANCE Check Air Conditioner Unit --- every 250 hours or 3 months Check the mounts of the AC switch panel, the AC unit and condenser, as well as the and hoses for damage and anything abnormal. NOTE: Inspect the AC unit before the season when it is needed to ensure it can be used whenever required.
Page 296: Check Air Conditioner Condenser
MAINTENANCE Check Air Conditioner Condenser --- every 250 hours or 3 months If condenser (1) become clogged with dirt or insects, their cooling efficiency is compromised. Remove cover (2) on the top of condenser (1). Use tap water to wash away dirt and debris from the fins of condenser (1). Use a soft brush on stubborn dirt.
Page 297: Check Refrigerant Level
IMPORTANT: For collection/refilling of refrigerant during MNCH-07-025 checks and maintenance (including disposal), contact a company certified to handle refrigerant or your nearest Hitachi representative. Check the Compressor and Pulley --- every 250 hours or 3 months Check around compressor (2) for grime, its mounting condition, operation and gas leaks;...
Page 298: Miscellaneous
MAINTENANCE L. Miscellaneous Check for Looseness/Wear to the Bucket’s Bolt-On Cutting Edge --- every 10 hours (check daily) Check bucket cutting edge for wear and looseness. Replacement Guide WARNING: Guard against injury from flying pieces of metal. Wear goggles or safety glasses, and safety equipment appropriate for the job.
Page 299: Check And Replace Seat Belt
MAINTENANCE Check and Replace Seat Belt Check--- every 10 hours (check daily) Replace --- every 4 years Examine tang (1), buckle (2) and the condition of the belt. If any part is damaged or worn, replace them. Check the retracting mechanism as well. Replace the seat belt every 4 years regardless of its apparent condition.
Page 300: Check Steering Wheel Play
MAINTENANCE Check Steering Wheel Play --- every 10 hours (check daily) WARNING: Turning the steering wheel makes the area between the front and rear frames narrower, presenting the risk of someone getting caught in between. Do not allow anyone nearby during this inspection.
Page 301: Accelerator Pedal Operation, Color And Sound Of Exhaust
MAINTENANCE Accelerator Pedal Operation, Color and Sound of Exhaust --- every 10 hours (check daily) WARNING: Put the F-N-R lever in neutral, engage the parking brake, set the bucket on the ground level, and chock the tires. Operate accelerator pedal (1), gradually pressing it in; the engine speed should increase smoothly.
Page 302: Damage Or Looseness Of Rearview Mirrors
MAINTENANCE Damage or Looseness of Rearview Mirrors --- every 10 hours (check daily) Check that inside rearview mirror (1) and outside rearview mirror (2) (cab-equipped machines) are facing in the correct direction and check for dirt or damage. Cab-Equipped Machine Canopy-Equipped Machine M4FG-01-033 Damage or Looseness of Steps or Handrails --- every 10 hours (check daily)
Page 303: Inspect Sound Dampening Mat Around Engine
MAINTENANCE Inspect Sound Dampening Mat around Engine --- every 1000 hours CAUTION: If the sound dampening mat inside the engine compartment peels, it may touch hot parts inside the compartment, leading to a fire. Check that the sound dampening mat around the engine has not peeled.
Page 304: Retighten Front Axle Mounting Nuts, Rear Axle And Transmission Mounting Nuts
MAINTENACE Retighten Front Axle Mounting Nuts, Rear Axle and Transmission Mounting Nuts --- every 1000 hours (first time only, at 50 hours) Check for looseness of front axle mounting nuts, rear axle and transmission mounting nuts. Torques when Retightening Front Axle Mounting Nuts, Rear Axle and Transmission Mounting Nuts Front Axle Rear Axle,...
Page 305: Tighten And Retighten Nuts And Bolts
MAINTENACE Tighten and Retighten Nuts and Bolts --- every 250 hours (first time only, after 50 hours) Tighten or retighten nuts and bolts used on this machine in accordance with the torque values shown in the following table. Also, replace any damaged nuts or bolts. Check daily for loose or missing nuts and bolts before and after work;...
