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Hitachi EX1900-5, Operator'S Manual

The Hitachi EX1900-5 Operator's Manual is a comprehensive guide to operating and maintaining the powerful excavator. Download this manual for free from our website and unlock valuable insights into machine functionalities, safety procedures, and troubleshooting techniques. Enhance your productivity and maximize your investment with this essential manual.

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CONTENTS

Loading Shovel Front Joint Pins ..................7-22
Backhoe Front Joint Pins.............................7-25
Swing Bearing..............................................7-28
Swing Internal Gear .....................................7-29
Center Joint .................................................7-30
Operating the Lubricator ..............................7-31

B. Engine..........................................................7-33

Engine Oil Level...........................................7-34
Change Engine Oil.......................................7-35
Replace Engine Oil Filters ...........................7-35
Check Alternator Belt Tension .....................7-36
Check Injection Nozzle ................................7-37
Inspect Bolts and Nuts Outside Engine .......7-37
Inspect and Adjust Valve Clearance............7-37
Check Fuel Injection Timing ........................7-37
Check Starter and Alternator .......................7-37
Check Turbocharger....................................7-37

C. Transmission ..............................................7-38

Pump Transmission.....................................7-39
Swing Reduction Gear .................................7-42
Travel Reduction Gear.................................7-44

D. Hydraulic System .........................................7-46

Inspection and Maintenance
of Hydraulic Equipment................................7-47
Check Hydraulic Oil Level............................7-49
Drain Hydraulic Oil Tank Sump ...................7-50
Change Hydraulic Oil ...................................7-51
Replace Full-Flow Filter and Drain Filter......7-54
Replace Pilot Oil Filter .................................7-56
Suction Filter ...............................................7-58
Replace High-Pressure Strainer ..................7-60
Clean Oil Cooler Core..................................7-61
Check Hoses and Lines...............................7-62
Service Recommendations for

Hydraulic Fittings ...................................7-65

E. Fuel System .................................................7-67

Refueling......................................................7-67
Drain Fuel Tank Sump.................................7-69
Water Separator Filter .................................7-69
Replace Fuel Filter.......................................7-70
Check Fuel Hoses .......................................7-72

F. Air Cleaner ...................................................7-74

Clean Air Cleaner Outer Element ................7-74
Replace Air Cleaner Outer

and Inner Elements ...............................7-74

G. Cooling System............................................7-76

Check Coolant Level....................................7-78
Clean Radiator Core ....................................7-80
Clean Intercooler Core.................................7-80

H. Air Conditioner .............................................7-81

Recirculation Air Filter..................................7-81
Ventilation Air Filter......................................7-82
Check Refrigerant Quantity .........................7-83
Check Compressor Belt Tension.................7-84
Clean Condenser Core ................................7-85
Check Tightening Torque ............................7-86

Seasonal Maintenance................................ 7-87

I.

Electrical System ........................................ 7-88
Batteries ...................................................... 7-88
Replace Batteries ........................................ 7-91
Replacing Fuses.......................................... 7-92
Power Source Terminal............................... 7-94
Fusible Link ................................................. 7-95
Check Electrical Cables and

Wire Harnesses for Short Circuits ........ 7-96

Check Emergency Engine Stop Switch....... 7-98

J. Miscellaneous ............................................. 7-99

Check Bucket Teeth.................................. 7-100
Inspect Emergency Evacuation

Equipment and Hanger ....................... 7-104

Auto-Lubrication System ........................... 7-105
Check and Replace Seat Belt ................... 7-109
Check Windshield Washer Fluid Lever..... 7-109
Check and Adjust Track Sag .................... 7-110
Check Accumulator and Track

Adjuster Cylinder Circuit...................... 7-112

Check Side Frame Area............................ 7-112
Check Tightening Torque of Bolts

and Nuts.............................................. 7-113

MAINTENANCE UNDER SPECIAL

   ENVIRONMENTAL CONDITIONS

Maintenance Under Special

Environmental Conditions ............................. 9-1

STORAGE

Storing the Machine........................................... 10-1
Removing the Machine from Storage................ 10-2

TROUBLESHOOTING

Engine Troubleshooting..................................... 11-1
Engine .............................................................. 11-3
Electrical System ............................................... 11-7
Control Levers ................................................. 11-10
Hydraulic System............................................. 11-10
Auto-Idle .......................................................... 11-13

SPECIFICATIONS

Specifications ................................................... 12-1
Working Range (Loading Shovel) ..................... 12-2
Working Range (Backhoe) ................................ 12-3

INDEX

............................................................. 14-1

Summary of Contents for EX1900-5

Page 1: ......

Page 2: ...oduct is out of warranty Should the equipment be abused or modified to change its performance beyond the original fac tory specifications the warranty will become void and field improvements may be denied Setting fuel delivery above specifications or otherwise overpower ing machines will result in such action Moreover when replacement parts are required be sure to use genuine Hitachi parts Failure...

Page 3: ...CT IDENTIFICATION NUMBER PRODUCT IDENTIFICATION NUMBER NOTE 18CP000101 PRODUCT IDENTIFICATION NUMBER PIN ENGINE TYPE AND SERIAL NUMBER TYPE MFG NO TRAVEL MOTOR TYPE AND SERIAL NUMBER TYPE MFG NO M18C 01 001 M18C 01 001 M18C 01 002 M144 12 002 Marks to indicate the start and end of the PIN ...

Page 4: ... SERIAL NUMBER TYPE MFG NO HYDRAULIC PUMP TYPE AND SERIAL NUMBER TYPE MFG NO FRONT TYPE AND SERIAL NUMBER Loading Shovel TYPE MFG NO BUCKET TYPE AND SERIAL NUMBER Loading Shovel TYPE MFG NO M18C 01 003 M18C 01 004 M117 12 001 M117 12 003 ...

Page 5: ...HINE NUMBERS FRONT TYPE AND SERIAL NUMBER Backhoe Boom TYPE MFG NO FRONT TYPE AND SERIAL NUMBER Backhoe Arm TYPE MFG NO BUCKET TYPE AND SERIAL NUMBER Backhoe TYPE MFG NO M18C 01 033 M18C 01 005 M146 01 020 ...

Page 6: ...23 Evacuating in Case of Fire S 24 Beware of Exhaust Fumes S 24 Precautions for Welding and Grinding S 25 Avoid Heating Near Pressurized Fluid Lines S 26 Avoid Applying Heat to Lines Containing Flammable Fluids S 26 Remove Paint Before Welding or Heating S 26 Prevent Battery Explosions S 27 Service Air Conditioning System Safely S 27 Handle Chemical Products Safely S 28 Dispose of Waste Properly S...

Page 7: ...MACHINE Drive the Machine Carefully 4 1 Steering the Machine Using Pedals 4 2 Steering the Machine Using Levers 4 3 Travel Speed Switch 4 4 Travel Alarm 4 5 Traveling 4 6 Operating on Soft Ground 4 7 Raise One Track Using Boom and Arm 4 7 Towing Machine a Short Distance 4 8 Operating in Water or Mud 4 9 Precautions for Traveling on Slopes 4 10 Parking the Machine on Slopes 4 11 Parking the Machine...

Page 8: ...r Cleaner Outer and Inner Elements 7 74 G Cooling System 7 76 Check Coolant Level 7 78 Clean Radiator Core 7 80 Clean Intercooler Core 7 80 H Air Conditioner 7 81 Recirculation Air Filter 7 81 Ventilation Air Filter 7 82 Check Refrigerant Quantity 7 83 Check Compressor Belt Tension 7 84 Clean Condenser Core 7 85 Check Tightening Torque 7 86 Seasonal Maintenance 7 87 I Electrical System 7 88 Batter...

Page 9: ...azardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs Some safety signs don t use any of the designated signal words above after the safety al...

Page 10: ...r are in tended to illustrate basic safety procedures of machines However it is impossible for these safety messages to cover every hazardous situation you may encounter If you have any questions you should first consult your su pervisor and or your authorized dealer before operating or performing maintenance work on the machine 003 E01B 0003 SA 003 PREPARE FOR EMERGENCIES Be prepared if a fire st...

Page 11: ...rating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating the machine 005 E01A 0438 SA 438 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 006 E01A 0434 SA ...

Page 12: ...Store them in their specified locations Avoid storing transparent bottles in the cab Don t at tach any transparent type window decorations on the windowpanes as they may focus sunlight possibly starting a fire Refrain from listening to the radio or using music headphones or mobile telephones in the cab while op erating the machine Keep all flammable objects and or explosives away from the machine ...

Page 13: ...ippery conditions on platforms steps and handrails when leaving the machine 008 E01A 0439 SA 439 ADJUST THE OPERATOR S SEAT A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations The seat should be adjusted whenever changing the operator for the machine The operator should be able to fully depress the ped als and to correctl...

Page 14: ... SAFELY Bystanders can be run over Take extra care not to run over bystanders Confirm the location of bystanders before moving swinging or operating the machine Always keep the travel alarm and horn in working con dition if equipped It warns people when the machine starts to move Use a signal person when moving swinging or operat ing the machine in congested areas Coordinate hand signals before st...

Page 15: ... be jump started be sure to follow the instructions shown in the OPERATING THE EN GINE chapter The operator must be in the operator s seat so that the machine will be under control when the engine starts Jump starting is a two person operation Never use a frozen battery Failure to follow correct jump starting procedures could result in a battery explosion or a runaway ma chine S013 E01A 0032 SA 03...

Page 16: ...vations and road shoulders When working on an incline or on a road shoulder employ a signal person as required Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist When the footing is weak reinforce the ground before starting work When working on frozen ground be extremely alert As ambient temperatures rise footing becomes...

Page 17: ...l personnel obey the signal person s direc tions 018 E01A 0481 SA 481 CONFIRM DIRECTION OF MACHINE TO BE DRIVEN Incorrect travel pedal lever operation may result in seri ous injury death Before driving the machine confirm the position of the undercarriage in relation to the operator s position If the travel motors are located in front of the cab the machine will move in reverse when travel ped als...

Page 18: ...ay cause the machine to slip or over turn possibly resulting in serious injury or death When driving up or down a slope keep the bucket fac ing the direction of travel approximately 0 5 to 1 0 m approximately 1 8 to 3 3 A above the ground If the machine starts to skid or becomes unstable im mediately lower the bucket to the ground and stop Driving across the face of a slope or steering on a slope ...

Page 19: ...ls to the ground Turn the auto idle switch off Run the engine at slow idle speed without load for 5 minutes to cool down the engine Stop the engine and remove the key from the key switch Pull the pilot control shut off lever to LOCK position Block both tracks and lower the bucket to the ground Thrust the bucket teeth into the ground if you must park on a grade Position the machine to prevent rolli...

Page 20: ...NDERS BEFORE MOVING MACHINE USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED ALWAYS KEEP THE SIGNAL PERSON IN VIEW Use hand signals which conform to your local regula tions when work conditions require a signal person No machine motions shall be made unless signals are clearly understood by both signalman and operator Learn the meanings of all flags signs and markings used on the job...

Page 21: ... E01A 0386 SA 386 NEVER POSITION BUCKET OVER ANYONE Never lift move or swing bucket above anyone or a truck cab Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket 023 E01A 0487 SA 487 AVOID UNDERCUTTING In order to retreat from the edge of an excavation if the footing should collapse always position the undercar riage perpendicular to the edge ...

Page 22: ...Keep the bucket low to the ground and close to the machine Reduce operating speeds to avoid tipping or slipping Avoid changing direction when traveling on grades NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable Reduce swing speed as necessary when swinging loads Be careful when working on frozen ground Temperature increases will cause the ground t...

Page 23: ...WITH CAUTION If the front attachment or any other part of the machine hits against an overhead obstacle such as a bridge both the machine and the overhead obstacle will be damaged and personal injury may result as well Take care to avoid hitting overhead obstacles with the boom or arm 028 E01A 0389 SA 389 AVOID POWER LINES Serious injury or death can result if the machine or front attachments are ...

Page 24: ...arefully Never move it sud denly Keep all persons will away from the load Never move a load over a person s head Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground Never attach a sling or chain to the bucket teeth They may come off causing the load to fall 030 E01A 0014 SA 014 PROTECT AGAINST FLYING DEBRIS If flying debris hit ey...

Page 25: ... SA 390 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 Always stop the engine before refueling the machine Fill the fuel tank outdoors All fuels most lubricants and some coolants are flam mable St...

Page 26: ...he LOCK posi tion 10 Allow the engine to cool If a maintenance procedure must be performed with the engine running do not leave machine unattended If the machine must be raised maintain a 90 to 110 angle between the boom and arm Securely support any machine elements that must be raised for service work Never work under a machine raised by the boom Inspect certain parts periodically and repair or r...

Page 27: ...7 SA 287 SUPPORT MACHINE PROPERLY Never attempt to work on the machine without securing the machine first Always lower the attachment to the ground before you work on the machine If you must work on a lifted machine or attachment securely support the machine or attachment Do not support the machine on cinder blocks hollow tires or props that may crumble under continuous load Do not work under a ma...

Page 28: ...uction 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 503 E01B 0344 SA 344 STORE ATTACHMENTS SAFELY Stored attachments such as buckets hydraulic hammers and blades can fall and cause serious injury or death Securely store atta...

Page 29: ...become hot dur ing operation The engine hoses lines and other parts become hot as well Wait for the oil and components to cool before starting any maintenance or inspection work 505 E01B 0498 SA 039 SA 225 REPLACE RUBBER HOSES PERIODICALLY Rubber hoses that contain flammable fluids under pres sure may break due to aging fatigue and abrasion It is very difficult to gauge the extent of deterioration...