Page 306 MAINTENACE Tightening Torque Chart Hexagon Wrench Socket Bolt Bolt Wrench Wrench Dia. Socket Bolt size size N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft) 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.1) (3.0) (22) (2.0) (1.0) (7.4) (2.0)
Page 307 MAINTENACE 1. Front Axle Mounting Nuts Bolt Diameter (in) 20 (0.8) Qty. MNCH-07-029 2. Rear Axle, Transmission Mounting Nuts Bolt Diameter (in) 20 (0.8) Qty. 3. Wheel Rim Mounting Nuts M4FG-07-051 Bolt Diameter (in) 22 (0.9) Qty. M4FG-07-032 7-91...
Page 308 MAINTENACE 4 Propeller Shaft Mounting Bolts Bolt Diameter (in) 10 (0.4) Qty. M4FG-07-052 M4FG-07-070 5. HST Motor Mounting Bolts Bolt Diameter (in) 16 (0.6) Qty. 6. HST Pump Mounting Bolts Bolt Diameter (in) 16 (0.6)/12 (0.5) Qty. MNCH-07-030 7-92...
Page 309 MAINTENACE 7. Engine Mounting Bolts; Bracket Front Rear Bolt Diameter (in) 12 (0.5) 14 (0.6)/12 (0.5) Qty. MNCH-07-031 8. Engine Mounting Bolts; Rubber Cushion Bolt Diameter (in) 18 (0.7) Qty. 9. Muffler Mounting Nuts MNCH-07-031 Bolt Diameter (in) 10 (0.4) Qty.
Page 310: Mounting Nuts
MAINTENACE 10. Counterweight Mounting Bolts Bolt Diameter (in) 20 (0.8) Qty. 11. Upper Center Pin MNCH-01-517 Retainer fixing Mounting nuts nuts Bolt Diameter (in) 24 (0.9) 10 (0.4) Qty. MNCH-07-033 12. Lower Center Pin Rotation Block Bolt Diameter (in) 12 (0.5) MNCH-07-034 Qty.
Page 311 MAINTENACE 13. Loader Front Pin Rotation Blocks Bolt Diameter (in) 12 (0.5) Qty. M4FG-07-059 14. Steering Cylinder Pin Rotation Blocks Bolt Diameter (in) 12 (0.5) Qty. M4FG-07-060 15. Radiator Frame Mounting Bolts Bolt Diameter (in) 12 (0.5)/10 (0.4) Qty. M4FG-07-061 7-95...
Page 312 MAINTENACE 16. Cutting Edge Mounting Nuts Bolt Diameter (in) 16 (0.6) Qty. M4FG-07-062 17. Canopy Mounting Bolts Bolt Diameter (in) 16 (0.6) Qty. M4FG-07-063 18. Cab Rubber Cushion Bolt Diameter (in) 16 (0.6) Qty. M4FG-07-064 7-96...
Page 314: 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 315 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 8. After warming up the engine, cycle the front attachment system. Slowly operate the loader control lever 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 316 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 318: Storage
STORAGE Removing the Machine from Storage WARNING: In case lubrication operation is unavoidably performed indoors, open windows and doors to maintain good air ventilation to prevent asphyxiation. Lubricant property will deteriorate even if the machine is kept stored. Check all lubricants before operating the machine after being stored.
Page 319 STORAGE 1. Remove the covers. 2. Remove grease from the cylinder rods if coated. 3. Fill the fuel tank. Bleed air from the fuel system. Check all fluid levels. 4. Adjust the alternator and fan belt tension. 5. Check the oil level. Add oil as needed. 6.
Page 320 STORAGE MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................10-4...
Page 322: Troubleshooting
TROUBLESHOOTING Engine does not Start. Symptom Cause Solution The starter does not turn. Reduced battery voltage Charge the batteries. Replace. High resistance in the starter circuit * Clean and/or retighten the battery terminals and starter terminals. Faulty key switch * Replace Damaged wire harness * Repair, Replace Faulty battery relay...
Page 323 TROUBLESHOOTING Hydraulic System After the machine has been kept stored for a long time, air in the oil may be separated and accumulate in the upper section in the cylinder, causing slow response time in operation or reducing cylinder power. In case these symptoms appear, repeatedly operate all actuators several times.