Page 30: ...ulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard take care to protect hands and body from high pressure fluids Wear a face shield or goggles for eye protection If an accident occurs see a doctor familiar with this type of injury immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may r...

Page 31: ...lectrical cables and wires Check before each shift or after eight 8 to ten 10 hours operation for missing or damaged terminal caps DO NOT OPERATE MACHINE if cable or wires are loose kinked etc Clean up Flammables Spilled fuel oil antifreeze fluid and window washer fluid and trash grease debris accumulated coal dust and other flammables may cause fires Prevent fires by inspecting and cleaning the m...

Page 32: ...e repaired or replaced before operating the machine 508 E02A 0393 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 In an emergency if the cab door or front window can not be opened break the front or rear window panes with...

Page 33: ...e before starting welding Only qualified personnel should perform welding Never allow an unqualified person to perform welding Grinding on the machine may create fire hazards Store flammable objects in a safe place before starting grind ing After finishing welding and grinding recheck that there are no abnormalities such as the area surrounding the welded area still smoldering 523 E01A 0818 SA 818...

Page 34: ...lammable fluids Clean them thoroughly with nonflammable solvent be fore welding or flame cutting them 510 E01B 0030 SA 030 REMOVE PAINT BEFORE WELDING OR HEATING Hazardous fumes can be generated when paint is heated by welding soldering or using a torch If inhaled these fumes may cause sickness Avoid potentially toxic fumes and dust Do all such work outside or in a well ventilated area Dispose of ...

Page 35: ...se terminals may produce sparks Securely tighten all terminals Battery electrolyte is poisonous If the battery should ex plode battery electrolyte may be splashed into eyes pos sibly resulting in blindness Be sure to wear eye protection when checking electro lyte specific gravity 512 E01B 0032 SA 032 SERVICE AIR CONDITIONING SYSTEM SAFELY If spilled onto skin refrigerant may cause a cold contact b...

Page 36: ...oducts used with your ma chine 515 E01A 0309 SA 309 DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the environ ment 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 drinkin...

Page 37: ...SAFETY SIGNS S 29 SS 411 SS 691 SS 442 M18C 01 006 SS 445 M144 07 107 ...

Page 38: ...SAFETY SIGNS S 30 SS 446 SS 723 SS3076117 SS 723 SS 410 SS 723 Loading Shovel ...

Page 39: ...SAFETY SIGNS S 31 SS3091476 M146 01 035 ...

Page 40: ...SAFETY SIGNS S 32 SS 413 M18C 01 007 M18C 01 008 ...

Page 41: ...33 SS 449 M18C 01 010 SS4420336 Sign indicates a burn hazard from spurting hot water or oil if radiator or hydraulic tank is uncapped while hot Al low radiator or hydraulic tank to cool before removing cap M18C 01 009 ...

Page 42: ...SAFETY SIGNS S 34 MEMO ...

Page 43: ...m Cylinder 7 Boom 8 Cab 9 Emergency Escape Device Hanger 10 Emergency Escape Device Case 11 Fuel Tank 12 Radiator Intercooler 13 Counterweight 14 Travel Device 15 Ladder 16 Track Shoe 17 Link B 18 Link A Loading Shovel M18C 01 038 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Backhoe M18C 01 011 5 6 7 18 3 2 1 17 ...

Page 44: ...e machine always maintain a three point contact with the steps and handrails and face the machine Never jump on or off the machine Never mount or dismount a moving machine Be careful of slippery conditions on platforms steps and handrails when leaving the machine Ladder extending retracting speed can be changed by ad justing bolt 2 Clockwise Turn Faster Extending Retracting Speed Counterclockwise ...

Page 45: ... up ladder 1 to locked position OPERATING LADDER ON THE UPPER STRUCTURE CAUTION Step back immediately after releasing ladder lock as spring force slides the ladder up quickly potentially causing injury Extending 1 Pull up handle 5 to release lock 2 Push down the ladder to locked position Retracting 1 Pull up handle 6 to release lock 2 Pull up the ladder to locked position M18C 01 012 M18C 01 034 M...

Page 46: ...e belt 6 around your chest 5 While holding two ropes move to the outside fence and face toward the cab as long as the two ropes are held emergency escape device will not operate 6 As soon as the ropes are released your body is slowly lowered Descend while softly pushing the ma chine surface by hand to prevent the body from turn ing 7 After landing immediately take life belt 6 off and evacuate to a...

Page 47: ...serious personal injury or death Avoid the risk of injury or death while evacuating from the machine during a fire by checking the following regularly Always check if left window 1 can be opened and closed smoothly before starting the engine If it fails to open or close smoothly repair the window Left win dow 1 can be used as an emergency exit Malfunction of emergency escape device 4 worn rope or ...

Page 48: ...s on fire first evacuate from cab 11 through cab door 6 to cab side platform 10 Then get off the machine using emergency escape device 4 Emergency rope 3 is provided in the case located on the left outside wall of the cab see the EMERGENCY ESCAPE DEVICE chapter If the fire is around cab door 6 evacuate the cab by opening left window 1 and stepping to platform 10 Then get off the machine using the ...

Page 49: ... Travel Lever 6 Right Travel Pedal 7 Bucket Open Pedal For Loading Shovel 8 Right Control Lever 9 Pilot Control Shut Off Lever 10 Switch Panels Right 11 Operator s Seat 12 Monitor Panel and Switch Panels Left 13 Hour Meter 14 Glove Compartment 15 Trainer Seat 16 Fuse Box M146 01 002 M144 01 033 M146 01 023 M146 07 048 1 2 3 4 5 6 7 9 10 11 13 8 12 15 14 16 ...

Page 50: ...OPERATOR S STATION 1 8 MONITOR PANEL AND SWITCH PANELS LEFT M146 01 039 1 Monitor Panel 2 Switch Panel 3 FM AM Radio 4 Ashtray 5 Engine Speed Control Lever 2 1 5 4 3 ...

Page 51: ...Mode Indicator Slow Speed 16 Auto Idle Indicator 17 Engine Room Light Indicator 18 Entrance Light Indicator 19 Preheat Indicator 20 Travel Mode Indicator Fast Speed 21 Coolant Level Indicator Warning 22 Auto Lubrication Indicator 23 Engine Stop Indicator Warning 24 Engine Warning Indicator 25 Engine Exhaust Gas Temperature Indicator Warning 26 Air Cleaner Restriction Indicator Warning 27 Pump Cont...

Page 52: ...contact your author ized dealer COOLANT TEMPERATURE GAUGE Start the engine Run at slow idle until the needle enters green zone indicating normal operating temperature IMPORTANT Prevent possible engine damage Do not stop engine when needle enters red zone as temperature will rise further Instead reduce load and run engine at slow idle If the needle enters the red zone reduce the load immedi ately a...

Page 53: ...ine damage If engine oil pressure indicator comes on while operating stop the engine imme diately Red indicator will light and buzzer will sound when engine oil pressure is low Stop the engine immediately NOTE Cold oil low oil level or operating on a steep slope may cause indicator to light OVERHEAT INDICATOR WARNING Red indicator will light and buzzer will sound when the en gine coolant overheats...

Page 54: ... liters 79 US gal of fuel remains ENGINE OIL LEVEL INDICATOR When level check switch is pushed green indicator will light if level is adequate for operation NOTE This check does NOT take the place of daily inspection DOWNLOAD INDICATOR When the monitoring system optional is provided the green indicator comes ON if the system memory is fully occupied If the indicator comes ON download the data Ask ...

Page 55: ...INDICATOR When level check switch is pushed green indicator will light if hydraulic oil level is adequate for operation NOTE This check does NOT take the place of daily inspection TRAVEL MODE INDICATOR SLOW SPEED This indicator will light when the travel mode is shifted to the slow travel speed mode AUTO IDLE INDICATOR This indicator will light when the auto idle device is turned ON M117 01 035 M1...

Page 56: ...LIGHT INDICATOR This indicator will light when the entrance lights located at the cab rear is ON PREHEAT INDICATOR This indicator stays ON during preheating When preheat ing is complete the indicator goes OFF TRAVEL MODE INDICATOR FAST SPEED This indicator will light when the travel mode is shifted to the fast travel speed mode M117 01 045 M117 01 046 M157 01 013 M585 01 010 ...

Page 57: ...n the MANUAL or OFF position ENGINE STOP INDICATOR WARNING If any serious abnormal condition occurs in the engine and or engine related parts the red indicator comes ON Automatically the engine speed may be reduced or the engine may be stopped depending on the extent of the ab normal condition Immediately set the machine in the safety position and stop the engine Then contact your nearest Hitachi ...

Page 58: ...e engine is operated with the exhaust temperature excessively high damage to the engine may result As soon as the indicator comes ON reduce the engine speed to the slow idle speed to lower the exhaust temperature AIR CLEANER RESTRICTION INDICATOR WARNING Red indicator will light when the air cleaner elements are clogged Clean or replace outer elements PUMP CONTAMINATION INDICATOR WARNING Red indic...

Page 59: ...N under this condition The indicator will go off when the emergency engine stop switch is turned to the NORMAL position The starter will operate Other engine emergency stop switches are located as fol lows Engine Compartment Two Switches Pump Compartments Two Switches LADDER POSITION INDICATOR WARNING While the ladder is extended this red indicator will light and the machine will not be able to sw...

Page 60: ...ide Panel 7 Air Conditioner Front Panel 8 Indicator Light Check Switch 9 Level Check Switch 10 Buzzer Stop Switch 11 Dimmer Switch 12 Engine Speed Control Lever 13 Work Light Switch 14 Dome Light Switch 15 Engine Room Light Switch 16 Entrance Light Switch 17 Travel Speed Switch 18 Auto Idle Switch 19 Spare 20 Preheat Switch 4 3 6 7 8 9 10 11 20 19 18 17 15 14 13 12 5 2 1 16 ...

Page 61: ... position E Wiper operates at approx 4 second intervals position F Wiper operates at approx 8 second intervals position G Wiper operates at approx 15 second intervals LONG position H Wiper operates at approx 25 second intervals WASHER SWITCH IMPORTANT Washer motor may be damaged if washer switch 4 is held for more than 20 seconds or continually operated with no fluid in the washer tank Press washe...

Page 62: ...n trol panels are provided in the cab each designated for one of the three air conditioners Component Designation 1 Front Air Flow Vents 2 Side Air Flow Vents 3 Rear Air Flow Vents NOTE Direction of air flowing out of each vent can be changed by adjusting the louver 4 Air Conditioner Front Panel 5 Air Conditioner Side Panel 6 Air Conditioner Rear Panel M117 01 054 M144 01 012 M146 01 035 M18C 01 0...

Page 63: ...rature control switch 10 to increase the temperature Press temperature control switch 10 to decrease the temperature Temperature Indicator 11 The number of the lit LEDs indicates the relative tem perature of the air blowing out The higher the number of the lit LEDs the higher the temperature of the air blowing out is Blower Control Switches 12 Control blower speed using these switches Each time bl...

Page 64: ...l flow from the vents Use temperature control switch 10 and blower control switch 12 to adjust the temperature inside the cab HEATING Set the temperature to the highest setting using tempera ture control switch 10 Repeatedly press temperature control switch 10 until all temperature indicators 11 turn on Press blower control switch 12 to turn on the blower fan Warm air will flow from the vents Use ...

Page 65: ...ors 11 turn on Press blower control switch 12 to turn on the blower fan Press air conditioner switch 8 Air conditioner indica tor 9 should turn on Warm air will flow from the vents Adjust front air flow vents 1 and side air flow vents 2 so that the air flow is directed toward the windshield Use temperature control switch 10 and blower control switch 12 to adjust the temperature inside the cab M117...

Page 66: ... temperature control switch 10 until all temperature indicators 11 turn on Repeatedly press blower switch 12 to the high speed position until blower indicator 13 comes on Adjust front air flow vents 1 and side air flow vents 2 so that the air flow is directed toward the windshield M117 01 054 M117 01 050 M144 01 012 11 1 12 10 13 2 ...

Page 67: ... switch 12 to turn on the blower fan Air will flow from the vents VENTILATION THE CAB Turn on the fresh air indicator using ventilation switch 7 Set the temperature to the lowest setting using temperature control switch 10 Repeatedly press temperature control switch 10 until only the leftmost temperature indi cator 11 is on Press blower control switch 12 to turn on the blower Fresh air will flow f...

Page 68: ...to light the in dicator bulb may be burned out Engine warning indi cator 6 will go OFF after staying ON for approx 2 seconds 2 When indicator light check switch 1 is pressed and held all indicators will come ON and stay ON until the switch is released If any indicator fails to light the in dicator bulb may be burned out 3 The buzzer will sound as long as indicator light check switch 1 is depressed...

Page 69: ... panel will light when level check switch 1 is pushed NOTE Use the level check switch only when the en gine is stopped IMPORTANT The monitor system on this machine is not intended to guarantee the complete machine condition Don t relay only on the monitor indication Be sure to per form visual checks such as oil levels at regular intervals to ensure using the ma chine safely M18C 01 023 M18C 01 024...

Page 70: ...w Engine oil pressure indicator 4 lights also 4 Engine coolant overheat Overheat indicator 5 lights also 5 Hydraulic oil tank oil level is low Hydraulic oil level indicator 6 lights also 6 Stop valve in the low pressure circuit is closed Stop valve indicator 7 lights also Depress buzzer stop switch 1 to stop buzzer Buzzer is automatically reset after releasing buzzer stop switch 1 If the buzzer so...

Page 71: ...erature gauge 6 ta chometer 7 and switches 8 illumination Clockwise Turn Brighter Illumination Counterclockwise Turn Darker Illumination ENGINE SPEED CONTROL LEVER Use engine speed control levers 9 to adjust engine speed Slow Idle Move lever 9 to the LOW position 10 Fast Idle Move lever 9 to the HIGH position 11 M18C 01 023 M146 01 039 M117 01 013 9 11 10 2 1 3 4 5 6 8 7 ...

Page 72: ... air cond panels 3 fuel gauge 4 hydraulic oil temperature gauge 5 coolant temperature gauge 6 tachometer 7 and radio 8 will be lit NOTE Work light 2 will stay ON for approx 1 minute and go OFF after the key switch is turned OFF with work light switch 1 ON M18C 01 022 M18C 01 014 M18C 01 006 M146 01 039 1 3 6 5 4 8 7 2 2 2 2 2 ...

Page 73: ...OPERATOR S STATION 1 31 DOME LIGHT SWITCH Press dome light switch 1 to turn on dome lights 2 and 3 located on the front and rear parts of the cab ceiling M18C 01 022 M144 01 033 M144 01 034 1 2 3 ...

Page 74: ... the engine room and in the pump room respectively Engine room light indicator 2 will also light NOTE Engine room lights 3 4 and 5 will stay ON for approx 1 minute go OFF after the key switch is turned OFF with engine room light switch 1 ON M18C 01 020 M141 01 017 M18C 01 025 M141 01 019 1 2 In Engine Room In Pump Room In Room Under the Cab 3 5 4 ...

Page 75: ...nce light switch 1 to turn on entrance light 3 Entrance light indicator 2 will also light NOTE Entrance light 3 will stay ON approx 1 minute go OFF after the key switch is turned OFF with entrance light switch 3 ON M18C 01 020 M18C 01 024 M18C 01 026 1 2 3 2 ...

Page 76: ...idle switch 4 is turned on engine speed de creases to the auto idle setting from the engine speed con trol lever setting approximately 4 seconds after the control levers are returned to neutral Auto idle indicator 5 stays on while auto idle switch 4 is turned on Push auto idle switch 4 again to turn off the auto idle func tion Auto idle indicator 5 will also be turned off M18C 01 020 M18C 01 024 M...

Page 77: ... switch 1 to the EMERG STOP position from the NORMAL position to stop the engine Air vent valve 3 located in front of the hydraulic oil tank will open at the same time to relieve pressure from the hydraulic oil tank Turn engine emergency stop switch 1 to the NOR MAL position to restart the engine KEY SWITCH 4 OFF Engine Off 5 ACC Horn Radio etc 6 ON Engine On 7 START Engine Start M117 01 093 M117 ...

Page 78: ...s turned ON completing pre heating NOTE Preheating starts only when key switch 1 is in the ACC position NOTE After preheating for more than 15 seconds if preheating is required again turn preheat switch 2 OFF Then wait for more than 60 seconds before restarting preheating Other wise preheating system will not operate After completing preheating turn preheat switch 3 OFF and close cover 4 Operate p...

Page 79: ...l and either en gine warning indicator 3 or engine stop indicator 4 lights or continues flashing display fault codes flashing the en gine warning indicator by operating engine troubleshooting switch 2 Don t operate engine troubleshooting switch 2 when the engine is normal Refer to the ENGINE TROUBLESHOOTING on page 11 1 for the details M146 07 048 M18C 01 029 M18C 01 023 M18C 01 023 1 2 3 4 ...

Page 80: ...he top of the left control lever The horn continuously sounds as long as switch 2 is pressed CAUTION If horn 3 does not sound when pushed immediately stop the engine and contact your authorized dealer for repair Operating the machine with a malfunctioning horn may result in personal injury or death M144 01 033 M177 01 057 M146 01 010 M18C 01 014 1 3 2 ...

Page 81: ...d 2 Automatic Search Function Press and hold one of tuning switch 5 for more than half a second until an electronic tone is heard then release The frequency display will move up to the next higher frequency station To go up to the next higher frequency station press and hold the tuning switch To go down to the next lower frequency station press and hold the tuning switch After displaying the next ...

Page 82: ...lock The functions of time set switch 8 and set switch 9 are as follows Time Set Switch H Each time set switch H is pressed the hour display will increase by one Time Set Switch M Each time set switch M is pressed the minute display will increase by one The time is displayed in 12 hour standard If either of the switches H or M is pressed and held the hour or minute display will change continuously...

Page 83: ...eight of the front part of the seat thus adjusting the an gle of the seat setting in the front part a The front part of the seat will be positioned in its highest position by pushing and holding of lever 1 without applying any weight against the seat In practice lean back against the backrest to take weight off the front part while pushing and holding lever 1 until the front part of the seat rises...

Page 84: ... to raise the armrest angle Turn the dial clockwise to lower the armrest angle Headrest Adjustment Headrest height and angle can be adjusted Pull headrest 7 upward or push downward to the de sired position Height adjustment range 50 mm 2 0 in Headrest 7 can be adjusted 60 degrees forward from the upright position Move headrest by hands to the desired angle Lumbar Support A lumbar support mechanism...

Page 85: ...ess of appearance Seat Belt 1 This machine is equipped with a retractable seat belt 1 2 Pull out the end of seat belt 1 and securely insert it into buckle 2 Confirm that seat belt 1 is not twisted NOTE If seat belt 1 is locked before the end is se curely inserted into buckle 2 release the end of seat belt 1 to completely return it to the original position Then retry 3 Push button 3 on buckle 2 to ...

Page 86: ...in the fully opened posi tion Open the door all the way until it locks in the latch on the side of the cab Push button 1 to unlock the door OPENING CAB LEFT WINDOW The cab left window can be opened Pull out lock pin 2 to unlock and open the cab left window M146 01 019 M146 01 035 1 2 ...

Page 87: ...r completion of local reas sembly be sure to operate the ma chine with the travel speed switch set to the slow speed mode Check lower rollers and front idlers every 10 minutes for excessively high temperature 4 Perform correct break in procedures for the front attachment pins 1 Operate the engine horsepower up to about 80 of full load 2 Avoid excessive engine idling 3 Check indicator lights and ga...

Page 88: ...ng points at the regular intervals Grease the front attachment pins every day 3 Retighten bolts at the regular intervals 4 Re drive in the tooth point holding wedges 5 Check the monitor for any abnormality while operat ing the machine 6 Operate the machine after thoroughly warming up the engine and hydraulic oil 7 Check the machine for any abnormal operations while operating the machine ...

Page 89: ...LUBRICATION Check lubrication points PROTECTIVE DEVICES Check guards shields and covers FIRE PREVENTION Clean machine of debris SAFETY Walk around machine to clear all persons from machine area Engine Counterweight Air Cleaner Oil Cooler Intercooler Radiator Lower Roller Pump High Pressure Strainer Front Idler Emergency Escape Device Hanger Compressor Track Adjuster Accumulator Accumulator Swing B...

Page 90: ...d engine stop in dicator 7 will come ON 2 Press indicator light check switch 3 As long as indicator light check switch 3 is pressed and held all indicators stay ON If any indicator fails to light the bulb may be burned out 4 Adjust the seat to allow full pedal and control levers stroke with operator s back against the backrest Fasten the seat belt NOTE Use a damp cloth when wiping dust off monitor...

Page 91: ...ls 3 and engine oil levels 2 indicators will light if levels are adequate for operation IMPORTANT Prevent possible machine damage Check fluid levels individually The level check does not take the place of daily inspection at hydraulic oil level window engine coolant reserve tank and engine oil level dipstick M18C 01 023 M18C 01 024 1 4 2 3 ...

Page 92: ...horn to alert bystanders 5 Turn the key switch to the START position and hold it there until the engine starts IMPORTANT Prevent damage to the starter Do not keep to rotate the starter more than 15 seconds If engine do not start do over again after 2 to 3 minute 6 When engine starts release key switch key switch 3 will automatically return to the ON position M117 05 002 M18C 01 022 M117 01 093 LOC...

Page 93: ...be complete and preheat indicator will go OFF CAUTION Preheating system doesn t operate unless key switch 1 is in the ACC position When preheat switch 5 is turned ON preheating is continuously performed for approx 30 seconds with key switch 1 in the ACC position If key switch 1 is turned to a position other than the ACC position before preheating is complete pre heating will be automatically compl...

Page 94: ...arge amount of cur rent so that the batteries will be quickly discharged if preheating is frequently performed Perform proper preheating corresponding to the ambient tempera ture table below for proper preheating time when the atmospheric temperature is below 5 C Ambient Temperature 5 C to 15 C 15 C or less 10 to 20 seconds 20 to 30 seconds M117 01 094 M18C 01 028 4 3 1 2 START ON ACC OFF ...

Page 95: ...indicator 3 is off 4 Pump transmission oil pressure indicator 4 is off 5 Engine oil pressure indicator 5 is off 6 Engine stop indicator 6 is off 7 Engine noise and exhaust gas are normal NOTE Handy engine troubleshooting can be done by checking the exhaust gas color Check with the engine running with no load after sufficient warm up operation Colorless or faint blue normal proper combustion Black ...

Page 96: ...e only 24 volt booster batteries When the machine batteries are exhausted start the en gine using booster batteries as shown below Connecting the booster batteries 1 Stop the engine of the machine on which booster bat teries are mounted 2 Connect one end of red cable to the positive ter minal of machine batteries 1 and the other end to the positive terminal of booster batteries 2 3 Connect one end...

Page 97: ...onnect the other end of black negative cable from booster batteries 3 3 Disconnect red positive cable from booster batter ies 2 4 Disconnect red positive cable from machine bat teries 1 M117 03 002 Machine Batteries Booster Batteries To Upperstructure of the Machine Red Upper Lower Black Connecting the Booster Batteries 4 3 2 1 ...

Page 98: ...vel surface 2 Lower the bucket to the ground 3 Turn auto idle switch 1 off IMPORTANT Turbocharger may be damaged if the engine is not properly shut down 4 Set engine speed lever 2 to the Low position Run the engine at slow idle speed without load for five minutes 5 Turn key switch 3 OFF Remove the key from key switch 3 6 Pull pilot control shut off lever 4 to the LOCK position M18C 01 020 M117 01 ...

Page 99: ...ulting in serious damage to the turbocharger 1 Turn emergency engine stop switch 1 in the cab from the NORMAL position to the EMERG STOP po sition when emergency engine stopping is required 2 Engine will stop and emergency engine stop indicator 2 on the monitor panel will come ON 3 At the same time air pressure is purged from the hy draulic oil tank 4 Turn emergency engine stop switch 1 to the NOR...

Page 100: ...rted with key switch Engine emergency stop indicator 2 will come ON at this time When engine stop switch 1 is turned to the EMERG STOP position the engine will be stopped Turn engine stop switch 1 to the NORMAL position to restart the en gine NOTE Although the engine stops in case the engine stop switches are turned to the EMERG STOP position air pressure will not be purged from the hydraulic oil ...

Page 101: ... tracks using boom move machine care fully to prevent damage to drive train and tracks If engine stops under load remove the load Start engine immediately Run the engine 30 seconds in slow idle speed be fore you add load Select a route that is as flat as possible Steer machine as straight as possible making small gradual changes in di rection When driving over rough terrain reduce engine speed to ...

Page 102: ...travel pedals are placed in neutral travel brakes automatically will be applied to hold the ma chine RIGHT TURN Push down on front of left pedal LEFT TURN Push down on front of right pedal SHORT TURN Spin turn Push down the front of one pedal and the rear of the other NOTE For long term traveling push down on pedal tabs D and rest feet on footrests Travel lever dampers are provided for smooth cont...

Page 103: ... the travel levers are placed in neutral travel brakes automatically will be applied to hold the ma chine RIGHT TURN Push left lever forward LEFT TURN Push right lever forward SHORT TURN Spin turn Push one lever forward and pull the other rearward NOTE For long term traveling push down on pedal tabs D and rest feet on footrests Travel lever dampers are provided for smooth control In extremely cold...

Page 104: ...ravel motors may result Fast speed rabbit or slow speed turtle can be selected by pushing travel speed switch 1 at any engine speed Indicator lights 2 or 3 show mode selection To decrease travel speed for traveling on a slope or in a tight space press switch to turtle position 1 Travel Speed Switch 2 Travel Mode Indicator Slow Speed 3 Travel Mode Indicator Fast Speed M18C 01 020 M18C 01 024 Travel...

Page 105: ... machine is traveling CAUTION If the travel alarm does not sound when the travel levers or pedals are operated immediately stop the engine and contact your authorized dealer for repair Operating with the travel alarm malfunctioning may result in a seri ous accident 1 Travel Alarm M117 04 001 1 ...

Page 106: ...to apply the road as evenly as possible to all of the lower rollers Examine strengths of bridges and road shoulders and reinforce if necessary Use wood plates in order not to damage the road sur face Be careful of steering when operating on asphalt roads in summer When crossing rail roads use wood plates in order not to damage them Do not make contact with electric wires or bridges When crossing a...

Page 107: ...Tow the machine if it becomes stuck but can still operate its engine Be sure to attach a towing wire correctly RAISE ONE TRACK USING BOOM AND ARM CAUTION Keep the angle between boom and arm 90 to 110 and position the bucket s round side on the ground Swing the upperstructure 90 and lower the bucket to raise track off ground Do not dig bucket teeth into the ground when using the loader bucket Place...