Page 324 TROUBLESHOOTING Drive Function Steering System Symptom Cause Solution Steering wheel is heavy to operate. Faulty hydraulic pump * Repair, Replace Faulty steering device * Repair, Replace Relief valve set pressure reduction *Adjust Faulty steering column * Repair, Replace Steering wheel turns in unexpected Faulty steering device * Repair, Replace direction.
Page 325 TROUBLESHOOTING Service Brake Symptom Cause Solution Service brake does not work properly. Malfunction of brake valve * Repair, Replace Oil leak from brake line, Air mixing * Repair, Bleed air Brake is dragged. Malfunction of brake valve * Repair, Replace Faulty brake pedal * Repair, Replace Lack of brake fluid (hydraulic oil)
Page 326 TROUBLESHOOTING MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................11-6...
Page 328: Specifications (Canopy)
SPECIFICATIONS Specifications (Cab) 45 ° 40 ° MNCH-12-004 Model ZW80-5B Bucket Type Coupler Type Bucket Capacity (heaped) 0.9 (1.18) Operating Weight kg (lb) 5715 (12600) Straight kgf (lbf ) 3840 (8470) Static Tipping Load Full 40 degree turn kgf (lbf ) 3250 (7170) Engine DEUTZ TD2.9L4 49 kW/2200 rpm (67 PS/2200rpm)
Page 330: Optional Attachments
OPTIONAL ATTACHMENTS Quick Coupler Working with a Quick Coupler (Hydraulic) WARNING: Do not allow anyone in the area during this job. The quick coupler systems make it easy to change from one work attachment, such as a bucket, to another one. It may not be possible to attach any extra buckets purchased or already owned buckets if the stopper is not adjusted.
Page 331 OPTIONAL ATTACHMENTS Quick Coupler 3. Move attachment control lever (5) forward to Remove to withdraw coupler cylinder pins (4) (left and right). Remove 4. Lowering the arm slightly and tilting the attachment forward allows the bucket (attachment) to be removed from the quick coupler.
Page 332 OPTIONAL ATTACHMENTS Quick Coupler Installation WARNING: Mounting an attachment is complete only after confirming that coupler pins (6) (left and right) are in position. Apply the parking brake before getting down off the machine. IMPORTANT: Grease the surfaces of coupler pins (6) before mounting an attachment to prevent galling.
Page 333 OPTIONAL ATTACHMENTS Quick Coupler Connecting Hydraulic Hoses It is necessary to connect and disconnect hydraulic hoses in order to use the hydraulic pressure from the machine, when an attachment is equipped with hydraulic cylinders other than lift arm and bucket cylinders. To do so, follow the steps below for connecting and disconnecting hydraulic hoses.
Page 334 OPTIONAL ATTACHMENTS MEMO ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................13-6...
Page 336: Index
INDEX Coolant ..................... 7-57 Fuse Box B (Cab) ..............1-56, 7-69 Coolant Temperature Gauge ............ 1-12 Cooling System ................7-57 GETTING ON/OFF THE MACHINE ..........1-3 General Precautions for Cab ............S-5 DRIVING MACHINE ................4-1 Grading ....................5-9 Damage or Looseness of Rearview Mirrors ......7-86 Greasing ...................
Page 337 INDEX Monitor Operation Checks ............3-8 Provide Signals for Jobs Involving Multiple Machines..S-11 Monitor Panel ...................1-7 Mono-Lever Type ............1-6, 1-42, 1-43 Quick Coupler ................13-1 Move and Operate Machine Safely ...........S-8 Radio Unit (Optional) ..............1-64 Name of Components ........1-1, 1-48, 1-51, 1-52 Rear Wiper Switch (Cab-Equipped Machine) .....
Page 338 INDEX Stop ....................4-12 Stop and Restart of Travel ............4-7 Stopping the Engine ..............3-14 STORAGE ..................10-1 Store Attachments Safely ............S-22 Storing the Machine ..............10-1 Sun Visor ..................1-59 Support Machine Properly ............S-26 Support Maintenance Properly ..........S-27 Switch Operation ................

Hitachi ZW 80-5B Operator's Manual

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