Page 108: ...wire rope tow lines as illustrated at right and slowly tow your machine to firm ground using another machine Be sure to attach the wire ropes around the track frames of both machines as illustrated To prevent the wire ropes from being damaged place some protective material between the track frame and the wire ropes IMPORTANT 1 Slowly tow keeping the tow line hori zontal and in a straight line with...

Page 109: ...water is flow ing slowly When operating in such conditions check the machine s position often Reposition the machine if necessary Avoid submerging the swing bearing swing gears and cen ter joint If the swing bearing swing gears and center joint are sub merged remove the cover to drain mud and water Clean swing area Install cover Lubricate swing internal gear and swing bearing Lubricate swing beari...

Page 110: ...nd then change the direction to ensure safe operation 5 Avoid swinging the upperstructure on slopes Never attempt to swing the upperstructure downhill The machine may tip over If swinging uphill is unavoidable carefully operate the upperstructure and boom at slow speed 6 If the engine stalls on a slope immediately lower the bucket to the ground Return the control levers to neu tral Then restart th...

Page 111: ...ket to the ground 3 Turn the auto idle switch off IMPORTANT Turbocharger may be damaged if the en gine is not properly shut down 4 Move engine speed control lever 1 to the slow idle position Run the engine approximately 5 minutes to cool the engine 5 Turn key switch 2 to OFF Remove the key from the key switch 6 Pull pilot control shut off lever 3 to the LOCK posi tion IMPORTANT Protect cab electri...

Page 112: ...DRIVING THE MACHINE 4 12 MEMO ...

Page 113: ...rol before operating The machine is equipped with a label showing the control patterns of the levers and pedals IMPORTANT When digging avoid hitting tracks with boom cylinders When digging over the end of the tracks travel motors should be at the rear to maximize machine stability and lift ca pacity When a lever is released it will automatically return to neu tral and that machine function will st...

Page 114: ...l before operating The machine is equipped with a label showing the control patterns of the levers and pedals IMPORTANT When digging avoid hitting tracks with boom cylinders When digging over the end of the tracks travel motors should be at the rear to maximize machine stability and lift ca pacity When a lever is released it will automatically return to neu tral and that machine function will stop...

Page 115: ...control before operating The machine is equipped with a label showing the control patterns of the levers and pedals IMPORTANT When digging avoid hitting tracks with boom cylinders When digging over the end of the tracks travel motors should be at the rear to maximize machine stability and lift ca pacity When a lever is released it will automatically return to neu tral and that machine function wil...

Page 116: ...ntrol before operating The machine is equipped with a label showing the control patterns of the levers and pedals IMPORTANT When digging avoid hitting tracks with boom cylinders When digging over the end of the tracks travel motors should be at the rear to maximize machine stability and lift ca pacity When a lever is released it will automatically return to neu tral and that machine function will ...

Page 117: ...OPERATING THE MACHINE 5 5 BUCKET OPEN CLOSE PEDALS LOADING SHOVEL 9 Bucket Closing 10 Bucket Opening M146 01 010 M117 05 031 10 9 10 9 ...

Page 118: ... the machine may unexpectedly move when the pilot control shut off lever is operated possibly causing personal injury or death Pilot Control Shut Off Lever Operation Before Leaving the Machine 1 Park the machine on a firm level surface Lower the bucket to the ground Return all control levers to neu tral Properly shut down the engine 2 Pull pilot control shut off lever 1 up into the full LOCK posit...

Page 119: ...emperature reaches 20 C in the following proce dures before starting to work 1 Run the engine at slow idle speed for 5 minutes 2 Increase the engine speed to middle speed by operat ing the fuel lever Run the engine for 5 minutes with the bucket held in the rolled out tilted out position while relieving the hydraulic oil pressure for 10 to 15 seconds at an interval of 5 to 10 seconds 3 Increase the...

Page 120: ...sure while rolling in the bucket and raising the boom 4 While warming the hydraulic oil by the method men tioned above circulate hydraulic oil by slowly operat ing each cylinder of the boom arm and bucket full stroke and the swing motor in both directions and traveling the machine approximately 5 m distance several times at an interval of 3 to 5 minutes IMPORTANT If hydraulic oil is warmed only by...

Page 121: ...tedly increase when any control lever is operated causing unexpected machine movement thus possibly resulting in serious personal injury 3 Prevent the machine from unexpected move ment Be sure to turn off auto idle switch 1 when unexpected machine movement is un desirable especially when loading unloading the machine for transportation Note that auto idle function can be turned on or off only when...

Page 122: ... left console as illus trated Slow Idle Move lever 1 to the LOW position 2 Fast Idle Move lever 1 to the HIGH position 3 Before stopping the engine always move engine speed control lever 1 to the slow idle setting Run the engine five minutes to cool the engine Then turn the key switch to OFF position to stop the engine M18C 01 022 1 3 2 ...

Page 123: ...ty equipment appropriate for the job such as a hard hat etc when operating the machine Clear all persons and obstacles from area of operation and machine movement Always beware of the surroundings while operating When working in a small area surrounded by obsta cles take care not to hit the upperstructure against obstacles When loading onto trucks bring the bucket over the truck beds from the rear...

Page 124: ...re to investigate the area first and confirm that no danger of the cliff or bank collapsing exists If any possibil ity of cliff or bank collapsing exists do not work on the area 3 Soft ground may collapse when operating the machine on it possibly causing the machine to tip over When working on a soft ground is required be sure to reinforce the ground first using large pieces of steel plates strong...

Page 125: ...cks parallel to the trench After digging to the desired depth move the machine as required to continue the trench NOTE When crowding the arm it is normal for the arm to pause briefly at the lowest point of its curve as shown This is due to the fact that the force of gravity pulls the arm down quickly and it takes a moment for the hydraulic force in the cylinder to catch up This does not indicate m...

Page 126: ...PERATION Do not use travel as an additional digging force Severe machine damage may result Do not raise rear of machine to use the machine s weight as additional digging force Severe machine damage may result M145 05 011 M145 05 012 WRONG WRONG ...

Page 127: ...ull loads on every pass is more productive than a faster cycle with a partially filled bucket Full load should be the first objective followed by speed to increase productivity IMPORTANT Do not attempt to break ledge rock by extending the arm to maximum reach and dropping the front of the bucket on the bucket teeth for penetration Serious damage to the machine can result Once the trench is open le...

Page 128: ...m end of the boom cylinders raising the boom When the bucket cylinders are fully extended and the bucket comes into contact with the stopper the straight retraction cannot be performed To perform the straight retraction retract the arm cylinder after dumping the bucket slightly PROHIBITED OPERATION 1 Never dig with the bucket retracted too closely to the undercarriage as the machine components wil...

Page 129: ...efully CAUTION When excavating with boom extended to high levels do not tilt bucket back as materi als will spill on operator s cab Dump bucket slightly to prevent spilling IMPORTANT 1 When digging with the upperstruc ture at an angle to the undercarriage avoid striking the tracks with the bucket 2 Avoid further extension of the bucket cylinder after the bucket comes into contact with the stopper ...

Page 130: ...posi tioned parallel with the tracks Machine stability is reduced when the load is swung to the side and when operating the front attachment perpendicular to the tracks Sudden stop of boom lowering movement is espe cially likely to cause tipping over When working on weak soft surfaces or when loading high density materials operate the machine at re duced bucket loads M117 05 009 M117 05 010 M117 0...

Page 131: ... not attach sling chain to the bucket teeth Secure sling chain tightly to the load to be lifted Wear gloves when securing sling chain Fasten sling chain to bucket loop with the bucket curled and arm retracted Coordinate hand signals with your signal man before starting Be aware of the location of all persons in the working area Attach a hand line to load and make sure person hold ing it is well aw...

Page 132: ... or floods Park the machine referring to the PARKING THE MACHINE in the DRIVING THE MACHINE section 2 Fill the fuel tank with fuel 3 Clean the machine 4 If anti freeze or long life coolant is not used in cold weather be sure to drain coolant from the radiator and the engine jacket Also be sure to put a No Wa ter in Radiator tag in a visible place if the coolant has been drained M117 05 023 ...

Page 133: ...ng general appearance noise heat etc Check for loose or missing parts If there is any problem with your machine repair it before operating or contact your authorized dealer IMPORTANT y y y y Use only recommended fuel and lubri cants y Use only genuine HITACHI parts y Failure to use recommended fuel lu bricants and genuine Hitachi parts will result in loss of Hitachi product warranty y Never adjust...

Page 134: ... pages CHECK THE HOUR METER REGULARLY Check hour meter 2 to determine when your machine needs periodic maintenance Intervals on the periodic maintenance chart are for op erating in normal conditions If you operate your ma chine in more adverse conditions you should service it at SHORTER INTERVALS USE CORRECT FUELS AND LUBRICANTS IMPORTANT Always use recommended fuels and lu bricants Failure to do ...

Page 135: ...nance must be performed with engine running do not leave machine unattended 6 Pull the pilot control shut off lever 1 to the LOCK po sition 7 Before performing any work on the machine attach a Do Not Operate tag on the right control lever 8 Ground Disconnector This machine is equipped with a battery ground dis connector located outside of engine unit compartment on the right side The battery groun...

Page 136: ... EMERG STOP position to assure safety 10 When using a vacuum pump to create negative pres sure in the hydraulic oil tank while working on the hy draulic lines close stop valve cock 4 on the hydrau lic oil tank air bleed valve Be sure to open cock 4 af ter completing the repair work M18C 01 025 M18C 01 031 M18C 01 027 3 4 Engine Stop Switch Engine Stop Switch Close Open ...

Page 137: ...lose accidentally possibly resulting in per sonal injury 2 When opening or closing the hood and the ac cess doors take extra care not to catch fin gers between the base machine and the hood or the access doors To keep the access door open lower rod 1 into a gap on the platform or into locking hole 2 as illustrated M18C 07 002 M18C 07 003 M18C 07 004 Door Position Door Position 1 1 2 ...

Page 138: ... maintenance work in room 1 under the cab in engine room 2 and in pump room 3 Use engine room light switch 4 located on the switch panel in the cab to turn on off these lights M141 01 017 M18C 01 025 M141 01 019 M18C 01 020 1 4 In Room Under the Cab 3 In Pump Room 2 In Engine Room ...

Page 139: ... that the chain has no damage If any damage such as wear or breaks are found replace with new one 1 Remove chain 1 from hook 3 located on the left upper front cab and from handrail 5 2 Install the free end of chain 1 to right hook 7 to at tach the chain 3 Check that chain 1 is securely installed to both hooks 6 and 7 4 Before re starting machine operation remove chain 1 from right hook 7 After han...

Page 140: ...MAINTENANCE 7 8 MEMO ...

Page 141: ...e Strainer Front Idler Emergency Escape Device Hanger Compressor Track Adjuster Accumulator Accumulator Swing Bearing Upper Roller Boom Cylinder Bucket Cylinder Center Joint Hydraulic Oil Tank Control Valve Side Frame Travel Device Battery Swing Device Fuel Tank Ladder Lubricator Arm Cylinder Arm Bucket Boom Cab Arm Cylinder Dump Cylinder Bucket Cylinder Boom Bucket Link A Link B Arm Boom Cylinder...

Page 142: ...rol valves 2 The pilot valves actuated by the control levers pedals send pilot oil from the pilot pumps to the control valves moving their spools This spool movement routes the pump delivery oil to the cylinders and mo tors 3 Relief valves of sufficient capacity are provided in the control valves full flow filters and the pilot and oil cooler circuits in order to protect each circuit from ab norma...

Page 143: ...LVE ARM 21 CONTROL VALVE BUCKET 22 CONTROL VALVE BOOM 23 CONTROL VALVE RIGHT TRAVEL 24 CONTROL VALVE SWING 25 CONTROL VALVE ARM EXTEND 26 RADIATOR 27 INTERCOOLER 28 ENGINE 29 MAIN PUMP No 3 4 30 MAIN PUMP No 1 2 31 MAIN PUMP No 5 6 32 FAN DRIVE PUMP 33 PILOT PUMP 34 AIR CON COMP PUMP 35 TRANSMISSION OIL PUMP 36 HYDRAULIC OIL TANK 37 FAN DRIVE MOTOR 38 OIL COOLER 40 TRAVEL MOTOR 42 PILOT FILTER 43 ...

Page 144: ...VE RIGHT TRAVEL 19 CONTROL VALVE SWING 21 RADIATOR 22 INTERCOOLER 23 ENGINE 24 MAIN PUMP No 3 4 25 MAIN PUMP No 1 2 26 MAIN PUMP No 5 6 27 FAN DRIVE PUMP 28 PILOT PUMP 29 AIR CON COMP PUMP 30 TRANSMISSION OIL PUMP 31 HYDRAULIC OIL TANK 32 FAN DRIVE MOTOR 33 OIL COOLER 35 TRAVEL MOTOR 37 PILOT FILTER 38 TRANSMISSION OIL COOLER 39 GREASE PUMP 40 FULL FLOW FILTER 41 SUCTION MANIHOLD 42 HIGH PRESSURE ...

Page 145: ...alone Thus if rubber hoses are not replaced periodically serious personal in jury may result due to falls of the front penetra tion of high pressure oil into the skin or fire Regardless of regular replacement intervals if hoses are found to be defective by periodic in spection refer to pages 7 62 to 7 64 be sure to repair or replace them before operating the ma chine Be sure to replace seals such ...

Page 146: ...MAINTENANCE 7 14 Hoses Q ty in Use Transmission Oil Cooler Hose 5 2 M18C 07 062 5 ...

Page 147: ...MAINTENANCE 7 15 Hoses Q ty in Use Loading Shovel Front Hoses Main Frame to Boom 12 M144 07 133 Hoses Q ty in Use Backhoe Front Hoses Main Frame to Boom 10 M144 07 134 ...

Page 148: ...MAINTENANCE 7 16 Fuel Hoses Hoses Q ty in Use Fuel Tank to Water Separator Filter a 2 Water Separator to Engine b 3 Engine to Fuel Tank c 1 M18C 07 007 M18C 07 008 M18C 07 045 a b b a b c ...

Page 149: ...e 172 L 45 4 US gal 3 Replace Engine Oil Main Filter 4 4 Replace Engine Oil Bypass Filter 1 5 Check Alternator Belt Tension 1 6 Check Injection Nozzle 7 Inspect Bolts and Nuts Outside Engine 8 Inspect and Adjust Valve Clearance 9 Check Fuel Injection Timing 10 Check Starter and Alternator 11 Check Turbocharger NOTE First time only See your authorized dealer C TRANSMISSION See Page 7 38 Interval ho...

Page 150: ...ines for crack bend etc NOTE Hydraulic oil changing interval differs according to the kind of hydraulic oil used See recommended oil chart First time only E FUEL SYSTEM See Page 7 67 Tank capacity 3085 liter 815 US gal Interval hours Parts Quantity 10 50 250 500 1000 1500 2000 1 Drain Fuel Tank Sump 1 Drain 2 2 Water Separator Filter Replacement 2 3 Replace Fuel Filter 2 Check Fuel Hoses for leak ...

Page 151: ...oolant As long as Genuine Hitachi Long Life Coolant is used the service inter vals between changing the coolant is once every two years or every 4000 hours whichever comes first H AIR CONDITIONER See Page 7 81 Interval hours Parts Quantity 10 50 250 500 1000 1500 2000 Cleaning 3 As required 1 Recirculation Air Filter Replacement 3 Replace per 4 cleaning Cleaning 3 As required 2 Ventilation Air Fil...

Page 152: ...ness 6 2 Inspect Emergency Rope and Rope Mounting Hardware 1 3 Check Auto Lubrication System 1 Check 2 4 Seat Belt Replacement 2 At least once every 3 years 5 Check Washer Tank 2 As required 6 Check and Adjust Track Sag 2 7 Check Accumulator and Track Adjuster Cylinder Circuit 2 Every year 8 Clean Side Frame Area 2 9 Check Tightening Torque of Bolts and Nuts NOTE First time only ...

Page 153: ...039 Brand Names of Recommended Grease Swing Internal Gear Front Joint Pins Swing Bearing Where to be applied Manufacturer 20 to 50 C 4 to 122 F British Petroleum BP Energrease LS EP2 BP Energrease LS EP1 Caltex Oil Multifax EP2 Multifax EP1 Esso Beacon EP2 Beacon EP1 Idemitsu Kosan Daphne Coronex Grease EP2 Daphne Coronex Grease EP1 Mobil Oil Mobilux EP2 Mobilux EP1 Nippon Oil Epinoc Grease AP2 Ep...

Page 154: ...grease to all fittings shown below daily Most of the fittings are grouped as shown for quick and safe lubrication Bucket Cylinder Bottom Pin 1 Dump Cylinder Bottom Pin 2 Dump Cylinder Rod Pin 3 Bucket Joint Pin 4 M114 07 008 M144 07 002 M144 07 003 M144 12 005 4 2 3 1 1 2 3 4 ...

Page 155: ...MAINTENANCE 7 23 2 Grouped Grease Fittings 5 Boom Ñ Lubrication M144 07 078 3 Boom Cylinder Rod Pins 6 M144 07 070 M18C 01 001 5 6 ...

Page 156: ...MAINTENANCE 7 24 4 Grouped Grease Fittings 7 Arm Ñ Lubrication M144 07 079 M144 07 005 7 ...

Page 157: ... Backhoe Front Joint Pins daily Add grease to all fittings shown below daily Most of the fittings are grouped as shown for quick and safe lubrica tion 1 Grease Fittings for bucket and link pins M144 07 081 M144 07 082 ...

Page 158: ...MAINTENANCE 7 26 Grease Fittings for Bucket and Link Pins Auto lubrication system equipped M18C 07 072 VIEW B VIEW A ...

Page 159: ...MAINTENANCE 7 27 2 Grouped Grease Fittings 1 Boom Arm Fittings for boom foot pins and boom cylinder rod pins 3 Boom Cylinder Rod Pin 2 M18C 07 009 M18C 01 001 2 1 ...

Page 160: ...ANT The turbocharger may be damaged if the engine is not properly shut down 4 Run the engine at slow idle speed without load for five minutes 5 Turn the key switch OFF Remove the key from the key switch 6 Pull the pilot control shut off lever to the LOCK posi tion 7 With the upperstructure stationary apply grease to the four grease fittings 8 Start the engine Raise the bucket several inches off th...

Page 161: ... the key switch 6 Pull the pilot control shut off lever to the LOCK posi tion 7 Remove cover 2 on the left side of the upperstruc ture In order to add new grease evenly to the swing gear swing the upperstructure twelve 30 intervals one full turn and add grease at each interval using a putty knife 8 In case the grease deteriorate and or water becomes mixed in the grease change grease by following t...

Page 162: ...vel surface 2 Lower the bucket to the ground 3 Turn the auto idle switch off IMPORTANT The turbocharger may be damaged if the engine is not properly shut down 4 Run the engine at slow idle speed without load for five minutes 5 Turn the key switch OFF Remove the key from the key switch 6 Pull the pilot control shut off lever to the LOCK posi tion 7 With the upperstructure stationary apply grease to...

Page 163: ...gun 4 attached to the hose end and pull out the hose from reel 5 4 Stop pulling hose at any desired position reel 5 clicks and automatically locks the hose 5 Insert the end of grease gun 4 in the desired fitting and pull gun lever automatically adds grease to the fitting Storing Grease Hose After Finishing Greasing 1 Slightly pull out the hose reel 5 unlocks automati cally winds and stores the hos...

Page 164: ...ith a new one 3 Install follower plate 8 into the grease can While holding and rotating follower plate 8 level in both directions push it downward so that an air pocked is not developed 4 Install cover assembly 6 on the lubricator housing while aligning grease tube with the hole on the fol lower plate in order not to push down the plate into grease when installing the cover Tighten wing nuts 7 M14...

Page 165: ...parts such as piston rings cylinders etc or ab normally wear moving parts It is best to stick with one and the same brand of oil at successive service intervals Recommended brands of Class CD oils API Service Clas sification are shown in the chart below If any oil other than these recommended oils is used the oil must be Class CD or CF API Service Classification and meet the MILL2104C specificatio...

Page 166: ... Recommended Oil Viscosities 22 13 4 5 14 23 32 41 50 59 68 77 86 95 104 113 122 Starting tempera ture C F 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 Oil viscosities Engine Oil Level check daily IMPORTANT For most accurate readings check the oil level every day before starting the machine Be sure the machine is on a level surface 1 Remove dipstick 1 Wipe oil off with a clean cloth Reinsert di...

Page 167: ... may be hot Use care to be sure you are not burned from hot oil 8 Prepare a container of 200 L 52 8 US gal or more capacity for the drain oil 9 Remove drain plug 4 from the tee located near the oil pan 10 Loosen drain cock 3 to drain the engine oil 11 Check if foreign material like metal particles are in cluded in the drain oil by filtering it with a clean cloth IMPORTANT Be sure to wipe off spilt...

Page 168: ... about 5 minutes Stop the engine after con firming that engine oil pressure is rising Ten to twenty minutes later check oil level again and add oil if necessary NOTE Always allow oil to drain back to the oil pan be fore checking the level This may require 15 minutes Check Alternator Belt Tension every 250 hours IMPORTANT Loose alternator belt tension may result in insufficient battery charging eng...

Page 169: ...time after 50 hours See your authorized dealer Inspect and Adjust Valve Clearance every 2 000 hours See your authorized dealer Check Fuel Injection Timing every 2 000 hours See your authorized dealer Check Starter and Alternator every 4 000 6 000 hours See your authorized dealer Check Turbocharger every 4 000 6 000 hours See your authorized dealer ...

Page 170: ...ersal Thuban SAE90 Esso Esso Gear Oil GP80W 90 or GP85W 90 Idemitsu Kosan Apolloil Gear HE90 Mobil Oil Mobilube GX90 Nippon Oil Gear Lube SP90 Shell Oil Shell Spirax EP90 Remarks API GL 4 Class NOTE The machine is filled with oil marked by when shipped from the factory Brand Names of Recommended Engine Oil Kind of Oil Engine Oil Pump Transmission Gear and Oil Cooler Fan Drive Application Air Temp ...

Page 171: ...is not properly shut down 4 Run the engine at slow idle speed without load for five minutes 5 Stop the engine Remove the key from the key switch 6 Pull the pilot control shut off lever to the LOCK posi tion CAUTION Oil may be hot Wait for oil to cool be fore starting work 7 Remove dipstick 1 Oil must be between the top and notch on the dipstick 8 If necessary remove dipstick 1 and add oil See oil ...

Page 172: ...to the LOCK position CAUTION Oil may be hot Wait for oil to cool before starting work 7 Prepare a container of 30 liter 7 9 US gal or more capacity for the drain oil 8 Remove drain plug 2 on the pump transmission housing and loosen cock 3 to drain the oil 9 Check if foreign material like metal particles are included in the drain oil by filtering it with a clean cloth 10 Tighten drain plug 2 and co...

Page 173: ...ly a light even coat of lubricat ing oil to the gasket sealing surface prior to installing the cartridge filter 3 Position cartridge filter 4 to the filter head Tighten by hand until the seal touches the filter head tighten an additional three fourths turn Clean Breather every 500 hours Remove breather cap 5 and clean the element M18C 07 017 M18C 07 018 5 4 ...

Page 174: ...he engine is not properly shut down 4 Run the engine at slow idle speed without load for five minutes 5 Stop the engine Remove the key from the key switch 6 Pull the pilot control shut off lever to the LOCK position CAUTION Gear oil may be hot Wait for gear oil to cool before starting work 7 Remove dipsticks 1 Oil must be between marks 8 If necessary add oil See oil chart 9 Recheck oil level 10 In...

Page 175: ...d for five minutes 5 Stop the engine Remove the key from the key switch 6 Pull the pilot control shut off lever to the LOCK position CAUTION Gear oil may be hot Wait for gear oil to cool before starting work 7 Remove drain plug 3 and loosen drain cock 2 to drain oil 8 Tighten drain cock 2 and drain plug 3 9 Remove plug 4 and add oil until it is between marks on dipstick 1 Clean Breather every 1000...

Page 176: ...heck plug air release plug 1 to release pressure 7 After gear oil has cooled slowly loosen oil level check plug air release plug 1 to release pressure 8 Remove oil level check plug 1 Oil must be up to the bottom of hole 9 If necessary after oil supply plugs 2 have been removed add oil until oil flows out of the oil level check plug hole See gear oil chart 10 Wrap oil level check plug 1 threads wit...

Page 177: ...sen oil level check plug air release plug 1 to release pressure 8 Remove drain plugs 2 to drain oil 9 Wrap the threads of drain plug 2 with sealing type tape Install drain plug 2 Tighten the plug to 69 Nxm 7 kgfxm 51 lbfxft 10 Remove oil level check plug 1 11 After oil supply plug 3 has removed add oil until oil flows out of the oil level check plug hole See gear oil chart 12 Wrap the threads of o...

Page 178: ...ed oil chart First time only M18C 01 039 Brand Names of Recommended Hydraulic Oil Kind of Lubricant Hydraulic Oil Where to be applied Hydraulic System Change Interval 4000 hours 2500 hours 2000 hours Environmental Temp Manufacturer 20 to 50 C 4 to 122 F 10 to 50 C 14 to 122 F 20 to 50 C 4 to 122 F 10 to 50 C 14 to 122 F 20 to 50 C 4 to 122 F 10 to 50 C 14 to 122 F Hitachi Super EX 46HN Idemitsu Ko...

Page 179: ...n While servicing heated and pressur ized hydraulic equipment hot parts or oil may fly off or escape suddenly with a potential of serious injury Keep body parts and face away from plugs or screws when removing them as they may be pressurized even when cooled 4 Before servicing hydraulic equipment bleed air from the hydraulic oil tank to release internal pressure 5 Even after bleeding the air from ...

Page 180: ...e specifications on the right side Do not overtighten 8 When adding hydraulic oil always use the same brand of oil do not mix brands of oil As the machine is filled with Super EX 46HN when it is shipped from the factory use it as a general rule When selecting to use another brand of oil listed in the table Brand Names of Recommended Hydraulic Oil be sure to completely replace the oil in the system...

Page 181: ... shut off lever to the LOCK posi tion 8 Check oil level gauge 1 on hydraulic oil tank Oil must be between marks on the gauge If necessary add oil CAUTION Keep body and face away from cap 2 Turn cap 2 slowly and remove the cap only after releasing the internal pressure completely To add oil 9 Insert the wrench as shown and turn the wrench clockwise and hold the wrench 10 Turn cap 2 counterclockwise...

Page 182: ...ody and face away from cap 1 Turn cap 1 slowly and remove the cap only after releasing the internal pressure completely 7 Insert the wrench as shown and turn the wrench clockwise and hold the wrench 8 Turn cap 1 counterclockwise about 30 at which point stop cap 1 to release the air 9 Turn cap 1 further and remove cap 1 10 Align the projected part of cap 1 with the projected part of the case and in...

Page 183: ...nutes 6 Stop the engine Remove the key from the key switch 7 Pull the pilot control shut off lever to the LOCK posi tion 8 Clean the top of the hydraulic oil tank to keep dirt out of the hydraulic system CAUTION Keep body and face away from cap 1 Turn cap 1 slowly and remove the cap only after releasing the internal pressure completely 9 Insert the wrench as shown and turn the wrench clockwise and...

Page 184: ...en drain plug 6 18 Tighten drain valve 3 19 Clean install and tighten drain plug 2 20 Add oil via cover 4 hole until it is between the marks on sight gauge 5 of hydraulic oil tank 21 Install cover 4 Tighten the bolts to 50 N m 5 kgf m 49 lbf ft IMPORTANT Never run the engine without oil in hy draulic oil tank M18C 07 016 M18C 07 023 M18C 07 022 5 3 2 4 6 ...

Page 185: ...oses 7 and 8 after oil flows from the pump Bleeding Air from Hydraulic Circuit 2 Refill hydraulic oil 3 Start the engine and run at slow idle 4 Purge air from the hydraulic circuit while operating each cylinder and swing motor slowly for approx 15 minutes 5 Position the front attachment as illustrated in the oil level checking posture 6 Check the hydraulic oil tank gauge Add oil if neces sary M18C...

Page 186: ...he pilot control shut off lever to the LOCK posi tion CAUTION Keep body and face away from cap 1 Turn cap 1 slowly and remove the cap only after releasing the internal pressure completely 7 Insert the wrench as shown and turn the wrench clockwise and hold the wrench 8 Turn cap 1 counterclockwise about 30 at which point stop cap 1 to release the air 9 Turn cap 1 further and remove cap 1 10 Align th...

Page 187: ...g load when removing the last two bolts Remove filter cover 2 12 Remove spring 5 valve 6 and element 7 13 Discard element 7 and O ring 4 14 Install a new element 7 valve 6 and spring 5 15 Install filter cover 2 with a new O ring 4 16 Install and tighten bolts 3 to 49 N m 5 kgf m 36 lbf ft 17 Repeat steps 11 to 16 for the other filter M18C 07 046 2 3 4 5 6 7 ...

Page 188: ...release pressure from the pilot accumulator 7 Pull the pilot control shut off lever to the LOCK posi tion CAUTION Keep body and face away from cap 1 Turn cap 1 slowly and remove the cap only after releasing the internal pressure completely 8 Insert the wrench as shown and turn the wrench clockwise and hold the wrench 9 Turn cap 1 counterclockwise about 30 at which point stop cap 1 to release the a...

Page 189: ...er housing 9 NOTE Remove element and inspect for materials on element and in bottom of filter housing Exces sive amounts of foreign materials can indicate abnormalities in the system 14 Inspect filter element 8 and filter housing 9 for for eign materials 15 Install new filter element 8 valve 6 and spring 5 into filter housing 9 16 Install washer 3 cover 4 and new O ring 7 17 Tghten bolts 2 to 88 N...

Page 190: ...remove rod as sembly 2 2 Clean the inside of the hydraulic oil tank and the suc tion filters 3 Before installing check dimensions of rod assembly 2 by referring the figure below Securely re install the rod assembly into pipe 3 4 Replace the O ring with new one and check that it is correctly installed before re installing cover 1 Se cure cover 1 with bolts 5 Bleed any air remaining in the hydraulic...

Page 191: ...rod as sembly 2 2 Clean the inside of the hydraulic oil tank 3 Replace the element of rod assembly 2 4 Before installing check dimensions of rod assembly 2 by referring the figure below Securely re install the rod assembly into pipe 3 5 Replace the O ring with new one and check that it is correctly installed before re installing cover 1 Se cure cover 1 with bolts 6 Bleed any air remaining in the h...

Page 192: ... and hold the wrench 8 Turn cap 1 counter clockwise about 30 at which point stop cap to release the air 9 Turn cap 1 further and remove cap 1 10 Align the projected part of cap with the projected part of the case and install cap 1 11 Remove bolts 2 cover 3 and strainer assembly 6 from housing 7 12 Discard O rings 4 and 5 and strainer assembly 6 13 Install new strainer assembly 6 into housing 7 wit...

Page 193: ...n using compressed air IMPORTANT High pressure air or water can damage the cooler core fins Use air pressure 0 2 MPa 2 kgf cm 2 or less and keep the nozzle more than 500 mm away from the core surface Clean the oil cooler core using compressed air 0 2 MPa 2 kgf cm 2 or less or tap water M18C 07 026 ...

Page 194: ...1 Park the machine on a firm level surface Lower the bucket to the ground Stop the engine Remove key from the key switch Pull the pilot control shut off lever to the LOCK position 2 Check for missing or loose clamps kinked hoses lines or hoses that rub against each other damaged oil cooler and loose oil cooler flange bolts for leaks Check hoses lines and oil cooler at the check points indicated be...

Page 195: ...s Hose Hose Hose ends and fittings Crack 4 Crack 5 Exposed reinforcement 6 Blister 7 Bend 8 Collapse 9 Deformation or Corrosion 10 Replace Replace Replace Replace Replace Replace Use proper bend radius Replace NOTE Refer to the illustrations in Fig 1 for each check point location or for a descrip tion of the abnormality Use genuine Hitachi parts M115 07 145 M115 07 146 M115 07 147 M115 07 148 M115...

Page 196: ...sing Deformation Replace Replace Replace NOTE Refer to the illustrations in Fig 2 for each check point location or for a descrip tion of the abnormality Use genuine Hitachi parts Table 3 Oil cooler Interval hours Check Points Abnormalities Remedies Every 250 hours Contact surfaces of flange joints Oil cooler Leak 14 Leak 15 Replace O ring and or retighten bolts Replace NOTE Refer to the illustrati...

Page 197: ...petroleum jelly to hold it in place 4 Tighten fitting 2 by hand pressing the fitting joint to gether to ensure O ring 1 remains in place and is not damaged 5 Tighten fitting 2 or nut 4 to the torque values shown Do not allow hose 5 to twist when tightening fittings 6 Check for leaks If oil leaks from a loose connection do not tighten fitting 2 Open the connection replace O ring 1 and check for cor...

Page 198: ...ious defects IMPORTANT Defects in the tube flare cannot be re paired Overtightening a defective flare fitting will not stop a leak 2 Tighten fitting 7 by hand 3 Tighten fitting 7 or nut 8 to the torque values shown Do not allow hose 5 to twist when tightening fittings Width across flats mm 19 22 27 36 Nxm 29 5 39 93 175 kgxm 3 4 9 5 18 Fastening torque lbfxft 21 5 29 69 130 M202 07 051 7 9 8 10 5 ...

Page 199: ...lity DIESEL FUEL OIL in accordance with JIS K 2204 ASTM2 D or equivalent For further details refer to the Commins Engine Operation and Maintenance Manual Refueling 1 Park the machine on a firm level surface 2 Lower the bucket to the ground 3 Turn the auto idle switch off 4 Check fuel gauge 1 on the monitor Add fuel if necessary as follows Fuel Tank Capacity 3085 liters 815 US gal NOTE Avoid conden...

Page 200: ...care not to spill fuel on the machine or ground Do not fill the tank more than specified 8 Remove filler cap 2 Add fuel via the filler tube while checking gauge 3 Do not fill the tank more than specified Be sure to select a charging pump of appropriate capacity when fueling to avoid overflowing 9 A filter is provided in the filler port Clean the filter in light oil at the regular interval 10 Reins...

Page 201: ...tor Filter Drain Fuel Filter Sediment daily 1 Stop the engine 2 Remove drain plug 4 and loosen drain cock 5 on the underside of filter 3 to drain water and sediment 3 After draining install drain plug 4 and tighten drain cock 5 Replace Water Separator Filter every 1000 hours Be sure to catch the draining fuel using a container so as not to contaminate the ground and for safety 1 Close stop valve 6...

Page 202: ...ng oil to the gasket sealing surface prior to in stalling the filter 5 Position filter 9 to the filter head Tighten by hand un til the seal touches the filter head tighten an addi tional one half to three fourths turn NOTE Be sure to tighten the filter by hand If any tools are used for tightening breakage or deforma tion of the filter head may arise 6 Two fuel filters are located on either side of...

Page 203: ...ator filter has one plug 10 There are two plugs in total Bleed air from each plug following the same method Fuel Feed Pump 4 Remove fuel pump cover 5 Loosen air bleed plug 12 1 5 turns approximately 6 After rotating fuel pump 11 counterclockwise move up and down 7 After only fuel without air flows out of air bleed plug 12 tighten air bleed plug 12 At this time while pressing fuel feed pump 11 rota...

Page 204: ...e Remove key from the key switch Pull the pilot control shut off lever to the LOCK position 2 Check for kinked hoses and hoses that rub against each other parts for leaks Check hoses at the check points indicated below for leaks and other damage that may result in future leaks If any abnormalities are found replace or retighten them as shown in Table 4 3 Repair or replace any loose or damaged hose...

Page 205: ... Hose Hose Hose ends and fit tings Crack 4 Crack 5 Exposed rein forcement 6 Blister 7 Bend 8 Collapse 9 Deformation or corrosion 10 Replace Replace Replace Replace Replace Replace Use proper bend ra dius Replace NOTE Refer to the illustrations in Fig 4 for each check point location or for a description of the abnormality Use genuine Hitachi parts M115 07 145 M115 07 146 M115 07 147 M115 07 148 M11...

Page 206: ... element is replaced 1 Park the machine on a level surface 2 Lower the bucket to the ground 3 Turn the auto idle switch off IMPORTANT The turbocharger may be damaged if the engine is not properly shut down 4 Run the engine at slow idle speed without load for five minutes 5 Stop the engine Remove the key from the key switch 6 Pull the pilot control shut off lever to the LOCK position 7 Loosen clamp...

Page 207: ...f outer ele ment 4 tighten it to 5 9 0 1 Nxm 0 6 0 1 kgfxm 4 3 0 1 lbfxft by hand 13 Install cover 2 and tighten clamps 1 14 Start the engine and run at slow idle 15 Check the air filter restriction indicator on the monitor panel If the air filter restriction indicator comes ON stop the engine and replace the outer element 4 16 When replacing the air cleaner filter element re place both outer 4 an...

Page 208: ...inter vals between changing the coolant is once every two years or every 4000 hours whichever comes first Coolant Fill the radiator with soft pure tap or bottled water Anti rust agent Add approximately 3 9 L 4 1 US qt of anti rust agent to the new coolant when the coolant is changed It is not necessary to add anti rust agent when antifreeze is used Antifreeze If the air temperature is expected to ...

Page 209: ...2 50 97 5 25 8 97 5 25 8 CAUTION 1 Antifreeze is poisonous if ingested it can cause serious injury or death Induce vomiting and get emergency medical attention immedi ately 2 When storing antifreeze be sure to keep it in a clearly marked container with a tight lid Al ways keep antifreeze out of the reach of chil dren 3 If antifreeze is accidentally splashed into eyes flush with water for 10 to 15 ...

Page 210: ...o supply coolant via the res ervoir Don t remove the radiator cap Check that the coolant level is between the HIGH and LOW marks on level gauge 2 If the coolant level is below the LOW mark remove cap 1 and add coolant via the opening M18C 07 078 M18C 07 079 2 1 ...

Page 211: ...eed air cocks 6 Remove radiator cap 1 Fill the radiator with soft water which contains less impurities or tap water and a radiator cleaner agent Start the engine and run at a speed slightly higher than slow idle when the needle of the temperature gauge reaches the white zone run the engine for about ten more min utes 4 Stop the engine and open radiator drain cock 2 and remove plugs 4 Flush out the...

Page 212: ...2 MPa 2 kgf cm 2 28 psi to clean radiator core IMPORTANT Compressed air or water can damage fins When cleaning the radiator core with compressed air or water keep the nozzle 500 mm 20 in or more away from the core face in order not to cause any damage The radiator is positioned along with the intercooler in se ries In case the radiator intercooler cores become ob structed with dust dirt or foreign...

Page 213: ...glasses or gog gles when using compressed air Less than 0 2 MPa 2 kgf cm 2 28 psi to clean filters IMPORTANT Plugged recirculation or ventilation air filter will reduce cooling capacity of the air conditioner Be sure to clean them periodically Cleaning as required 1 Open cover 1 Remove recirculation air filters 2 2 Clean recirculation air filters 2 with compressed air Less than 0 2 MPa 2 kgf cm 2 ...

Page 214: ...equired 1 Ventilation air filters 2 three pieces are located in room 1 under the cab Remove ventilation air filters 2 2 Clean ventilation air filters 2 with compressed air Less than 0 2 MPa 2 kgf cm 2 28 psi or a soft brush Replace Air Filter after cleaning 4 times Changing interval of ventilation air filter 2 differs de pending on environmental conditions If the cooling capacity decreases after c...

Page 215: ...ant quantity lowers cooling effect of the air conditioner Check the re frigerant quantity through sight glass on liquid tanks 2 three pieces 1 Start the engine and run at fast idle speed 2 Turn the air conditioner and blower fan speed to the high speed 3 Press temperature control switch repeatedly until the air temperature is maximum cool 4 Check the refrigerant quantity through sight glass M18C 0...

Page 216: ...cessary Start the engine and run for 10 minutes Check belt tension by depressing the midpoint between the hydraulic motor and compressor pulleys with the thumb Deflection must be 13 to 14 mm 0 5 to 0 6 in at a depressing force of approximately 98 N 10 kgf 22 lbf If tension is not within specifications loosen the com pressor mounting bolts to adjust belt tension M18C 01 012 M141 07 028 M141 07 029 ...

Page 217: ...or gog gles when using compressed air Less than 0 2 MPa 2 kgf cm 2 28 psi to clean condenser core Remove condenser cover 2 three pieces located in room 1 under the cab Use compressed air Less than 0 2 MPa 2 kgf cm 2 28 psi to clean the condenser core three pieces M18C 01 012 M146 07 010 1 2 ...

Page 218: ...orque Wrench Size mm N m kgf m lbf ft 19 11 5 to 14 5 1 2 to 1 5 8 7 to 10 5 24 19 5 to 24 5 2 to 2 5 14 5 to 18 27 29 5 to 34 3 to 3 5 21 5 to 25 5 Torque Specifications for Compressor Mounting Bolts Fastening Torque Wrench Size mm N m kgf m lbf ft 10 19 5 to 29 5 2 to 3 14 5 to 21 5 Torque Specifications for Liquid Tank Fastening Torque Wrench Size mm N m kgf m lbf ft 10 7 8 to 11 5 0 8 to 1 2 5...

Page 219: ...cludes replenishment of refriger ant inspection and replacing if necessary of inner and outer air filters line connections pressure switches and inspection and cleaning of evaporator 2 Off season maintenance 1 Operate the compressor once a week at low speed for several minutes in order to maintain its parts in well lubricated condition Be sure to run the engine at slow idle and air temperature to ...

Page 220: ...Batteries CAUTION Battery gas can explode Keep sparks and flames away from batteries Use a flashlight to check the battery electrolyte level Do not continue to use or charge the battery when electrolyte level is lower than specified Ex plosion of the battery may result Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in cloth ing and cause blindness if s...

Page 221: ...ower level the battery may deteriorate quickly IMPORTANT Don t refill electrolyte more than the specified upper level Electrolyte may spill damaging the painted surfaces and or corroding other machine parts NOTE In case electrolyte is refilled more than the specified upper level line or beyond the bottom end of the sleeve remove the excess electro lyte until the electrolyte level is down to the bo...

Page 222: ...e accurate elec trolyte level in this case Therefore when the elec trolyte level is flush with the U L the level is judged to be proper Then referring to the right illustrations check the level When the electrolyte level is lower than the bottom end of the sleeve refill with distilled water or commercial battery fluid up to the bottom end of the sleeve Be sure to refill with distilled water before...

Page 223: ...unts of water or milk 2 Then drink milk of magnesia beaten eggs or vegetable oil 3 Get medical attention immediately IMPORTANT Check the specific gravity of the electrolyte after it is cooled not immediately after operation Check the electrolyte specific gravity in each bat tery cell The lowest limit of the specific gravity for the elec trolyte varies depending on electrolyte tempera ture The spec...

Page 224: ...BED LIGHT 5A 11 ENG ROOM LIGHT 5A 12 PUMP ROOM LIGHT 5A 13 WORK LIGHT UPPER 10A 14 WORK LIGHT REAR 10A 15 WORK LIGHT RIGHT 10A 16 WORK LIGHT LEFT 10A 17 C S U MAIN POWER 5A 18 WIPER MOT LOWER 10A 19 WIPER MOT UPPER 10A 20 MAIN C U SOL 10A 21 SOL VALVE 15A 22 MOT ALARM 5A 23 DC DC 15A 24 E C M RELAY 5A 25 C S U BACK UP 5A 26 HORN 10A 27 ILLUMINAT 5A 28 CAB DOME LIGHT 5A 29 SWITCH VALVE RELAY 5A 30 ...

Page 225: ...e wall of the left console in the cab Also check the fuses 1 RADIO BACK UP 5A 2 RADIO ACC 5A 3 LIGHTER 10A 4 POWER TERMINAL ACC 10A 5 POWER TERMINAL 24V 15A 6 POWER TERMINAL 12V 15A M146 07 048 M18C 01 029 M144 07 111 B Trainer Seat 6 5 4 3 2 1 ...

Page 226: ...ft console in the cab 12 volts and 24 volts terminal are located in the side wall of the left console Use this terminal to power electrical devices of 12 volts and 24 volts rating Fuses for this terminal are provided with 10 ampere and 15 ampere fuses M146 07 048 M18C 01 029 M117 07 172 24V 24V 12V 10A 10A 5A 1 ...

Page 227: ...se Box No 13 to 20 and 42 3 Fusible Link 75 A Fuse Box No 21 to 23 4 Fusible Link 75 A Fuse Box No 24 27 46 and power terminal 5 Fusible Link 75 A Fuse Box No 9 to 12 and 27 6 Fusible Link 45 A Fuse Box No 1 to 3 25 37 41 and key switch 7 Fusible Link 45 A Engine Stop Solenoid 8 Fusible Link 45 A Optional Light Power 9 Fusible Link 250 A For Starter Relay 10 Fusible Link 300 A For Pre heat Relay F...

Page 228: ... tighten all electrical connections 3 Check before each shift or after ten 10 hours of op eration for loose kinked hardened or frayed electrical cables and wires Check before each shift or after ten 10 hours of missing or damaged terminal caps DO NOT OPERATE MACHINE if cable or wire are loose kinked etc Check cables and harnesses at the check points indi cated below for damage that may result in f...

Page 229: ...rt edge Replace Replace Replace Replace Connector 3 Degree of Hardening Loose locking Contact with part edge Damaged and crushed parts Loose or worn part Replace Lock Replace Replace Replace Terminal and termi nal cover 4 Degree of hardening of cover Cracks Worn cover Missing cover Loose locking Replace Replace Replace Replace Reconnect Daily Clamps of the har nesses or connec tors 5 Missing Clamp...

Page 230: ...s following the procedures below 1 Start the engine and run it at slow idle 2 Turn emergency engine stop switch 1 to the EMERG STOP position 3 Confirm that engine stop and relieve pressure from the hydraulic oil tank If any abnormalities are found be sure to repair them before operating the machine M117 01 093 1 NORMAL EMERG STOP ...

Page 231: ...g Hardware 1 3 Check Auto Lubrication System 1 Check 2 4 Seat Belt Replacement 2 At least once every 3 years 5 Check Washer Tank 2 As required 6 Check and Adjust Track Sag 2 7 Check Accumulator and Track Adjuster Cylinder Circuit 2 Every year 8 Clean Side Frame Area 2 9 Check Tightening Torque of Bolts and Nuts NOTE First time only M18C 01 039 M18C 01 040 8 7 6 2 3 4 5 2 1 2 2 1 ...

Page 232: ...N Guard against injury from flying pieces of metal Wear goggles or safety glasses and safety equipment appropriate to the job 1 Use hammer 2 and drift 3 to drive out locking pin 5 Be careful not to damage rubber pin lock 4 while removing locking pin 5 2 Remove tooth 1 Inspect locking pin 5 and rubber pin lock 4 for damage replace if necessary Short locking pins and damaged rubber pin locks must be...

Page 233: ...shown M104 07 060 5 Position new tooth 1 over shank 6 M104 07 061 6 Drive locking pin 5 fully into the hole as shown M104 07 062 NOTE Check the bucket teeth periodically to ensure that wear does not exceed the designed service limit 1 5 6 1 6 4 RIGHT WRONG WRONG WRONG WRONG WRONG RIGHT RIGHT ...

Page 234: ...oint 1 alternately with hammer to knock off pebbles soil etc stuck in the gap between tooth point 1 and adapter 2 2 Removing the lock pin Remove pebbles dirt etc completely from the gap between lock pin 3 and adapter 2 Place pin removing special tool on the top end of lock pin 3 and hit it with hammer to remove lock pin 3 When driving out the pin first hit with shorter jig 3 When top end of lock p...

Page 235: ... cannot be driven in Also check that lock pin has no cracks Insert tooth point 1 slowly while turning it to the right 2 Insert lock pin 3 Be sure to check the direction of lock pin 3 3 With tooth point 1 fully inserted onto adaptor 2 tap lock pin 3 into tooth point 1 with a hammer until the top of lock pin 3 comes flat with the tooth point M113 07 106 M113 07 107 M113 07 108 M113 07 109 2 2 3 1 1 ...

Page 236: ...ergency Escape Device and Hanger daily Inspect emergency escape device 1 and hanger 2 be fore operating the machine If any item is worn and or damaged replace the equipment and or hanger with genuine Hitachi parts M146 07 002 2 1 ...

Page 237: ...or rectly Also check grease piping for leakage 1 Move auto lubrication toggle switch 1 to the MAN UAL position Check that the grease pump begins op erating and indicator pins 2 retract 2 Move auto lubrication toggle switch 1 to the AUTO LUB position Indicator pin positions are as follows Indicator pins 2 are retracted while the grease pump is operating Indicator pins 2 are extended while the greas...

Page 238: ... AUTO LUB position Disconnect hose 6 at coupler 7 The grease pump intermittently delivers grease for approximately one minute with an interval of 3 minutes according to the greasing schedule preset at the factory The greasing schedule interval and volume can be adjusted as shown below IMPORTANT Do not adjust greasing interval to be too long or the greasing volume to be too small M146 07 107 M18C 0...

Page 239: ...3 Turn adjusting nut 10 indicator pin counterclock wise approximately 10 turns This is the maximum de livery position of 1 165 cm 3 0 071 in 3 Select appro priate greasing volume between the maximum and minimum volumes Tighten locknut 11 NOTE Injectors 3 have been adjusted as shown be low at the time of shipment Front attachment joint pins Maximum Swing bearing Minimum Center joint Minimum Model S...

Page 240: ... using a grease gun Refer to pages 7 22 to 7 30 of this manual After finishing greasing disconnect hose 7 from cou pler 6 release grease pressure in hose reel 12 via the grease gun NOTE When manual greasing is selected the auto lubrication indicator on the monitor panel will come on This is not abnormal M18C 07 011 M141 07 017 1 7 6 12 ...

Page 241: ... the seat belt or component before operating the machine We recommend that the seat belt be replaced every three years regardless of its apparent condition Check Windshield Washer Fluid Lever as required Windshield washer tank 5 is located in room 4 under the cab Check fluid in windshield washer tank 5 If the fluid level is low remove cap of windshield washer tank 5 and add fluid via the opening D...

Page 242: ... to 640 mm 22 4 in to 25 2 in NOTE When operating the machine on sand gravel snow or mud providing longer track sag is rec ommended in the above mentioned value range Precautions for Adjusting Track Sag 1 When measuring track sag after adjusting be sure to rotate the raised track one full rotation 2 When adjusting track sag lower the bucket to the ground to raise one track off the ground Repeat th...

Page 243: ...o loosen the track 3 If grease does not drain smoothly slowly rotate the raised track 4 When proper track sag is obtained turn valve 1 clockwise and tighten to 147 Nxm 15 kgfxm 108 lbfxft Tighten the Track CAUTION It is abnormal if the track remains tight after turning valve 1 counterclockwise or if the track is still loose after charging grease to fit ting 2 In such cases NEVER ATTEMPT TO DIS ASS...

Page 244: ...IMPORTANT Low pressure in the track adjuster cylin der circuit will cause damage to the track adjuster and travel device Be sure to check the accumulator and adjuster cyl inder circuit regularly to maintain correct circuit pressure Consult your authorized dealer when checking accumulator Check Side Frame Area daily Soil or rocks stuck in the side frame area will disturb smooth rotation of the unde...

Page 245: ...lt 10 16 17 49 5 36 12 Cab mounting bolt 18 10 27 295 30 220 13 Cab bed mounting bolt 16 40 24 265 27 195 Swing bearing mounting bolt Upperstructure 45 58 70 4700 480 3470 14 Swing bearing mounting bolt Track 45 60 70 4700 480 3470 15 Counterweight mounting bolt 45 6 75 3920 400 2890 16 Engine bed mounting bolt 30 20 30 1420 145 1050 17 Oil cooler mounting bolt 27 4 41 1370 140 1010 18 Radiator mo...

Page 246: ...950 97 0 700 700 71 5 520 280 28 5 205 M27 41 19 1400 143 1030 1050 107 770 400 41 0 295 M30 46 22 1950 200 1440 1450 148 1070 550 56 0 410 M33 50 24 2600 265 1920 1950 200 1440 750 76 5 550 M36 55 27 3200 325 2360 2450 250 1810 950 97 0 700 IMPORTANT Make sure bolt and nut threads are clean before installing Apply lubricant e g white zinc B solved into spindle oil to bolts and nuts to sta bilize ...

Page 247: ...55 mm Torque 3140 Nxm 320 kgfxm 2320 lbfxft 2 Engine bracket mounting bolt Flywheel housing side Tool 41 mm Torque 1030 Nxm 105 kgfxm 760 lbfxft Fan side Tool 30 mm Torque 390 Nxm 40 kgfxm 290 lbfxft M18C 07 014 M18C 07 015 2 Fan side 1 2 1 Flywheel housing side ...

Page 248: ...bolt Tool 46 mm Torque 1420 Nxm 145 kgfxm 1050 lbfxft 5 Pump transmission mounting bolt Tool 19 mm Torque 88 Nxm 9 kgfxm 65 lbfxft 6 Pump mounting bolt Main pump Tool 30 mm Torque 540 Nxm 55 kgfxm 400 lbfxft Fan pump Tool Hex Wrench 17 mm Torque 540 Nxm 55 kgfxm 400 lbfxft M18C 07 024 M18C 07 028 M18C 07 018 M18C 07 052 ...

Page 249: ...bfxft 8 Control valve mounting bolt Tool 24 mm Torque 265 Nxm 27 kgfxm 195 lbfxft 9 Swing device mounting bolt Tool 50 mm Torque 2550 Nxm 260 kgfxm 1880 lbfxft 10 Swing motor mounting bolt Tool 30 mm Torque 390 Nxm 40 kgfxm 290 lbfxft M18C 07 053 M18C 07 042 M18C 01 003 M18C 01 003 ...

Page 250: ...mounting bolt Tool 17 mm Torque 49 Nxm 5 kgfxm 36 lbfxft 12 Cab mounting bolt Tool 27 mm Torque 295 Nxm 30 kgfxm 220 lbfxft 13 Cab bed mounting bolt Tool 24 mm Torque 265 Nxm 27 kgfxm 195 lbfxft M117 07 083 M117 07 084 M18C 07 044 ...

Page 251: ...0 mm Torque 4700 Nxm 480 kgfxm 3470 lbfxft Track Remove cover A and check the tightening torque Tool 70 mm Torque 4700 Nxm 480 kgfxm 3470 lbfxft 15 Counterweight mounting bolt Tool 75 mm Torque 3920 Nxm 400 kgfxm 2890 lbfxft M18C 01 001 M18C 07 076 M18C 01 006 M18C 07 054 ...

Page 252: ...1050 lbfxft 17 Oil cooler mounting bolt Tool 41 mm Torque 1370 Nxm 140 kgfxm 1010 lbfxft 18 Radiator mounting bolt Tool 41 mm Torque 1370 Nxm 140 kgfxm 1010 lbfxft 19 Fan motor mounting bolt Tool 24 mm Torque 205 Nxm 21 kgfxm 152 lbfxft M18C 07 080 M117 07 086 M18C 07 037 M141 07 036 ...

Page 253: ...65 lbfxft 21 Travel motor mounting bolt Tool 30 mm Torque 390 Nxm 40 kgfxm 290 lbfxft 22 Upper roller mounting bolt Tool 30 mm Torque 390 Nxm 40 kgfxm 290 lbfxft 23 Lower roller mounting bolt Tool 46 mm Torque 1910 Nxm 195 kgfxm 1410 lbfxft M141 07 036 M144 12 002 M144 07 062 M144 07 063 ...

Page 254: ...2 mm Torque 740 N m 75 kgf m 540 lbf ft B Tool 50 mm Torque 2550 N m 260 kgf m 1880 lbf ft C Tool 46 mm Torque 1910 N m 195 kgf m 1410 lbf ft 25 Sprocket mounting bolt Tool 46 mm Torque 1910 Nxm 195 kgfxm 1410 lbfxft M18C 07 081 M144 12 002 M18C 07 069 C A B ...

Page 255: ...ting bolt Tool 46 mm Torque 1910 N m 195 kgf m 1410 lbf ft 27 Track shoe bolt Tool 50 mm Torque 3190 N m 325 kgf m 2350 lbf ft 28 Side frame mounting bolt Tool 70 mm Torque 4710 N m 480 kgf m 3470 lbf ft M144 07 063 M144 07 101 M144 07 065 ...

Page 256: ...gf m 290 lbf ft Tool 24 mm Torque 205 N m 21 kgf m 152 lbf ft Tool 36 mm Torque 690 N m 70 kgf m 510 lbf ft 30 Front pin retaining bolt Backehoe Tool 30 mm Torque 390 N m 40 kgf m 290 lbf ft Tool 24 mm Torque 205 N m 21 kgf m 152 lbf ft M144 07 004 M144 07 067 M144 07 066 M117 07 170 ...

Page 257: ...r service intervals Electrical Equipment Clean them regularly in particular the terminals of the al ternator and starter Rocky Ground Tracks Carefully operate while checking for cracks damage and loose bolts and nuts Loosen the tracks a little more than usual Front Attachment Standard attachment may be damaged when digging rocky ground Reinforce the bucket before using it or use a heavy duty bucke...

Page 258: ...MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS 9 2 MEMO ...

Page 259: ... with grease 4 Lubricate all grease points 5 Park the tracks on long stable blocks 6 Wash the machine 7 Remove the batteries and store them in a dry pro tected place after charging fully If not removed dis connect the negative battery cable from the termi nal 8 Loosen the alternator belt and fan belt 9 Paint necessary areas to prevent rust 10 Store the machine in a dry protected place If stored ou...

Page 260: ...s several times 6 Carefully check all systems before operating the ma chine at full load NOTE When the machine has been stored for a long time be sure to perform the following steps as well a Check condition of all hoses and connec tions b Warm up the engine c Stop the engine d Install new fuel filters Replace the engine oil filter and fill the engine with oil IMPORTANT If the machine has not been...

Page 261: ...ator Flashing Pattern Abnormal Throttle Sensor Engine Warning Indicator 2 5 Abnormal Boost Pressure Engine Warning Indicator 2 3 Abnormal Engine Speed Sensor Engine Stop Indicator 2 1 Abnormal Actuator Power Source Engine Stop Indicator 4 1 Abnormal Actuator Sensor Engine Stop Indicator 4 5 Abnormal Sensor Power Source Engine Warning Indicator 4 3 NOTE Flashing pattern fault code 2 5 means that th...

Page 262: ... Sensor 9 Actuator Sensor 10 Radiator Coolant Temperature Sensor 11 Radiator Coolant Temperature Switch 12 Exhaust Gas Temperature Sensor 13 Engine Oil Pressure Switch Low 14 Engine Oil Pressure Switch High 15 Radiator Coolant Level Switch M146 01 039 M18C 07 074 M18C 01 002 M18C 07 075 5 6 11 12 8 10 7 9 14 13 15 ...

Page 263: ...fuel system Clean fuel tank strainer Engine compression low See your authorized dealer Injection nozzles dirty or not working correctly See your authorized dealer Fuel shut off solenoid valve failure Replace solenoid valve Leaks in fuel system Check fuel system connections Air in fuel system Bleed air Engine oil level low Add oil Engine Knocks Runs Ir regularly or Stops Plugged air intake system C...

Page 264: ...ur authorized dealer Exhaust restriction Remove muffler and run engine Engine is too hot or cold See below Engine failure See your authorized dealer Valve clearance Check and adjust valves Intake or exhaust system leakage See your authorized dealer Engine Overheats Low coolant level Add coolant Thermostat See your authorized dealer Engine overloaded Check hydraulic relief valves Radiator cap fault...

Page 265: ... high Check cooling system Wrong oil Drain oil Use correct oil Engine Uses Too Much Oil Wrong oil Drain oil Use correct oil Oil leaks Check engine oil drain plug Engine temperature too high Check cooling system Plugged air cleaner Clean element or install new element Internal engine component wear See your authorized dealer Engine Uses Too Much Fuel Plugged or dirty air intake system Clean air int...

Page 266: ...ove exhaust elbow and air inlet hose and inspect Oil Dripping from Turbocharger Adapter Damaged or worn bearings and or worn seals See your authorized dealer Inspect and clean air cleaner Check for proper engine service intervals or dirt enter into engine Excessive crankcase pressure Check vent tube to ensure tube is not plugged Clean Turbocharger oil return line carbon build up where line passes ...

Page 267: ... solenoid See your authorized dealer Starter Repair or replace start motor Starter pinion jammed in flywheel gear Repair or replace starter Major engine failure See your authorized dealer Starter Solenoid Chatters Poor connections at batteries or starter Clean connections Low battery charge Recharge or replace batteries Starter solenoid hold in windings open See your authorized dealer Starter Moto...

Page 268: ...on Excessive electrical load from added accessories Remove accessories or install higher output alternator Loose or corroded electrical connections on battery ground strap starter or alternator Inspect clean or tighten electrical connections Battery voltage low Change or replace battery Alternator or regulator See your authorized dealer Indicator circuit See your authorized dealer Noisy Alternator...

Page 269: ...ight in Gauge Panel is Inoperative Fuse Replace fuse Sender Do sender check Wiring harness failure See your authorized dealer Fuse Replace fuse Coolant Temperature Gauge Does Not Work Gauge See your authorized dealer Gauge sender Do coolant temperature gauge sender check Wiring harness See your authorized dealer Fuel Gauge Does Not Work Fuse Replace fuse Gauge See your authorized dealer Wiring har...

Page 270: ...ulic oil to normal cycle times Wrong oil Drain tank Use correct oil Engine speed too low Increase speed or see your authorized dealer Pilot circuit See your authorized dealer Worn pump See your authorized dealer Restricted pump suction line See your authorized dealer Hydraulic Oil Overheats Wrong oil Use correct oil Air leak in pump suction line See your authorized dealer Oil lines restricted See ...

Page 271: ...il in system Fill with correct oil Worn cylinder packings See your authorized dealer Relief valve See your authorized dealer Hydraulic pump See your authorized dealer No Hydraulic Functions Noise from pumps Lack of hydraulic oil Add oil Damaged suction line or hose See your authorized dealer Clogged suction filter Clean Hydraulic pump worn See your authorized dealer Hydraulic Cylinders Operate but...

Page 272: ... ring in fitting damaged Install new O ring Pilot valve See your authorized dealer Pilot lines Repair or replace Piston seals leaking See your authorized dealer One Cylinder Does Not Work or Has Little Power Cylinder rod damaged See your authorized dealer Pilot lines Repair or replace Pilot valve See your authorized dealer Both Travel Motors Do Not Work Center joint failure See your authorized dea...

Page 273: ...Solution Auto Idle Does Not Work Fuse Replace Auto Idle switch Replace Pilot pressure switch Replace Failure of connector contact Repair or replace Wiring harness Repair or replace Engine speed control lever sensor Replace Controller Replace Controller on the engine See your authorized dealer Failure of connector contact Repair or replace Wiring harness Repair or replace Engine Speed Control Lever...

Page 274: ...TROUBLESHOOTING 11 14 MEMO ...

Page 275: ...10 mm 19 ft 9 in C Rear end Length 5930 mm 19 ft 5 in D Minimum Ground Clearance 795 mm 2 ft 7 in E Counterweight Clearance 1995 mm 6 ft 7 in F Overall Width of Upperstructure 5890 mm 19 ft 4 in G Undercarriage Length 7480 mm 24 ft 6 in H Crawler Width 5400 mm 17 ft 9 in I Undercarriage Width 5620 mm 18 ft 5 in J Sprocket Center to Idler Center 5780 mm 18 ft 12 in K Track Shoe Width 800 mm 2 ft 8 ...

Page 276: ...0 mm 25 ft 1 in C Level Crowding Distance 4820 mm 15 ft 10 in D Maximum Digging Reach 13430 mm 44 ft 1 in E Maximum Cutting Height 14610 mm 47 ft 11 in F Maximum Dumping Height 10440 mm 34 ft 3 in G Maximum Digging Depth 5920 mm 19 ft 5 in NOTE The dimensions do not include the height of the shoe lug 16m 12m 10 6 8 6 6 4 2 0 2 14 12 10 8 6 4 14 18 0 2 4 6 8 10 12 16 20 22m ...

Page 277: ... in B Maximum Digging Reach on grond 14770 mm 48 ft 6 in C Maximum Digging Depth 8180 mm 26 ft 10 in D Maximum Cutting Height 14140 mm 46 ft 5 in E Maximum Dumping Height 9060 mm 29 ft 9 in NOTE The dimensions do not include the height of the shoe lug 16m 6 4 22m 20 18 16 14 12 10 8 0 2 12m 14 12 10 8 6 2 4 4 0 2 8 6 10 ...

Page 278: ...SPECIFICATIONS 12 4 MEMO ...

Page 279: ...1 10 Coolant Level Indicator Warning 1 15 Coolant Level Indicator 1 13 Coolant Temperature Gauge 1 10 Cooling System 7 76 Cooling 1 22 Correct Maintenance and Inspection Procedures 7 1 D Defrosting 1 24 Dehumidifying and Heating 1 23 Dig with Caution S 15 Digital Clock Setting Procedure 1 40 Dimmer Switch 1 29 Dispose of Waste Properly S 28 Dome Light Switch 1 31 Download Indicator 1 12 Drive Mach...

Page 280: ...g in Water or Mud 4 9 Operating Ladder on the Ground 1 3 Operating Ladder on the Upperstructure 1 3 Operating on Soft Ground 4 7 OPERATING THE ENGINE 3 1 OPERATING THE MACHINE 5 1 Operating Tips 5 15 OPERATOR S STATION 1 7 Operator s Seat Adjustment 1 41 Overheat Indicator Warning 1 11 Overnight Storage Instructions 5 20 P Park Machine Safely S 17 Parking the Machine on Slopes 4 11 Parking the Mac...

Page 281: ...nsmission 7 38 Travel Alarm 4 5 Travel Mode Indicator Fast Speed 1 14 Travel Mode Indicator Slow Speed 1 13 Travel Speed Switch 1 34 4 4 Traveling 4 6 TROUBLESHOOTING 11 1 U Understand Signal Words S 1 Use a Chain to Prevent Falling Accidents 7 7 Use Correct Fuels and Lubricants 7 2 Use Handholds and Steps S 5 Using Booster Batteries 3 8 Using Ladder 1 2 V Ventilation the Cab 1 25 W Warming Up Ope...

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